MOTO GUZZI Stelvio 1200 4V User manual

SERVICE STATION MANUAL
895768
STELVIO 4V - 1200

SERVICE STATION
MANUAL
STELVIO 4V - 1200
THE VALUE OF SERVICE
Only the mechanics of the Official Moto Guzzi Service Network know this vehicle well, thanks to constant
technical professional development and Moto Guzzi specific training programmes, and have the tools
needed to carry out maintenance and repair operations correctly.
Thereliabilityofthevehiclealsodependsonitsmechanicalconditions.Checkingthevehiclebeforeriding
it, carrying out routine maintenance and using only Moto Guzzi Original Spare parts is fundamental!
For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or
search directly on the inset map in our Official Website:
www.motoguzzi.it
Only by purchasing Moto Guzzi Original Spare Parts will you get a product designed and tested during
the bike designing phase. Moto Guzzi Original Spare Parts are subject to systematic quality control
procedures so that their reliability and performance over time is guaranteed.
The descriptions and illustrations given in this publication are not binding; While the basic features as
described and illustrated in this booklet remain unchanged, Moto Guzzi reserves the right, at any time
and without being required to update this publication beforehand, to make any changes to components,
parts or accessory supplies, which it deems necessary to improve the product or which are required for
manufacturing or commercial reasons.
Notallversions/modelsshowninthispublicationareavailableinallcountries.Theavailabilityofindividual
versions should be checked with the Official Moto Guzzi sales network.
© Copyright 2010- Moto Guzzi. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. Moto Guzzi - After sales service.
The Moto Guzzi trademark is the property of Piaggio & C. S.p.A.

SERVICE STATION MANUAL
STELVIO 4V - 1200
This manual provides the main information to carry out regular maintenance operations on your vehicle.
This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have
been deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself to
continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International
Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of
need or further queries on repair and check procedures, consult Moto Guzzi CUSTOMER
DEPARTMENT, which will be prepared to provide any information on the subject and any further
communications on updates and technical changes related to the vehicle.
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarked withthis symbolindicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee

INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE

INDEX OF TOPICS
CHARACTERISTICS CHAR

Rules
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VA-
POURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES
WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPERSE FUEL IN THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN
Hot components
The engine and the exhaust system components become very hot and remain hot for some time after
the engine has been switched off. When handling these components, wear insulating gloves or wait
until the engine and the exhaust system have cooled down.
Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE-
HICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN
STELVIO 4V - 1200 Characteristics
CHAR - 7

Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM-
PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING
THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR
EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY
WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN
Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,
IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY
ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT
OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTSOF BATTERY ACID MAYCAUSEBLINDNESS.IFTHEFLUID GETS IN CONTACTWITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-
QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN
BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-
TERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle follow the recommendations reported below
carefully.
BEFORE REMOVING COMPONENTS
•Beforedismantling components, remove dirt, mud,dust andforeign bodiesfrom thevehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
•Donot loosenand/or tightenscrews and nuts using pliers or any other tools than the specific
wrench.
•Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and
identify them with different distinctive symbols.
•Each component needs to be clearly marked to enable identification during reassembly.
•Clean and wash the dismantled components carefully using a low-flammability detergent.
•Keep mated parts together since they have "adjusted" to each other due to normal wear.
Characteristics STELVIO 4V - 1200
CHAR - 8

