Malaguti Dune 125 Service Station Manual Download

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Dune 125 - Dune X 125 - Euro 4

Characteristics

CHAR - 9

BEFORE DISASSEMBLING COMPONENTS



Remove the dirt, mud, dust and foreign objects from the vehicle before disassembling com-

ponents. Wherever required, use the special tools designed for this vehicle.

DISASSEMBLING COMPONENTS



Do not loosen and/or tighten the screws and nuts using pliers or other tools, but always use

the specific wrench.



Mark the positions on all the connection joints (hoses, cables, etc.) before separating them

and identify them with different distinctive marks.



Each piece should be clearly marked in order to be identified during the installation phase.



Carefully clean and wash the disassembled components with detergents with a low flam-

mability grade.



Keep the coupled parts together because they have "adapted" to one another following

normal wear.



Some components must be used together or replaced entirely.



Keep away from heat sources.

REASSEMBLING COMPONENTS

CAUTION

BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.



Only use ORIGINAL Malaguti SPARE PARTS.



Comply with lubricant and consumables use guidelines.



Lubricate parts (whenever possible) before reassembling them.



When tightening nuts and screws, start either from the components with the largest diameter

or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-

cessive steps before applying the tightening torque.



Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins

and screws with new parts if the thread 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, carry out pre-ride checks and test the vehicle on

private grounds or in an area with low traffic.



Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of

lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand

or batch number facing outward (visible side).

ELECTRICAL CONNECTORS

Electric connectors must be disconnected as described below; failure to comply with this procedure

causes irreparable damage to both the connector and the wiring harness:

Press the relative safety clips, if applicable.

Summary of Contents for Dune 125

Page 1: ...SERVICE STATION MANUAL ZP682837 Dune 125 Dune X 125 Euro 4 ...

Page 2: ...itself All Malagutioriginal spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only While the basic features as described and illustrated in this manual remain unchanged KSR Solution GmbH reserves the right at any time and without being required to update this publication beforeh...

Page 3: ...cations and changes in repair procedures are communicated to all Malaguti 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 Malaguti CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on u...

Page 4: ...Dune 125 Dune X 125 ...

Page 5: ... MAIN ELECTRICAL SYSTEM P59 109 ELE SYS ENGINE FROM VEHICLE P110 115 ENG VE ENGINE P117 173 ENG POWER SUPPLY P175 177 P SUPP SUSPENSIONS P179 190 SUSP CHASSIS P192 221 CHAS BRAKING SYSTEM P223 236 BRAK SYS COOLING SYSTEM P238 244 COOL SYS BODYWORK P246 264 BODYW PRE DELIVERY P266 268 PRE DE ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...S WHICH MAY CAUSE IGNITION OR EXPLOSION DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot parts The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off Before handling these components make sure that you are wearing insulating gloves or wait until the engine and ...

Page 8: ...K 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 ...

Page 9: ... use ORIGINAL Malaguti SPARE PARTS Comply with lubricant and consumables use guidelines Lubricate parts whenever possible before reassembling them When tightening nuts and screws start either from the components with the largest diameter or from the innermost components proceeding diagonally Tighten nuts and screws in suc cessive steps before applying the tightening torque Always replace self lock...

Page 10: ...THESE COMPONENTS COULD LOOSEN AND COME OFF BLOCKING A WHEEL OR CAUSING OTHER PROBLEMS THAT WOULD COMPROMISE MA NOEUVRABILITY LEADING TO A CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN DEATH Running in Running the engine in correctly is essential for ensuring engine longevity and functionality Twisty roads and gradients are ideal for running in the engine brakes and suspension effectively Vary your...

Page 11: ...l number 6 digits CHASSIS NUMBER The chassis number is stamped on the RH side of the headstock ENGINE NUMBER in countries where applica ble The engine number is stamped on the top of the right hand side of the crankcase near the rear shock absorber The engine number is visible from right hand side of the vehicle looking from the rear Engine No Dimensions and mass WEIGHT AND DIMENSIONS Specificatio...

Page 12: ...operates the fork and drum selector mechanism Type Transmission DRIVE RATIOS Specification Desc Quantity Drive ratio 1st gear 11 33 1 3 000 Drive ratio 2nd gear 15 30 1 2 000 Drive ratio 3rd gear 18 27 1 1 500 Drive ratio 4th gear 20 24 1 1 200 Drive ratio 5th gear 25 27 1 1 080 Drive ratio 6th gear 23 22 1 0 956 Final drive ratio 13 62 1 4 769 Capacities CAPACITY Specification Desc Quantity Fuel ...

Page 13: ...ation Desc Quantity SUSPENSIONS Specification Desc Quantity Front Upright hydraulic telescopic fork Front fork travel Dune125 160 mm 6 30 in fork travel Dune X 125 182 mm 7 165 in Rear hydraulic single shock absorber Rear shock absorber travel Dune125 42 5 mm 1 673 in Rear shock absorber travel DuneX125 47 5 mm 1 87 in Brakes BRAKES Specification Desc Quantity Front brake disc Rear brake disc Whee...

Page 14: ...htening torque values refer to the table with the generic torque values indicated below GENERAL TIGHTENING TORQUES M4 M5 M6 M8 M10 M12 Metric tightening torque TE TEFL SHC TBEI TCC TS 3 Nm 2 21 lb ft 6 Nm 4 43 lb ft 10 Nm 7 38 lb ft 25 Nm 18 44 lb ft 50 Nm 36 88 lb ft 80 Nm 59 00 lb ft GENERAL TIGHTENING TORQUES FOR SELF TAPPING SCREWS FOR PLASTIC 2 9 mm 3 9 mm 4 2 mm 5 mm Tightening torque 2 Nm 1...

Page 15: ... Euro 4 Characteristics CHAR 15 FRONT WHEEL pos Description Type Quantity Torque Notes 1 Wheel fastening pin M14 1 70 80 Nm 51 63 59 lb ft 2 SHC front brake disc fastening screws M6x20 6 10 12 Nm 7 38 8 85 lb ft Loct 243 ...

