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MOTO GUZZI Stelvio 1200 4V Service Manual

MOTO GUZZI Stelvio 1200 4V
274 pages
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SERVICE STATION MANUAL
895768
STELVIO 4V - 1200

Table of Contents

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MOTO GUZZI Stelvio 1200 4V Specifications

General IconGeneral
Displacement1151 cc
Bore x Stroke95 x 81.2 mm
Fuel SystemElectronic Fuel Injection
Torque113 Nm at 5, 800 rpm
Transmission6-speed
Final DriveShaft drive
Rear Tire150/70 R17
Wheelbase1535 mm
Seat Height840 mm
Engine TypeV-twin, 90°
Power105 hp (77 kW) @ 7250 rpm
Front BrakesDual 320 mm discs
Rear BrakesSingle 282 mm disc

Summary

General Characteristics and Specifications

General Safety Rules and Precautions

General safety guidelines for handling fuel, hot components, chemicals, and ensuring personal safety.

Vehicle Identification and Dimensional Specifications

Information on serial numbers, dimensions, mass, wheelbase, and saddle height.

Engine and Transmission Technical Specifications

Details on engine type, capacity, bore, stroke, and transmission gear ratios.

Vehicle Capacities and Fluid Specifications

Fluid capacities for engine oil, gearbox, fuel, and maximum weight limits.

Electrical System Component Specifications

Details on spark plugs, battery, alternator, fuses, and lighting.

Chassis and Braking System Specifications

Frame type, trail, headstock angle, and brake system component details.

Wheels, Tyres, and Fuel Supply Specifications

Information on wheel models, tyre sizes, fuel system, and tightening torques.

Engine Running-in Procedure Guidelines

Guidelines for the initial period of use to ensure engine longevity and performance.

Special Tools for Service

Engine and Gearbox Special Tools

Tools specifically for engine and gearbox maintenance, including specific tooling codes.

Flywheel, Valve, and Clutch Special Tools

Tools for flywheel locking, valve fitting/removal, and clutch spring operations.

Chassis and Suspension Special Tools

Tools for steering tightening, gearbox opening, and front fork seal installation.

Bevel Gear Set Special Tools

Tools related to the bevel gear system, including gearbox support and seal buffers.

Front Fork Specific Tools

Tools for front fork assembly, oil seal fitting, and protection during operations.

Vehicle Maintenance Procedures

Scheduled Maintenance Tasks and Intervals

A comprehensive table of routine maintenance tasks at specific mileage intervals.

Fluid Level Checks and Replacements

Procedures for checking and replacing transmission oil, engine oil, and brake fluid.

Air and Oil Filter Maintenance

Steps for replacing the air filter and engine oil filter.

Valve Clearance Check and Adjustment

Procedures for inspecting and adjusting valve clearances for optimal engine operation.

Electrical System Overview and Troubleshooting

Electrical System Component Arrangement and Wiring Diagrams

Diagrams showing component locations and the overall wiring distribution.

Electrical System Installation and Connection Checks

Guidance on cable routing, fastening, and critical connection checks for reliability.

General Wiring Diagram and ECU Information

Schematic of the entire electrical system and key ECU connector pin configurations.

Dashboard Diagnosis Functions and ECU Error Codes

Accessing diagnostic functions, understanding error codes, and panel errors.

System Component Checks and Maintenance

Checks for battery recharge circuit, stator, and starter system.

Sensor Functions and Troubleshooting Guide

Details on various sensors including function, operation, and troubleshooting.

Coil, Injector, and Oil Pressure Sensor Operations

Function, operation, and error handling for coils, injectors, and oil pressure sensor.

Fuses and Control Unit Details

Information on main and auxiliary fuses, control unit model, and battery specifications.

Engine Mechanical Procedures

Gearbox Removal, Disassembly, and Assembly

Step-by-step instructions for removing, disassembling, and reassembling the gearbox.

Shaft Inspection and Installation

Procedures for checking and installing primary and secondary shafts.

Generator Removal, Installation, and Belt Tensioning

Steps for removing, installing, and tensioning the generator belt.

Starter Motor and Clutch Removal/Disassembly

Procedures for removing the starter motor and disassembling the clutch.

Crankshaft and Connecting Rod Procedures

Steps for removing, inspecting, and assembling crankshaft and connecting rods.

Crankcase Assembly and Lubrication System Details

Refitting crankcase halves and conceptual diagrams of the lubrication system.

Oil Pump and Oil Sump Removal and Installation

Procedures for removing and installing the oil pump and oil sump.

Power Supply System

Fuel System Circuit Diagram

Diagram illustrating the complete fuel pump unit and injection system layout.

Power Supply System Component Diagram

Overview diagram of power supply components, ECU, and sensor connections.

Throttle Body Pipe Routing and Cylinder Synchronization

Procedures for routing throttle body pipes and synchronizing cylinders.

Control Unit Adjustments and Parameter Settings

Throttle position detection, engine temperature settings, and control unit adjustments.

Diagnostic Screens and Error Handling Procedures

Information on ECU info, parameter screens, status screens, and error management.

Suspension System

Front Wheel and Fork Removal Procedures

Steps for removing the front wheel and fork legs from the motorcycle.

Front Fork Adjustment and Disassembly Guide

Adjusting suspension settings and procedures for disassembling the front fork.

Front Fork Reassembly and Component Checks

Steps for reassembling fork components and checking individual parts.

Front Fork Leg Installation Procedure

Instructions for installing the front fork legs onto the motorcycle.

Steering Bearing Adjustment and Preload

Procedures for adjusting play and setting preloading for the steering bearings.

Rear Wheel and Shock Absorber Removal and Adjustment

Steps for removing the rear wheel and adjusting/removing shock absorbers.

Chassis Components

Swinging Arm Removal, Checking, and Installation

Steps for removing, inspecting, and installing the swinging arm assembly.

Bevel Gears and Support Unit Procedures

Removal, checking, and fitting procedures for bevel gears and support units.

Exhaust System Component Removal

Diagram and key for exhaust parts, with steps for tail pipe and manifold removal.

Engine Oil Cooler Procedures

Steps for removing and installing the engine oil cooling radiator.

Braking System Service

Brake Calliper Diagrams and Pad Replacement

Diagrams for front and rear brake callipers and procedures for pad replacement.

Braking System Bleeding Procedure

Detailed steps for purging air from the front and rear hydraulic brake circuits.

Bodywork Components

Seat and Instrument Panel Removal

Procedures for removing the rider and passenger seats and the instrument panel.

Footrest Plates and Side Fairings Removal

Steps for removing rider footrest plates and side fairings.

Air Box and Fuel Tank Component Removal

Procedures for removing the air box, fuel tank cap, cover, and fuel tank.

Adjustable Windscreen Removal Procedure

Steps for removing the windscreen glass and its mounting components.

Pre-Delivery Inspection and Checks

Aesthetic, Torque, and Electrical System Checks

Visual checks, tightening torque verification, and electrical system functionality tests.

Battery, Fluid Levels, and Road Test

Battery checks, fluid level verification, and performance assessment during a road test.

Static Tests and Functional Inspections

Post-test drive checks, functional inspections of systems, and documentation verification.

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