•Some components must be used together or replaced altogether.
•Keep away from heat sources.
REASSEMBLY OF COMPONENTS
CAUTION
BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH-
ERWISE, THEY NEED TO BE REPLACED.
•Only use ORIGINAL Moto Guzzi SPARE PARTS.
•Comply with lubricant and consumables use guidelines.
•Lubricate parts (whenever possible) before reassembling them.
•When tightening nuts and screws, start from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-
plying the tightening torque.
•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new ones if their tread is damaged.
•When assembling the bearings, make sure to lubricate them well.
•Check that each component is assembled correctly.
•After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-
hicle on private grounds or in an area with low traffic density.
•Clean all coupling surfaces, oil guard rims and gaskets before refitting them. Smear a light
layer of lithium-based grease on the oil guard rims. Reassemble oil guards and bearings
with the brand or lot number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the cable harness:
Press the relevant safety hooks, if any.
•Grip the two connectors and disconnect them by pulling them in opposite directions.
•If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
•Ensure that the cables are correctly fastened to the internal connector terminals.
•Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY
ROUND.
TIGHTENING TORQUES
CAUTION
IF UNSCREWING A SELF-LOCKING NUT, IT MUST BE REPLACED WITH A NEW ONE.
CAUTION
DO NOT FORGET THAT THE TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON
WHEELS, BRAKES, WHEEL BOLTS AND ANY OTHER SUSPENSION COMPONENTS PLAY A
STELVIO 4V - 1200 Characteristics
CHAR - 9

KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COM-
PLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET
LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE
VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR
DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients
are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed during the run-
in. This ensures that components operate under both "loaded" and "unloaded" conditions, allowing the
engine components to cool.
CAUTION
THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON
SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH
PLATES GET ADAPTED.
ITIS IMPORTANT TOSTRAINENGINECOMPONENTS DURING RUN-IN,HOWEVER,MAKESURE
NOT TO OVERDO THIS.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow these guidelines:
•Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
•During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged
braking. That is to permit the adequate adjustment of the pad friction material to the brake
discs.
AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER
FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE-
NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI-
CLE.
Vehicle identification
SERIAL NUMBER LOCATION
These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR-
TICULAR, MODIFYING THE FRAME NUMBER IMMEDIATELY VOIDS THE WARRANTY.
Characteristics STELVIO 4V - 1200
CHAR - 10

This number consists of numbers and letters, as in
the example shown below.
ZGULZA000YMXXXXXX
KEY:
ZGU: WMI (World manufacturer identifier) code;
LZ: model;
A00: version variation;
0: free digit
Yyear of manufacture
M: production plant (M= Mandello del Lario);
XXXXXX: serial number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right hand
side of the headstock.
ENGINE NUMBER
The engine number is stamped on the left side,
close to the engine oil level check cap.
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification Desc./Quantity
Maximum width (without accessories) 2305 mm (90.75 in)
Maximum width at handlebar 910 mm (35.83 in)
Maximum width of vehicle with accessories 1080 mm (42.52 in)
Minimum / maximum height (adjustable windshield) 1395 / 1440 mm (54.92 / 56.69 in)
Saddle height 800 mm (31.5 in)
Minimum earth clearance 185 mm (7.3 in)
Wheelbase 1535 mm (60.43 in)
Kerb weight 251 kg (553 lb)
Kerb weight of full house vehicle 278 kg (613 lb)
Engine
ENGINE
Specification Desc./Quantity
Type traverse-mounted twin-cylinder four-stroke V 90°
Cylinder number 2
Cylinder arrangement V 90°
STELVIO 4V - 1200 Characteristics
CHAR - 11