Page 16: ...ring yoke fastening screws M8 35 2 20 24 Nm 14 75 17 70 lb ft 6 SHC steering yoke fastening screws M8 35 2 20 24 Nm 14 75 17 70 lb ft pos Description Type Quantity Torque Notes 1 Caps 2 15 25 Nm 11 06 18 44 lb ft 2 SHC wheel axle clamp fastening screws M6 25 3 4 6 Nm 2 95 4 42 lb ft 3 Hex head handlebar U bolt flanged fastening screws M8 30 6 20 25 Nm 14 75 18 44 lb ft 4 NUT M24 1 1 50 60 Nm 36 87...

Page 17: ... Clutch control fastening screws M6 25 2 6 8 Nm 4 43 5 90 lb ft 4 Front brake upper pump brake hose bolt M10 1 1 28 33 Nm 20 66 24 35 lb ft 5 PUMP FR DISC BRAKE M8 30 2 17 19 Nm 12 54 14 01 lb ft Loct 243 6 Throttle cable bolt M5 8 1 5 6 Nm 3 69 4 43 lb ft 7 Brake oil line clamp bolt M6 16 1 7 10 Nm 5 16 7 38 lb ft 8 Brake oil line clamp screw ST5 1 14 1 3Nm 2 21 lb ft 9 Front brake upper pump bra...

Page 18: ...3 Instrument cover self tapping screws St2 8 13 4 0 6 Nm 0 44 lb ft 4 Instrument cover self tapping bolt M5 16 2 2 3 Nm 1 48 2 21 lb ft 5 Headlight cover bolt M5 16 2 2 3 Nm 1 48 2 21 lb ft Loct 243 6 Front shroud bolt M5 16 4 2 3 Nm 1 48 2 21 lb ft 7 Headlight bolt M6 20 2 2 3 Nm 1 48 2 21 lb ft 8 Rearlight bolt M5 35 2 2 3 Nm 1 48 2 21 lb ft 9 License plate light bolt M5 16 1 2 3 Nm 1 48 2 21 lb...

Page 19: ...3 Instrument cover self tapping screws St2 8 13 4 0 6 Nm 0 44 lb ft 4 Instrument cover self tapping bolt M5 16 2 2 3 Nm 1 48 2 21 lb ft 5 Headlight cover bolt M5 16 2 2 3 Nm 1 48 2 21 lb ft Loct 243 6 Front shroud bolt M5 16 4 2 3 Nm 1 48 2 21 lb ft 7 Headlight bolt M6 20 2 2 3 Nm 1 48 2 21 lb ft 8 Rearlight bolt M5 35 2 2 3 Nm 1 48 2 21 lb ft 9 License plate light bolt M5 16 1 2 3 Nm 1 48 2 21 lb...

Page 20: ...48 2 21 lb ft 6 Front fender bolt M6 16 Dune125 M6 25 Dune X125 4 8 10 Nm 5 90 7 38 lb ft 7 Rear armrest bolt M8 30 4 17 19 Nm 12 54 14 01 lb ft Loct 243 8 Rear tail bolt M5 16 2 2 3 Nm 1 48 2 21 lb ft 9 Rear tail bolt M5 16 6 2 3 Nm 1 48 2 21 lb ft 10 License bracket bolt M6 16 2 8 10 Nm 5 90 7 38 lb ft 11 Rear fender bolt M6 16 2 8 10 Nm 5 90 7 38 lb ft 12 Rear fender bolt M5 16 4 5 6 Nm 3 69 4 ...

Page 21: ...racket bolt M6 30 2 8 10 Nm 5 90 7 38 lb ft 3 Engine bracket bolt M10 100 4 37 39 Nm 27 29 28 76 lb ft 4 Engine shroud bolt M5 16 3 2 3 Nm 1 48 2 21 lb ft 5 Front Pedal bolt M8 40 2 17 19 Nm 12 54 14 01 lb ft 6 Front fender bolt M6 25 1 8 10 Nm 5 90 7 38 lb ft 7 Engine bracket bolt M10 25 2 37 39 Nm 27 29 28 76 lb ft 8 Side bracket bolt M8 1 17 19 Nm 12 54 14 01 lb ft ...

Page 22: ...BLY FILTER BOX pos Description Type Quantity Torque Notes 1 Canister bracket bolt M6 10 1 5 7 Nm 3 69 5 16 lb ft pos Description Type Quantity Torque Notes 1 Air filter box fastening screw M5 12 4 3 5 Nm 2 58 lb ft 2 Air filter box bolt M6 16 4 5 7 Nm 3 69 5 16 lb ft ...

Page 23: ... 5 16 lb ft 2 Ignition coil Assy bolt M3 25 4 4 6 Nm 2 95 4 43 lb ft 3 ECU cable bracket bolt M5 15 1 2 7 3 3 Nm 1 99 2 43 lb ft 4 Instrument screw ST3 6 18 3 0 6 Nm 0 44 lb ft 5 Battery box bolt M6 16 3 5 7 Nm 3 69 5 16 lb ft 6 Relay bolt M6 16 1 5 7 Nm 3 69 5 16 lb ft 7 Horn bolt M8 20 1 17 19 Nm 12 54 14 01 lb ft 8 Rectifier bolt M6 25 2 8 10 Nm 5 90 7 38 lb ft ...

Page 24: ...olant tank bolt M6 16 2 8 10 Nm 5 90 7 38 lb ft 2 Fuel tank bolt M6 30 1 8 10 Nm 5 90 7 38 lb ft 3 Fuel tank lock bolt M5 12 4 2 7 3 3 Nm 1 99 2 43 lb ft 4 Fuel tank lock bolt M5 30 3 2 7 3 3 Nm 1 99 2 43 lb ft 5 Radiator bolt M6 25 3 8 10 Nm 5 90 7 38 lb ft 6 Oil pump bolt M5 16 6 4 5 5 5 Nm 3 32 4 06 lb ft ...

Page 25: ... pos Description Type Quantity Torque Notes 1 Electric Lock bolt M8 20 1 18 20 Nm 13 28 14 75 lb ft 2 Electric Lock bolt M8 20 1 18 20 Nm 13 28 14 75 lb ft 3 Electric Lock cover bolt M5 9 2 2 3 Nm 1 48 2 21 lb ft 4 Seat lock bolt M6 10 2 8 10 Nm 5 90 7 38 lb ft ...

Page 26: ... Muffler fixing clamp M6 1 8 10 Nm 5 90 7 38 lb ft 4 Muffer bolt M8 20 2 18 22 Nm 13 28 16 23 lb ft 5 Muffer bent pipe bolt M8 2 18 22 Nm 13 28 16 23 lb ft 6 Oxygen Sensor bolt M12 1 17 20 Nm 12 54 14 75 lb ft pos Description Type Quantity Torque Notes 1 Rear axle M14 1 70 80 Nm 51 63 59 lb ft 2 Rear brake disc bolt M8 24 2 3 15 18 Nm 11 06 13 27 lb ft Loct 243 3 Rear sprocket bolt M8 30 6 17 19 N...

Page 27: ... 65 Nm 10 56 47 94 lb ft 2 Rear shock absorber bolt M12 50 1 55 65 Nm 10 56 47 94 lb ft 3 Flat fork shaft M12 2 70 75 Nm 51 62 55 56 lb ft 4 Chain guard bolt M6 12 2 5 7 Nm 3 69 5 16 lb ft 5 Chain adjuster bolt M6 2 5 7 Nm 3 69 5 16 lb ft 6 Chain slider bolt M4 8 19 2 3 Nm 2 21 lb ft 7 Chain guide bolt M6 12 2 5 7 Nm 3 69 5 16 lb ft Loct 243 ...

Page 28: ...1 8 10 Nm 5 90 7 38 lb ft pos Description Type Quantity Torque Notes 1 Special brake pipe fastening screws M10 22 4 28 33 Nm 20 66 24 35 lb ft 2 Special brake pipe fastening screws M10 32 2 28 33 Nm 20 66 24 35 lb ft 3 SHC front brake caliper fastening screws M8 2 22 24 Nm 16 23 17 70 lb ft Loct 243 4 CBS control unit fastening screws M6 20 2 8 10 Nm 5 90 7 38 lb ft 5 SHC front brake caliper faste...

Page 29: ...ristics CHAR 29 Engine CRANKSHAFT CYLINDER PISTON pos Description Type Quantity Torque Notes 1 Gear fixing screw M10 1 40 Nm 29 50 lb ft pos Description Type Quantity Torque Notes 1 Chain tensioner fastener screw M6 16 2 12 Nm 8 85 lb ft ...

Page 30: ...HROTTLE BODY pos Description Type Quantity Torque Notes 1 Sleeve fixing screw M6 20 3 12 Nm 8 85 lb ft 2 Sleeve fixing clamp 1 0 8 Nm 0 59 lb ft 3 Injector mounting fixing screw M6 20 1 10 Nm 7 38 lb ft 4 Cable stay on throttle body M4 1 4 Nm 2 95 lb ft ...

Page 31: ... Quantity Torque Notes 1 Clutch cover fixing screw M6 35 10 12 Nm 8 85 lb ft 2 Oil filter cover M56 1 5 1 25 Nm 18 44 lb ft 3 Oil pressure sensor M10 1 13 Nm 9 59 lb ft pos Description Type Quantity Torque Notes 1 Spark plug M10 1 13 Nm 9 59 lb ft 2 Head cover fastener screw M6 4 11 Nm 8 11 lb ft ...

Page 32: ...Flywheel cover fastener screw M6 10 12 Nm 8 85 lb ft 2 Timing control cap M18 2 4 Nm 2 95 lb ft 3 Oil dipstick M12 1 5 1 5 Nm 3 69 lb ft pos Description Type Quantity Torque Notes 1 Chain tensioner pad fastener screw M6 16 1 10 Nm 7 38 lb ft Loctite 243 2 Timing system gear fastener screw M8 40 2 27 Nm 19 91 lb ft Loctite 243 ...

Page 33: ...Description Type Quantity Torque Notes 1 Clutch spring screw M5 5 4 Nm 2 95 lb ft 2 Crankshaft primary gear fastener nut M12 1 79 Nm 58 27 lb ft 3 Clutch nut 1 40 Nm 29 50 lbf ft pos Description Type Quantity Torque Notes 1 Starter motor fastener screw M6x25 2 12 Nm 8 85 lb ft ...

Page 34: ...e 125 Dune X 125 Euro 4 Characteristics CHAR 34 WATER PUMP pos Description Type Quantity Torque Notes 1 Water pump fastener screw M5 3 3 5 Nm 2 58 lb ft 2 Water pump rotor fastener screw 1 5 Nm 3 69 lb ft ...

Page 35: ...astener screw M5x35 3 4 Nm 2 95 lb ft Loctite 243 2 Oil cap retainer 1 25 Nm 18 44 lb ft pos Description Type Quantity Torque Notes 1 Selector sprocket fastener screw M5 1 4 Nm 2 95 lb ft 2 Lever fastener screw M6 1 9 Nm 6 64 lb ft 3 Clutch lever fastener screw 1 9 Nm 6 64 lb ft 4 Gear shift selector pin fixing 1 9 Nm 6 64 lb ft ...

Page 36: ...25 Dune X 125 Euro 4 Characteristics CHAR 36 ENGINE CRANKCASE pos Description Type Quantity Torque Notes 1 Crankcase retainer screw M6x60 4 12 Nm 8 85 lb ft 2 Crankcase retainer screw M6x75 4 12 Nm 8 85 lb ft ...

Page 37: ... 12 Nm 8 85 lb ft 2 Drainage side stud bolt retainer M8x40 2 12 Nm 8 85 lb ft 3 Camshaft cover fastener screw M6x40 4 11 Nm 8 11 lb ft 4 Head fastener screw M8x166 4 27 Nm 90 19 91 lb ft 90 5 Thermostat cover fastener screw M6x20 2 11 Nm 8 11 lb ft 6 Head dowels retainer M8x10 2 6 5 Nm 4 79 lb ft 7 Thermostat retainer 1 9 Nm 6 64 lb ft ...