Specification Desc./Quantity
Bore / stroke 95 x 81.2 mm (3.74 x 3.20 in)
Engine capacity 1151 cm³ (70 cu.in)
Compression ratio 11 : 1
Electric starter
Engine idle speed 1100 ± 100 rpm
Clutch hydraulically controlled single-plate dry clutch with incorpora-
ted flexible coupling
Lubrication system Pressure-fed, controlled by valves and trochoidal pump
Air filter cartridge-type dry filter
Cooling air and oil cooled with independent trochoidal pump and oil
pressure control valve
Timing system diagram single overhead camshaft with bucket tappets and rocker-op-
erated valves
Values valid with control clearance between rocker and valve intake: 0.15 mm (0.0059 in)
outlet: 0.20 mm (0.0079 in)
Transmission
TRANSMISSION
Specification Desc./Quantity
Primary drive Helical gears, ratio 26/35 = 1:1.346
Gearbox Mechanical, 6 speeds with foot lever on the left hand side of
the engine
Gear ratios, 1st gear 17/38 = 1:2.2353
Gear ratios, 2nd gear 20/34 = 1:1.7
Gear ratios, 3rd gear 23/31 = 1:1.3478
Gear ratios, 4th gear 26/29 = 1:1.1154
Gear ratios, 5th gear 31/30 = 1:0.9677
Gear ratios, 6th gear 29/25 = 1:0.8621
Final drive with U-joint
Ratio 12/44 = 1:3.6667
Capacities
CAPACITIES
Specification Desc./Quantity
Engine oil Oil change and oil filter replacement: 3,500 cm³ (214 cu.in)
Gearbox oil 500 cm³ (30.5 cu.in)
Transmission oil 380 cm³ (23.2 cu.in)
Fuel (reserve included) 18 ± 1.5 l (3.96 ± 0.33 UK gal)
Fuel reserve 4 l (0.88 UK gal)
Seats 2
Maximum weight allowed - standard version 475 kg (1047 lb)
Maximum weight allowed - NTX version 495 kg (1091 lb)
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Spark plug NGK PMR8B (long life)
Alternatively:
Spark plug NGK CR8EKB (long life)
Electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Battery 12 V - 18 Ampere/hour
Alternator (permanent magnet type) 12 V - 550 W
Main fuses 30A - 40A
Auxiliary fuses 3 A - 15 A
Front daylight running lights 12V - 5W
Characteristics STELVIO 4V - 1200
CHAR - 12

Specification Desc./Quantity
Low/high beam light (halogen) 12 V - 55 W / 60 W H4
Turn indicators 12V - 10 W
Rear daylight running light/stop light LED
Dashboard lighting LED
License plate light 12V - 5 W
Turn indicator warning light LED
Neutral gear warning light LED
Alarm-shift warning light LED
Side stand down warning light LED
Low fuel warning light LED
High beam warning light LED
Frame and suspensions
CHASSIS
Specification Desc./Quantity
Type high strength tubular steel frame with engine as stressed ele-
ment
Trail 125 mm (4.92 in)
Headstock angle 27°
Front Upside down telescopic hydraulic fork, with 45mm (1.77 in) di-
am., stanchions and radial calliper mounting bracket with ad-
justable spring preload and hydraulic compression and re-
bound damping.
Front wheel travel 170 mm (6.69 in)
Rear singlearmwithprogressivelinkage,singleshockabsorberwith
spring preload, hydraulic compression and rebound damping
adjustment.
Unloaded shock absorber spring length 180 mm (7.09 in)
Rear wheel travel 155 mm (6.10 in)
SIZES A AND B
Specification Desc./Quantity
Size A 745.0 mm (29.33 in)
Size B 403.16 mm (15.87 in)
Brakes
BRAKES
Specification Desc./Quantity
Front Dual 320 mm (12.6 in) diam. stainless steel floating wavy disc
with radial callipers with 4 differentiated, horizontally opposed
pistons.
Rear 282 mm (11.1 in) diam. stainless steel disc
STELVIO 4V - 1200 Characteristics
CHAR - 13