Page 38: ...R 38 IGNITION UNIT pos Description Type Quantity Torque Notes 1 Flywheel rotor fixing nut M14x1 5 1 86 Nm 63 43 lb ft 2 Rotor fastener screw 6 12 Nm 8 85 lb ft 3 Stator clamping screws 2 6 Nm 4 43 lb ft 4 Pick Up clamping screw 3 3 5 Nm 2 58 lb ft ...

Page 39: ...Dune 125 Dune X 125 Euro 4 Characteristics CHAR 39 COMPONENTS OF GEARBOX pos Description Type Quantity Torque Notes 1 Gear sensor retainer 1 3 Nm 2 21 lb ft ...

Page 40: ...min max Cylinder Piston M 58 010 58 017 57 963 57 970 0 040 0 054 Cylinder Piston N 58 017 58 024 57 970 57 977 0 040 0 054 Cylinder Piston O 58 024 58 031 57 977 57 984 0 040 0 054 Cylinder Piston P 58 031 58 038 57 984 57 991 0 040 0 054 pos Description Type Quantity Torque Notes 1 Pinion fastening screws M5 2 4 5 Nm 2 95 3 69 lb ft Loctite 270 2 Pinion cover fastening screws M5 2 2 5 3 5 Nm 1 8...

Page 41: ...Dune 125 Dune X 125 Euro 4 Characteristics CHAR 41 Rod small end pin piston Characteristic Rod small end Maximum diameter 15 023 mm 0 591 in Standard diameter 15 010 15 018 mm 0 5910 0 5912 in ...

Page 42: ...SPECIAL TOOLS INDEX OF TOPICS S TOOLS ...

Page 43: ...tools S TOOLS 43 866380 Water pump tool set SPECIAL TOOLS Stores code Description AP8140266 Dial gauge mount 865259 Flywheel retainer 864486 Countershaft lock tool 864868 Flywheel extractor 864567 Camshaft timing adjustment lock pins ...

Page 44: ... 44 020287Y Tool for installing seal rings 00H05300041 Clutch lock 020376Y Sleeve for adaptors Stores code Description 00H05600351 Oil seal guide 020382Y011 Valve removal installation tool 865261 Piston retainer 865260 Camshaft sprocket lock tool ...

Page 45: ...0 mm Adaptor 020439Y 17 mm punch for secondary shaft oil seal 020363Y 20 mm diam punch for crankshaft oil seal Stores code Description 020359Y 42 x 47 mm Adaptor 020357Y 32 x 35 mm Adaptor 020891Y 25 mm 0 98 in adapter 020412Y 15 mm diam punch for clutch oil seal ...

Page 46: ...XSM 125 XTM 125 Euro 4 Special tools S TOOLS 46 Stores code Description 020483Y 30 mm guide 020364Y 25 mm adapter 020375Y 28x30 mm punch ...

Page 47: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 48: ...on check that handlebar turns freely check clutch suspension engine lights indicator lamps 5 Replace at whichever of the following occurs first 36 000 km 22 369 36 mi or 4 years 6 Check every 1 000 km 621 37 mi 7 Replace every 30 000 km 18 641 14 mi SCHEDULED MAINTENANCE TABLE Km x 1 000 mi x 1 000 1 0 6 6 3 7 12 7 5 18 11 2 24 14 9 30 18 6 36 22 4 42 26 1 48 29 8 EVERY 12 MONTH S EVERY 24 MONTH S...

Page 49: ...lamps 6 Replace at whichever of the following occurs first 36 000 km 22 369 36 mi or every 4 years 7 Check every 1 000 km 621 37 mi 8 Replace every 30 000 km 18 641 14 mi SCHEDULED MAINTENANCE TABLE km mi x1000 1 0 6 6 3 7 12 7 5 18 11 2 24 14 9 30 18 6 36 22 4 42 26 1 48 29 8 Rear shock absorber I I I I Audible and visual warning devices I I I I I I I I I Battery I I I I I I I I Spark plug I R I ...

Page 50: ...6 ASTM D 4656 ASTM D 4985 CUNA NC 956 16 Brake fluid DOT 4 Synthetic brake fluid SAE J 1703 FMVSS 116 ISO 4925 CU NA NC 956 DOT4 Lithium based grease Lithium calcium soap based grease colour black contains EP Extreme Pressure additives excellent water re pellent properties Vaseline neutral grease for battery terminals Spray grease for chains Spray lubricant grease Fork oil 7 5W Fork oil SAE 7 5W S...

Page 51: ...EL MUST BE CHECKED WHEN THE ENGINE IS WARM THE OIL LEVEL MAY TEMPORARILY DROP BELOW THE MIN MARK WHEN THE ENGINE IS COLD GIVING A FALSE READING THIS SHOULD NOT BE CONSIDERED A PROBLEM PROVIDED THAT THE ALARM WARNING LIGHT AND THE ENGINE OIL PRESSURE ICON DISPLAY DO NOT TURN ON SIMULTANEOUSLY CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OP...

Page 52: ...s required Unscrew and remove the cap 1 When using a funnel or any other element make sure it is perfectly clean DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCES TO THE OIL CAUTION USE OIL MEETING THE SPECIFICATIONS INDICATED IN THE TABLE OF RECOMMENDED PRODUCTS AT THE END OF THIS MANUAL CAUTION DO NOT GO BEYOND THE MAX AND BELOW THE MIN LEVEL MARK TO AVOID SEVERE ENGINE DAMAGE Top up the oil in the r...

Page 53: ...specified tightening torque Fill with the specified quantity of engine oil via the filler port 1 Recommended products Engine oil 5W 40 Synthetic based lubricant for four stroke engines SAE 5W 40 JASO MA MA2 API SL ACEA A3 Characteristic Engine oil 900 cm 54 91 cu in Fit and tighten the filler plug 1 Start the engine and run at idle speed for approximately a minute to allow the oil to distribute co...

Page 54: ... Engine oil filter Remove the engine fairing lug and drain off the engine oil Undo and remove the oil filter cap 1 Retrieve the spring 2 Remove the oil filter 3 Air filter Remove the saddle Remove the tool kit 1 Unscrew and remove the four screws 2 ...

Page 55: ...e inside of the filter outwards Clean the outside of the filter element 4 with a clean cloth Clean the interior of the filter housing and the intake ducts with a clean cloth CAUTION WHEN CLEANING THE FILTER ELEMENT CHECK THAT THERE ARE NO TEARS IN THE ELEMENT ITSELF RE PLACE THE FILTER ELEMENT IF NECESSARY REPLACING THE AIR FILTER Replace the air filter with a new component of the same type NOTE N...

Page 56: ...RAKE FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH THE SKIN EYES AND PARTS OF THE MOTORCYCLE WHEN TOPPING UP PROTECT PARTS OF THE MOTORCYCLE IN THE VICINITY OF THE RES ERVOIR WITH ABSORBENT MATERIAL Recommended products Brake fluid DOT 4 Synthetic brake fluid SAE J 1703 FMVSS 116 ISO 4925 CUNA NC 956 DOT4 Front braking system Unscrew and remove the screws 1 on the front braking circuit fluid tank 2...

Page 57: ...ILL TO THE MAX LEVEL AFTER FITTING NEW BRAKE PADS DO NOT FILL TO THE MAX LEVEL WITH WORN PADS AS THIS WILL CAUSE FLUID TO ESCAPE WHEN REPLACING BRAKE PADS CHECK BRAKING EFFICIENCY IF THE DEAD ZONE OF THE BRAKE PEDAL OR BRAKE LEVER IS TOO LONG OR IN CASE OF FLUID LOSS IT MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN THE SYSTEM Adjusting the levers NOTE NO ADJUSTMENT IS POSSIBLE FOR THE FRONT BRAKE L...

Page 58: ...on its stand Remove the protection casing 2 Loosen the lock nut 3 Turn the set screw 1 until the empty travel at the clutch lever end is approx imately 10 15 mm 0 39 0 59 in see figure After adjusting tighten the check nut 3 to lock the adjuster screw 1 Check the empty travel at the clutch lever end Refit he protection casing 2 NOTE CHECK THE CONDITION OF THE CLUTCH CABLE THERE MUST BE NO SIGNS OF...

Page 59: ...Dune 125 Dune X 125 Euro 4 Electrical system ELE SYS 59 ELECTRICAL SYSTEM INDEX OF TOPICS ELE SYS ...

Page 60: ...Dune 125 Dune X 125 Euro 4 Electrical system ELE SYS 60 Components arrangement ...

Page 61: ... fuses 7 Fan relay 8 Light relay 9 Front light assembly 10 Starter relay 11 Electric fan 12 Oxygen sensor 13 Flasher unit 14 Oil pressure sensor 15 Coil 16 Fuel pump 17 Injection relay 18 Secondary fuses 19 Instrument 20 MIU G3 control unit 21 Regulator 22 Spark plug boot 23 Temperature sensor 24 Starter motor 25 Neutral sensor ...

Page 62: ...mables such as cable clamps cable fasteners or cable glands are indicated in the figures Special checks for the correct connection and routing of cables It is extremely important that any security locks for the following connectors are properly connected and correctly tightened to ensure proper engine and therefore proper vehicle operation The installation is shown with the vehicle ideally divided...

Page 63: ...ectly connected tothe turn indicators CABLE ROUTING ON RH SIDE Secure the wiring harnesses on the RH side of the motorcycle as indicated and pass them through the metal cable gland 1 on the chassis Central part A OIL PRESSURE SENSOR Using a clamp 1 placed near the red taping secure the oil pressure sensor wiring harness 2 ...

Page 64: ...lectrical system ELE SYS 64 A1 OIL PRESSURE SENSOR The oil pressure sensor wiring harness 2 mustpassthroughthemetalcableglandofthe frame 3 A2 OIL PRESSURE SENSOR The oil pressure sensor wiring harness 2 mustpassunderthewaterpipe 4 ...

Page 65: ...ystem ELE SYS 65 HORN Place the horn 1 as shown in the fig ure and once you have connected the Faston connectors secure the wiring harness with a clamp VOLTAGE REGULATOR After securing the voltage regulator 1 con nected the wiring harness 2 ...

Page 66: ...t the red taping is placed near the metal flanges which must be covered with apiece of PVC pipe MAIN WIRING HARNESS Place the main wiring harness 1 on the metal flange which must be cov ered with a piece of PVC pipe MAIN WIRING HARNESS Place the main wiring harness 1 on the metal flanges and tighten them to stop the wiring harness from moving ...

Page 67: ... ELE SYS 67 ECU Secure the ECU connector using the special metal plate FLYWHEEL The flywheel wiring harness must be fastened to the other wiring harnesses by a clamp STARTER MOTOR Make sure that the starter motor earth cable is fastened correctly ...

Page 68: ...r motor connector 1 and secure it to the chassis with a clamp 2 FUSES Place the fuses as shown Back side MAIN WIRING HARNESS ON REAR CHASSIS Secure the main wiring harness using two clamps 2 near the red taping FLASHER Make sure the flasher 1 is connected to the right side of the tailgate ...

Page 69: ...em ELE SYS 69 RELAY Make sure that the relays 1 are connected to the left side of the tailgate Taillight and rear turn indicators cable Make sure that the taillight and rear turn indicators cable 1 are connected to the rear side of the tailgate ...

Page 70: ...Dune 125 Dune X 125 Euro 4 Electrical system ELE SYS 70 General wiring diagram ...

Page 71: ...HECK THAT THE BATTERY VOLTAGE IS ABOVE 12V PROCEDURE FOR CHECKING CONNECTOR This procedure consists of the following checks and inspections 1 Visually inspect connector and check that it is fitted correctly onto the component or onto the relative connection point and where applicable check that the connector retainer or clip is correctly fastened 2 Visually inspect the terminals on the connector t...

Page 72: ...ng GROUND CONNECTION Purpose of check the purpose of this check is to verify that a cable or circuit is correctly connected to the ground of the vehicle Tester set the tester selector to the continuity symbol and place one of the tester probes on the vehicle ground point or on the battery negative pole and the other probe on the cable under inspection Nor mally the tester will sound an audible sig...

Page 73: ... does not light no icons illuminate and none of the fuel gauge indicator bars are dis played In this case the fuel reserve warning lamp will not illuminate even when the tank is empty Water temperature The red water temperature warning lamp 3 illuminates in the event of ex cessive coolant temperature T 116 C Engine alarm warning MI The amber engine alarm warning lamp MI 4 lights continuously in th...