Wheels and tyres
WHEELS AND TYRES - STELVIO (STANDARD)
Wheel Model Rim Size Tyre pressure with
rider only Tyre pressure, rider + passenger
Front (standard) Pirelli Scorpion Sync 2.50 x 19" 110/80
R19 - 59V 2.5 bar (250 kPa) (36.3 PSI) 2.5 bar (250 kPa) (36.3 PSI)
Rear (standard) Pirelli Scorpion Sync 5.50 x 17 180/55
R17 - 73V 2.9 bar (290 kPa) (42.1 PSI) 2.9 bar (290 kPa) (42.1 PSI)
WHEELS AND TYRES - STELVIO (ALTERNATIVE EQUIPMENT)
Wheel Model Rim Size Tyre pressure with
rider only Tyre pressure, rider + passenger
Front (alternatively) Pirelli Scorpion Trail 2.50 x 19" 110/80
R19 - 59V 2.5 bar (250 kPa) (36.3 PSI) 2.5 bar (250 kPa) (36.3 PSI)
Front (alternatively) Metzeler Karoo (*) (***) 2.50 x 19" 110/80
R19 - 59R
M+S
2.5 bar (250 kPa) (36.3
PSI) (**) 2.5 bar (250 kPa) (36.3 PSI) (**)
Rear (alternatively) Pirelli Scorpion Trail 4.25 x 17" 150/70
R17 - 69V 2.9 bar (290 kPa) (42.1 PSI) 2.9 bar (290 kPa) (42.1 PSI)
Rear (alternatively) Metzeler Karoo (*) (***) 4.25 x 17" 150/70
R17 - 69R
M+S
2.7 bar (270 kPa) (36.1
PSI) (**) 2.9 bar (290 kPa) (42.1 PSI) (**)
Supply
FUEL SYSTEM
Specification Desc./Quantity
Fuel system Electronic injection (Weber . Marelli) with Stepper motor
Venturi diameter: 50 mm (1.97 in)
Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
Tightening Torques
HEADS
Name Torque in Nm
Oil cap (2) 25 Nm (18.44 lb ft)
Rocking lever support nut - M10x1.5 (8) 15 Nm (11.06 lb ft) + 42 Nm (30.98 lb ft)
Camshaft - rocking levers support fixing screws (12) 17 Nm (12.54 lb ft)
Head fixing screw (4) - pre-tightening 15 Nm (11.06 lb ft)
Head fixing screw (4) - final tightening 42 Nm (31 lb ft)
Screw fixing head to chain compartment - M6x120 (4) 10 Nm (7.38 lb ft)
Oil temperature sensor 11 Nm (8.11 lb ft) - Loctite 243
Oil temperature sensor container 11 Nm (8.11 lb ft) - Loctite 601
Head covers fixing screws (8) 8 Nm (5.9 lb ft)
Spark plug (2) 15 Nm (11.06 lb ft) - Molykote
CRANKCASE
Name Torque in Nm
Crankcase stud bolt - cylinder (8) 25 Nm (18.44 lb ft)
Transmission side flange stud bolt - M8x66 (3) 35 Nm (25.81 lb ft)
Transmission side flange stud bolt - M8x75 (2) 35 Nm (25.81 lb ft)
Gear side crankshaft flange screw - TE M8x25 (8) 26 Nm (19.18 lb ft)
Timing system cover screw - TCEI M8x55 (4) 25 Nm (18.44 lb ft)
Timing system cover screw - TCEI M6x30 (10) 10 Nm (7.38 lb ft)
Oil vapour union screw - TCEI M6x20 (2) 10 Nm (7.38 lb ft)
TCEI M6x40 Screw (2) 10 Nm (7.38 lb ft)
Characteristics STELVIO 4V - 1200
CHAR - 14