Page 74: ...ton II 5 Function switch button I 6 Instrument function button operation instructions RESETTING THE SCHEDULED MAINTENANCE ICON Elimination warning only connect battery and ignition switch is off long press the function button I over 5S and switch on the ignition switch at the same time to remove warning ...

Page 75: ... CR9EB NGK CR8EB Electrode gap 0 6 0 7 mm 0 024 0 027 in Battery recharge circuit Key 1 Multiple connectors 2 Battery 3 Main fuses 4 Voltage regulator 5 Alternator RECHARGING SYSTEM Disconnect the six way connector 1 black colour located behind the left side cover NOTE THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER A ...

Page 76: ... turning fan on by using a tester using alternatively 3 of the 5 connector pins no 2 4 6 stage 1 pin 2 4 stage 2 pin 2 6 stage 3 pin 4 6 Take the measurement The correct value is determined by the value measured for each stage in which from time to time the resistance of the tester wires is subtracted obtained by touching the two lugs Example Resistance of stage 1 read on the display 0 67 Ohm Resi...

Page 77: ...d with those on the alternator side and the chassis side of the motorcycle The outgoing wires from pins 1 and 5 must maintain the continuity of the positive and negative of the pick up otherwise the engine will not start while the out going cables from pins 2 4 6 alterna tor side must have the ends free in order to perform the appropriate ac tion CAUTION KEEP THE THREE ENDS OF THE FREE CABLES WELL...

Page 78: ...of the motorcycle The outgoing wires from pins 1 and 5 must maintain the continuity of the positive and negative of the pick up otherwise the engine will not start while the ends of the outgoing cables from pins 2 4 6 alternator side must be short circuited witheach other in order to be able to perform the appropriate action Start the engine and with an ammeter clamp measure each single cable If t...

Page 79: ... bring the speed to 3000 5000 RPM then measure with a tester the voltage at the battery poles that must always be between 13V and 15V Otherwise if the correct operation of the alternator has already been checked replace the regulator CAUTION PERFORM THE CHECK DESCRIBED ABOVE WITH A BATTERY IN GOOD CONDITION START VOLTAGE ABOUT 13V MAKING SURE THAT THERE ARE NO ELEMENTS IN THE SHORT CIR CUIT Voltag...

Page 80: ...he check power up the motor with a 12 V 9 AH battery Win an AC ammeter clamp measure the steady running absorbed current after 5 seconds Correct value 50 60 A CHECKING THE STARTER MOTOR RELAY To check that the relay is operating correctly Power the two male terminals 85 86 with a 12 V voltage Using a tester in ohmmeter mode check the continuity between theother two terminals 87 30 Correct value wi...

Page 81: ...r button on right hand switch set Connector Electrical specifications Button released open circuit Button pressed closed circuit Diagnostic tool Parameters and statuses Starting request Absent Present Closed Loop Closed Diagnostics tool Logic errors Starter button P0512 signal not valid Error cause Fault in the switch lock of the engine start up or short circuit to ground Troubleshooting Check if ...

Page 82: ...Dune 125 Dune X 125 Euro 4 Electrical system ELE SYS 82 Horn control Testing voltage 13 V nominal 12 V Input 3 5 A Lights list ...

Page 83: ...7 Front stop switch 8 Multiple connectors 9 Rear right turn indicator 10 Licence plate light 11 Rear left turn indicator 12 Taillight 13 Starter motorrelay 14 Starter motor 15 Battery 16 Main fuses 17 Secondary fuses 18 MIU G3 control unit 19 Front left turn indicator 20 Light relay 21 Front daylight running light 22 Headlamp 23 High beam low beam light 24 Front right turn indicator ...

Page 84: ...TAILLIGHT Rear daylight running light stop light LED License plate light where applicable 12 V 5W Fuses MAIN FUSES DISTRIBUTION Specification Desc Quantity A 30A fuse Main fuse Vehicle circuit fuse B 10A fuse Secondary fuse EFI System and front back position lamp The fuses are located in the central part of the motorcycle under the saddle on the left hand side ...

Page 85: ... logic instrument cluster horn pre configuration for BlueDash USB port electric fan Position on the vehicle behind headstock connector on the battery Electrical specifications 12 V 4 Ah Pin out 1 Positive pole red approx 12 6 V 2 negative pole black ground lead DIAGNOSTIC TOOL PARAMETERS Battery voltage Example value with key ON 12 0 V Example value with engine on 14 2 V This is one of the values ...

Page 86: ...icate this error even if in ATT state Troubleshooting If too high check that the voltage regulator is working correctly If too low check voltage regulator connectors engine vehicle wiring harness connector and ECU connector check in particular for oxidation if not OK repair If OK check that resist ance of the Red White cable from the voltage regulator connector to the ECU connector is a few tenths...

Page 87: ...ution sensor negative signal X1 Engine speed sensor anti disturbance cable blue Diagnostic tool Parameters and statuses Engine speed rpm Target engine revs rpm Parameter valid at idle setting depends especially on engine temperature the ECU unit will try to keep the engine running at this revs acting on the ignition advance Diagnostic tool Electrical errors Engine revolution sensor P0336 inconsist...

Page 88: ...ical circuit diagram Temperature sensors Position Sensor On the head LH side Connector near the sensor Electrical specifications Resistance PIN B1 B2 at 25 C 77 F 2 05 kΩ 100 Ω Resistance PIN B1 B2 at 60 C 158 F 575 Ω 15 Ω Resistance PIN B1 B2 at 90 C 194 F 230 Ω 5 Ω Resistance PIN A1 A2 at 25 C 77 F 2 4 kΩ 200 Ω Resistance PIN A1 A2 at 60 C 158 F 557 Ω 30 Ω Resistance PIN A1 A2 at 90 C 194 F 196 ...

Page 89: ...e sensor connector and the control unit connector Control unit PIN 13 sensor PIN 3 and control unit PIN 15 sensor PIN 1 If necessary restore the wiring harness If the wiring harness is intact but the sensor resistance value is incorrect this means that the sensor is faulty and must be replaced otherwise proceed with the checks Short circuit to positive With the sensor connector and the control uni...