Name Torque in Nm
Timing sensor - TCEI M5x12 (2) 6 Nm (4.42 lb ft)
Service shaft bearing locking screw (2) 10 Nm (7.38 lb ft)
Oil pressure sensor (1) 25 Nm (18.44 lb ft)
Screw fixing oil pressure sensor support - TCEI M10x20 (1) 18 Nm (13.28 lb ft)
Oil cap (2) 25 Nm (18.44 lb ft)
OIL SUMP
Name Torque in Nm
Oil pipe on sump reduction (1) 20 Nm (14.75 lb ft)
Oil pipe on sump 20 Nm (14.75 lb ft)
Oil sump lower screw - TCEI M6x30 (4) 10 Nm (7.38 lb ft)
Oil sump screw - TCEI M6x55 (14) 10 Nm (7.38 lb ft)
Oil sump screw - TCEI M6x60 (2) 10 Nm (7.38 lb ft)
Oil drainage plug - M10x1 (1) 20 Nm (14.75 lb ft)
Oil filter (1) 15 Nm (11.06 lb ft)
Oil filter fitting (1) 40 Nm (29.5 lb ft) - Loctite 243
Oil pipe in sump 20 Nm (14.75 lb ft) - Loctite 648
Pressure-relief plug 40 Nm (29.5 lb ft)
Cap on oil sump flange (2) 20 Nm (14.75 lb ft)
Cap (1) 40 Nm (29.5 lb ft)
CRANKSHAFT - FLYWHEEL
Name Torque in Nm
Connecting rod screw (4) - pre-tightening 40 Nm (29.5 lb ft)
Connecting rod screw (4) - final tightening 80 Nm (59 lb ft)
Screw fixing clutch plate on crankshaft - M8x25 (6) 42 Nm (30.98 lb ft) - Loctite 243
Screw fixing clutch bell on disc - M7x16 (6) 20 Nm (14.75 lb ft)
Start-up crown gear fixing screw (6) 10 Nm (7.38 lb ft)
OIL PUMP
Name Torque in Nm
Oil pump fixing screws - M6x45 (3) 10 Nm (7.38 lb ft)
Oil pump gear nut - M10x1.25 (1) 20 Nm (14.75 lb ft)
Pressure-relief plug 40 Nm (29.5 lb ft)
Cooling oil intake filter fixing screw (5) 10 Nm (7.38 lb ft)
Lubrication oil intake filter fixing screw (2) 10 Nm (7.38 lb ft)
TIMING SYSTEM
Name Torque in Nm
Service shaft flange screw - TBEI M6x14 (2) 8 Nm (5.9 lb ft)
Timing system gear nut on service shaft - M18 (1) 150 Nm (110.6 lb ft)
Timing system gear nut on crankshaft - M25 (1) 200 Nm (147.51 lb ft)
Timing system upper gear TE screw (2) 30 Nm (22.13 lb ft)
Screw fixing timing system upper gear closing cap - TBEI
M5x10 (4) 7 Nm (5.16 lb ft)
Cylinder chain tensioner cap (2) 30 Nm (22.13 lb ft)
Screw fixing movable chain slider (2) 25 Nm (18.44 lb ft)
ALTERNATOR
Name Torque in Nm
Alternator fixing screw - TCEI M8x45 (1) 22 Nm (16.23 lb ft)
Alternator fixing nut - M10x1.5 (1) 30 Nm (22.13 lb ft)
Alternator pulley nut on crankshaft - M16 (1) 80 Nm (59 lb ft) - Loctite 243
Belt tension 50 Nm (36.88 lb ft)
Alternator belt cover screw - TCEI M6x16 (4) 10 Nm (7.38 lb ft)
Alternator belt cover screw (radiator bracket retainer) TCEI
M6x40 (2) 10 Nm (7.38 lb ft)
GEARBOX
Name Torque in Nm
Gear shift cable lever nut 10 Nm (7.38 lb ft)
Gear shift tie rod lever nut on gear pre-selector 10 Nm (7.38 lb ft)
STELVIO 4V - 1200 Characteristics
CHAR - 15

Name Torque in Nm
Gearbox to crankcase fixing nut - M8 (5) 20 Nm (14.75 lb ft)
TE flanged screw fixing gearbox to crankcase - M8x45 (1) 20 Nm (14.75 lb ft)
Oil cap M18x1.5 (1) 28 Nm (20.65 lb ft)
Breather cap (1) 8 Nm (5.9 lb ft)
Gear in neutral sensor (1) 10 Nm (7.38 lb ft)
Oil drainage plug - M10x1 (1) 24 Nm (17.7 lb ft)
Transmission shaft ring nut (1) 100 Nm (73.76 lb ft)
OIL RADIATOR
Name Torque in Nm
Radiator to chassis retainer M6x30 (3) 10 Nm (7.38 lbf ft)
Nipples to radiator retainer M16x1.5 (2) 20 Nm (14.75 lbf ft)
Oil pipes to radiator and engine retainer M16x1.5 (2 + 2) 20 Nm (14.75 lbf ft)
CHASSIS TO ENGINE UNIT
Name Torque in Nm
M6x40 TCEI DA screw 8 -12 Nm
Reduction 20 Nm
FUEL SUPPLY CONTROL UNIT
Name Torque in Nm
M5x12 TCEI screw 6 -7 Nm
Stainless M5x16 TBEI flanged screw 6 -7 Nm
M6x25 TCEI DA screw 8 -12 Nm
CHASSIS
Name Torque in Nm
Front engine to chassis retainer 80 Nm
Transmission to chassis retainer (M12x250 + M12x230) 50 Nm
Right fixing plate - transmission retainer 25 Nm
Plate clamp - Blow-by retainer 10 Nm
Coil plate retainer 10 Nm
Electronic control unit retainer 10 Nm
Bushings to electronic control unit retainer - M6x35 (1) 10 Nm (7.38 lbf ft) - Loct 243
Tank support rubber rings to chassis retainer (2) Manual - Loct 243
Filter casing fixing bolts 10 Nm
Left and right footrest plate to chassis upper retainer M8x30 (2
+2) 20 Nm (14.75 lbf ft)
Left and right footrest plate to chassis lower retainer M8x75 (2
+2) 20 Nm (14.75 lbf ft)
Brake switch on plate retainer Manual
Chrome-plated ring to plate retainer M5x10 (6) 6 Nm (4.42 lbf ft)
Retainer for cable guide on right footrest plate 6 Nm
Front speed sensor screws retainer 6 Nm (4.42 lbf ft) + Loc. 243
ABS control unit screws retainer (2) 10 Nm (7.37 lbf ft)
Rear speed sensor screws retainer 10 Nm (7.37 lbf ft)
FOOTRESTS AND LEVERS
Name Torque in Nm
Footrest rubber retainer 10 Nm
Rider footrest sliding pin - M8 25 Nm
Passenger footrest support to lateral plates retainer 38 Nm
Rider heelrest to plates retainer 6 Nm
Passenger heelrest retainer 3 Nm
Rod retainer (nut) 10 Nm
Gear shift lever / brake pin retainer 10 Nm
Gear shift lever / pre-selector retainer 10 Nm
Gear shift lever pin - brake retainer M8 (1+1) 15 Nm (11.06 lbf ft) - Loct 243
SIDE STAND
Name Torque in Nm
Stand plate to engine upper retainer 50 Nm
Characteristics STELVIO 4V - 1200
CHAR - 16

Name Torque in Nm
Stand plate to engine lower retainer 25 Nm
Side stand retainer pin 10 Nm
Switch fixing screw - M6x20 (1) 10 Nm (7.38 lbf ft) - Loct 243
Lock nut 30 Nm
Stand cable guide to engine retainer M8 (1) 25 Nm (18.44 lbf ft)
Side lever arm retainer - M6x16 (2) 10 Nm (7.38 lbf ft) - Loct 243
SWING ARM
Name Torque in Nm
Swingarm on bushing clamp retainer 10 Nm
Swingarm on bevel gear pair retainer 50 Nm
Reaction rod to bevel gear pair retainer 50 Nm
Reaction rod to chassis retainer 50 Nm
Swingarm bolt to swingarm retainer 60 Nm
Preloading bushing to swingarm bolt retainer 10 Nm
FRONT SUSPENSION
Name Torque in Nm
Tube lock plate to steering base retainer 6 Nm
Fork stem on upper plate retainer - M8x30 (2) 20 Nm (14.75 lbf ft)
Fork stem on lower plate retainer - M8x30 (4) 20 Nm (14.75 lbf ft)
Headstock ring nut 40 Nm
Headstock counter ring nut manual + 90 degrees
Upper yoke fixing cap 100 Nm
Fork hub closing - M6x30 (2+2) 10 Nm (7.38 lbf ft)
REAR SUSPENSION
Name Torque in Nm
Shock absorber to chassis retainer - 8.8 50 Nm
Double connecting rod/shock absorber retainer - 10.9 40 Nm
Single connecting rod/double connecting rod retainer - 10.9 50 Nm
Single connecting rod to chassis retainer - 8.8 50 Nm
Double connecting rod/swingarm retainer - 10.9 50 Nm
AIR FILTER CASING - BLOW-BY
Name Torque in Nm
Blow-by expansion tank spacer to engine retainer 10 Nm
Filter housing to chassis retainer 10 Nm
EXHAUST
Name Torque in Nm
Exhaust pipe to engine retainer 25 Nm
Silencer to chassis connecting pipe retainer 25 Nm
Muffler to chassis retainer - M8x45 (1) 25 Nm (18.44 lbf ft)
Heat guard retainer - M6 (3) 10 Nm (7.38 lbf ft)
Lambda probe retainer 38 Nm
Clamps retainer - M8 (3) 20 Nm (14.75 lbf ft)
FRONT WHEEL
Name Torque in Nm
Wheel axle nut 80 Nm
REAR WHEEL
Name Torque in Nm
Disc retainer 25 Nm
Rear wheel retainer 10.9 110 Nm
FRONT BRAKING SYSTEM
Name Torque in Nm
Front brake right and left calliper retainer 50 Nm
STELVIO 4V - 1200 Characteristics
CHAR - 17