Page 90: ...h a high operating temperature that is why there is a heating circuit inside Level in electrical circuit diagram Lambda probe Injection utilities relay Position Sensor exhaust duct Connector underneath battery behind headstock RH side Electrical specifications Heater circuit 12 14 Ω at 20 C 68 F Pin out 1 Heater power A 2 Heater ground B 3 Sensor signal C 4 Sensor signal D Diagnostic tool Electric...

Page 91: ...tore the wiring harness If the wiring harness is intact and the error persists proceed with the following checks Short circuit to negative Disconnect the sensor connector and the control unit connector Check the sensor connector PIN C ground insulation If there is no insulation restore the wiring harness Check the sensor connector PIN D ground insulation If there is no insulation restore the wirin...

Page 92: ... insulated from ground and in the absence of other errors fuel pump injector coil this means that the control unit is most likely faulty Injector Function Provide the correct amount of fuel at the correct time Operation Operating principle Injector coil is excited for the petrol passage to open Level in electrical circuit diagram Relay for injection utilities Coils and injectors Electrical specifi...

Page 93: ...ough the diagnostic tool Verify the presence of voltage at the ends of the injector connector if there is no voltage restore the wiring har ness otherwise proceed with the fol lowing checks Open circuit Carry out the check procedure of the injector and control unit connectors Check continuity of cable between ECU connector and injector connector ECU PIN 34 injector PIN 1 In the absence of continui...

Page 94: ...ough the diagnostics in strument Verify the presence of voltage between relay connector PIN 1 and 2 toward the cabling If no voltage is read disconnect the control unit and verify insulation from battery positive of the relay PIN 1 or control unit PIN 22 Restore the ca bling if necessary Shorted to negative Disconnect the injection relay No 35 on the electrical circuit diagram and the control unit...

Page 95: ...ation of the electrical discharge on the spark plug with an increase of voltage Pin out 1 Relay powered PIN 3 relay side 2 Activation by control unit control unit side PIN 1 BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER ELECTRICAL ERRORS H V Coil ...

Page 96: ...tage is read verify the continuity of the cabling between coil and injection relay No 35 on the electrical circuit diagram Coil PIN 1 relay PIN 3 If the above tests provided a positive result the coil should be replaced Shorted to negative Disconnect the control unit connector and the coil connector Verify the coil connector PIN 2 ground insulation or control unit connector PIN 1 Restore the cabli...

Page 97: ...e sensor Electrical specifications Gear in neutral closed circuit 0 V on wire from control unit to sensor switch in continuity Gearshift engaged open circuit 12 V on the wire from control unit to sensor Pin out 1 Voltage 12V green black Diagnostic tool Parameters and statuses Gear in neutral YES NO Diagnosis Warning light N always off Error cause Possible malfunction Troubleshooting Carry out the ...

Page 98: ...nuity replace the sen sor If there is no continuity this meansthat there is a short to ground of the green black cable which goes to PIN 3 of the control unit therefore restore the wir ing harness If there is no continuity restore the wir ing harness If there is no continuity replace the wir ing harness Clutch lever sensor Function Indicates the clutch lever position to the control unit Operation ...

Page 99: ...re is no continuity restore the wiring harness If there is continuity disconnect the sensor and with the clutch engaged check for continuity between the two sensor PINs If absent replace the sensor If present check for continuity of the blue green cable between the sensor and control unit PIN 15 If absent restore the wiring harness The vehicle starts even without pulling the clutch lever Error cau...

Page 100: ...lay on off DIAGNOSTIC TOOL ACTIVATIONS Fan The fan relay is excited No 42 in elec trical circuit diagram ALWAYS CHECK colour of wires to identify relay correctly for 10 seconds Electrical continuity is required in the wiring for the relay to activate correctly no errors are generated if the relay fails to acti vate ELECTRICAL ERRORS Fan relay P0480 short circuit to positive short circuit to negati...

Page 101: ... the cable between the relay connector PIN 1 and the ECU connector PIN 2 Check continuity of the cable between the relay connector PIN 2 and the secondary fuse box Check continuity between PIN 1 and PIN 2 of the relay If continuity is not confirmed replace the relay RUN STOP switch Function Indicates the control unit if the rider wishes to en able engine start up or to keep the engine running Oper...

Page 102: ...ring harness side If there is continuity with ground connection restore the wiring harness if it is OK set the key to KEY OFF and check the engine control unit connector if it is OK replace the engine control unit Engine does not shut off with switch in STOP Error cause Possible malfunction Troubleshooting Disconnect the connector and verify with the switch set to STOP that there is continuity bet...

Page 103: ...da probe input grey green 13 Temperature sensor input grey black 14 NO 15 External sensor ground black white 16 K line orange black 17 Neutral indicator lamp output green red 18 Analogue clutch input green yellow 19 Side stand input black yellow 20 Pick up input X1 21 NO 22 Injection relay white blue 23 Ground 2 power green 24 Fan relay output blue red 25 Warning lamp output green white 26 NO 27 N...

Page 104: ...arelli SW part number software part number Programming data control unit pro gramming data NIP code Diagnostic tool Parameters and statuses This screen page shows the parameters meas ured by the several sensors engine revs engine temperature etc or values set by the controlunit injection time ignition advance in addition to the parameters the status of the vehicle devices or the operation conditio...

Page 105: ...epper Base Opening of Stepper Reg KON count Injector bleeding Coil dwell RUN OFF Switch RUN OFF Start enable NO YES Checking of Probe1 value Lambda probe Not enabled Not active start Not active heat Not active rich Operating Not active lean Fault Engine mode Stepper motor status Tone wheel Recharge status Enabling Ignition Fan relay OFF Side stand Up Down Starting request Absent Present Closed Loo...

Page 106: ... sensor inside the control unit Troubleshooting Replace the control unit Air temperature sensor P0110 short circuit to positive open circuit short circuit to negative Cause of error Malfunction of sensor inside the control unit Troubleshooting Replace the control unit Error EEPROM P0601 circuit not working Cause of error The instrument panel does not indicate the presence of this error even in the...