REAR BRAKING SYSTEM
Name Torque in Nm
Rear brake calliper retainer 50 Nm
Rear brake fluid reservoir retainer 3 Nm
Rear brake fluid reservoir support to plate retainer 10 Nm
Rear brake rod lock nut manual
Brake pump retainer - M6x20 (2) 10 Nm (7.38 lbf ft) - Loctite 243
HANDLEBAR AND CONTROLS
Name Torque in Nm
Retainer for handlebar lower U-bolts on steering upper plate 50 Nm + Loct. 243
Retainer for handlebar upper U-bolts 25 Nm
Anti-vibration counterweight fastener 10 Nm
Brake pump and clutch U-bolts retainer 10 Nm
Right and left light switch retainer 1.5 Nm
Clutch control cylinder to gear retainer 10 Nm
Mirror Manual
ELECTRICAL SYSTEM
Name Torque in Nm
Coil retainer 2 Nm
Horn retainer 15 Nm
Odometer sensor on bevel gear pair retainer 3 Nm
INSTRUMENT PANEL AND LIGHTS
Name Torque in Nm
Instrument panel retainer 3 Nm
Front arrows retainer - M4 (2) 3 Nm (2.21 lbf ft)
Front headlamp retainer - M6x30 (6) 10 Nm (7.38 lbf ft)
Rear light to license plate retainer - M5x16 (4) 6 Nm (4.42 lbf ft)
FUEL PUMP FLANGE
Name Torque in Nm
Pump support to tank retainer 6 Nm
FUEL TANK
Name Torque in Nm
Filler to tank retainer 5 Nm
Screws on cap ring nut (aesthetic) 5 Nm
Tank to chassis front retainer 10 Nm
ENGINE COVER
Name Torque in Nm
Right cover plate retainer - M10x20 (2) 40 Nm (29.5 lbf ft)
Left cover plate retainer - M10 (1) 40 Nm (29.5 lbf ft)
Front oil sump guard retainer - M8x25 (4) 20 Nm (14.75 lbf ft)
FRONT BODYWORK
Name Torque in Nm
Front mudguard retainer 6 Nm
Air deflector self-tapping retainer (4+4) Manual
Fairing junction - M5 (2+2) Manual
Glove-box - self-tapping (4) Manual
Compartment lock - M6 (2) Manual
Hinge locking bracket - self-tapping (2) Manual
Rear tank cover - M5 (2) 4 Nm (2.95 lbf ft)
Rear tank cover - M6 (2) 10 Nm (7.38 lbf ft)
Left - right fairing - M5 (2) 4 Nm (2.95 lbf ft)
Left - right fairing - M6 (2) 10 Nm (7.38 lbf ft)
Characteristics STELVIO 4V - 1200
CHAR - 18

REAR BODYWORK
Name Torque in Nm
Left - right fairings retainer - M6 (3+3) 10 Nm (7.38 lbf ft)
Retroreflector to support retainer 4 Nm
Retroreflector support to license plate holder retainer 4 Nm
License plate holder and light reinforcing retainer - M5 (1) 4 Nm (2.95 lbf ft)
Cases support retainer - M6 (2) 10 Nm (7.38 lbf ft)
Cases support retainer - M8 (2+2) 25 Nm (18.44 lbf ft)
Passenger grab handle to chassis retainer - M8 (2) 25 Nm (18.44 lbf ft)
Passenger grab handle to chassis retainer - M6 (4) 10 Nm (7.38 lbf ft)
License plate holder to chassis retainer - M5 (4) 4 Nm (2.95 lbf ft)
Luggage carrier brackets retainer - M8 (2+2) 25 Nm (18.44 lbf ft)
FINISHINGS
Name Torque in Nm
Ignition lock retainer - shear head screw - Nm
Overhaul data
Assembly clearances
Cylinder - piston assy.
Measurement of the cylinder diameter must be done at three heights, turning the dial gauge 90°.
Check that cylinders and pistons are of the same selection types (D, E, F).
Check clearance between cylinders and pistons on the selected diameter; if it exceeds the value speci-
fied, it is necessary to replace cylinders and pistons.
The pistons of an engine must be balanced; a weight difference of up to 1.5 g (0.0033 lb) is allowed.
PISTON - CYLINDER SELECTION TYPES
Specification Desc./Quantity
Piston diameter - selection D 94.935 - 94.945 mm (3.73759 - 3.73798 in)
Cylinder diameter - selection D 95.000 - 95.010 mm (3.74015 - 3.74054 in)
Piston diameter - selection E 94.945 - 94.955 mm (3.73798 - 3.73837 in)
Cylinder diameter - selection E 95.010 - 95.020 mm (3.74054 - 3.74093 in)
Piston diameter - selection F 94.955 - 94.965 mm (3.73837 - 3.73877 in)
Cylinder diameter - selection F 95.020 - 95.030 mm (3.74093 - 3.74133 in)
STELVIO 4V - 1200 Characteristics
CHAR - 19

PIN - PISTON COUPLING
Specification Desc./Quantity
Pin diameter 21.998 - 21.994 mm (0.86606 - 0.86590 in)
Pin hole diameter on piston 22.016 - 22.011 mm (0.86677 - 0.86657 in)
Clearance between pin and holes on piston 0.013 - 0.022 mm (0.00051 - 0.00087 in)
Piston rings
On each piston there are:
•1 top piston ring;
•1 middle piston ring;
•1 oil scraper piston ring.
Turn the rings so that the coupling ends are 120 degrees from each other.
CLEARANCE BETWEEN PISTON RINGS AND SEATS ON PISTON
Specification Desc./Quantity
Top ring 0.030 - 0.065 mm (0.00118 - 0.00256 in)
Middle ring 0.020 - 0.055 mm (0.00079 - 0.00216 in)
Oil scraper ring 0.010 - 0.045 mm (0.00039 - 0.00177 in)
Gap between the end of the piston rings inserted in the cylinder:
•Top and middle piston ring: 0.40 - 0.65 mm (0.00158 - 0.00255 in)
•Oil scraper piston ring: 0.30 - 0.60 mm (0.00118 - 0.00236 in).
Crankcase - crankshaft - connecting rod
CRANKSHAFT SEAT (TIMING SYSTEM SIDE)
Specification Desc./Quantity
Diameter of crankshaft main journal, timing system side 37.975 - 37.959 mm (1.49507 - 1.49444 in)
Inside diameter of crankshaft bushing, timing system side 38.016 - 38.0 mm (1.49669 - 1.49606 in)
Clearance between bushing and main journal (timing system
side) 0.025 - 0.057 mm (0.00098 - 0.00224 in)
CRANKSHAFT SEAT ( CLUTCH SIDE)
Specification Desc./Quantity
Diameter of crankshaft main journal, clutch side 53.97 - 53.961 mm (2.12480 - 2.12444 in)
Inside diameter of crankshaft bushing on clutch-side flange 54.019 - 54.0 mm (2.12673 - 2.12598 in)
Clearance between bushing and main journal (clutch side) 0.030 - 0.058 mm (0.00118 - 0.00228 in)
Characteristics STELVIO 4V - 1200
CHAR - 20