Page 107: ...ool Adjustment Throttle positioner autodetection It allows the control unit to detect the closed throttle position just press the Enter key Reset of self adaptive parameters operation to be carried out after the throttle body is cleaned or in the case a new engine a new lambda probe or a new injector is fitted or the correct operation of the injection system or the valves is restored Diagnostic to...

Page 108: ...rning light green red 9 1th gear light pink 10 2th gear light pink black 11 3th gear light green black 12 Speed sensor green white 13 GND green 14 Speed sensor red yellow 15 IGN white red 16 BATT red blue 17 Left turn indicator light orange 18 Right turn indicator light light blue 19 Headlight brown 20 High light blue 21 4th gear light red white 22 5th gear light grey blue 23 Fuel level light yell...

Page 109: ...ENGINE FROM VEHICLE INDEX OF TOPICS ENG VE ...

Page 110: ...ain off the cooling system First remove the fairing lug the side fairings the battery the fuel tank the side fairing panels the drive chain the side bumpers the radiator and the expansion tank Removing the engine from the vehicle Undo and loosen the clutch cable ad justment nuts 1 Remove the clutch cable 2 from the points indicated in the figure Undo and remove the screw 3 Remove the earth cable 4...

Page 111: ...ne 125 Dune X 125 Euro 4 Engine from vehicle ENG VE 111 Undo and remove the screw 5 Remove the earth cable 6 Remove the spark plug tube 7 Remove the fuel pipe 8 Disconnect the water temperature sen sor 9 ...

Page 112: ... vehicle ENG VE 112 Disconnect the engine speed sensor connector 10 Remove the connector wiring harness 10 from the chassis area as shown in the figure Loosen the clamp 11 anddisconnect the pipe 12 Undo the screw 13 and remove the cable 14 ...

Page 113: ...125 Euro 4 Engine from vehicle ENG VE 113 Remove the cables from the cable gland shown in the figure Unscrew the pin 15 and remove it Block the nuts 16 and unscrew and remove the screws 17 Remove the support bracket 18 ...

Page 114: ...125 Euro 4 Engine from vehicle ENG VE 114 Remove the support bracket 19 Disconnect the engine oil sensor con nector 20 undo the screw 21 Remove the hose guide 22 Disconnect the injector connector 23 Loosen the clamp 24 ...

Page 115: ...nd remove the screw 25 Unscrew and remove the screw 26 Move the entire engine block to slide the sleeve 27 off the throttle body as shown in the figure Remove the complete engine 28 Installing the engine to the vehicle FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER ...

Page 116: ...ENGINE INDEX OF TOPICS ENG ...

Page 117: ...AR SELECTOR pos Description Type Quantity Torque Notes 1 Selector sprocket fastener screw M5 1 4 Nm 2 95 lb ft 2 Lever fastener screw M6 1 9 Nm 6 64 lb ft 3 Clutch lever fastener screw 1 9 Nm 6 64 lb ft 4 Gear shift selector pin fixing 1 9 Nm 6 64 lb ft ...

Page 118: ...ient with a capacity of at least 900 cm 54 91 cu in under the drain plug 1 on the clutch side Re move the plug and drain the oil into the recipient for a few minutes NOTE CHECK AND IF NECESSARY REPLACE THE DRAIN PLUG SEAL WASHER Remove the gearbox oil filter 2 and replace Remove the drain plug 3 on the alter nator side NOTE CHECK AND IF NECESSARY REPLACE THE DRAIN PLUG SEAL WASHER ...

Page 119: ...CESSARY REPLACE THE FILTER SEAL WASHER Gearbox shafts Disassembling the gearbox Remove the desmodromic drum Separate the crankcase halves Remove the gasket from the crank case Remove both the gearbox selector fork rods and the forks 1 2 Remove the desmodromic selector 3 Remove the secondary shaft 4 Remove the primary shaft 5 ...

Page 120: ...ft THE PRIMARY SHAFT CANNOT BE DISASSEMBLED IF NECESSARY REPLACE THE ENTIRE PRIMARY SHAFT Removing the secondary shaft FIT NEW CIRCLIPS WHEN REASSEMBLING Disassemble the secondary shaft as follows Remove the shim washer 1 Remove the first speed gear 2 Remove the roller bearing cage 3 ...

Page 121: ...Dune 125 Dune X 125 Euro 4 Engine ENG 121 Remove the spacer washer 4 Remove the fifth speed gear 5 Remove the circlip 6 Remove the spacer washer 7 ...

Page 122: ...Dune 125 Dune X 125 Euro 4 Engine ENG 122 Remove the third speed gear 8 Remove the fourth speed gear 9 Remove the sixth speed gear 10 Remove the spacer washer 11 ...

Page 123: ...Dune 125 Dune X 125 Euro 4 Engine ENG 123 Remove the spacer washer 12 Remove the second speed gear 13 Remove the bush 14 Remove the shim washer 15 ...

Page 124: ... desmodromic shaft and drum for any signs of damage scratches or wear and replace if necessary Check the channels in the desmodromic drum for any signs of damage or and replace the drum if necessary Check the desmodromic drum bearing for any signs of damage or pitting and change the drum if necessary Checking the forks THE FOLLOWING PROCEDURE IS APPLICABLE FOR ALL THE GEARBOX SELECTOR FORKS ...

Page 125: ...ormly and without impediment check for damage dents and signs of wear on the roller 1 and on the teeth 2 of the fork Replace the fork if necessary Starter motor STARTER MOTOR pos Description Type Quantity Torque Notes 1 Starter motor fastener screw M6x25 2 12 Nm 8 85 lb ft ...

Page 126: ...e the starter motor 2 NOTE THE STARTER MOTOR CAN ALSO BE REMOVED IF THE ENGINE IS FITTED TO THE VEHICLE Generator side FLYWHEEL COVER pos Description Type Quantity Torque Notes 1 Flywheel cover fastener screw M6 10 12 Nm 8 85 lb ft 2 Timing control cap M18 2 4 Nm 2 95 lb ft 3 Oil dipstick M12x1 5 1 5 Nm 3 69 lb ft ...

Page 127: ...fastener screw 6 12 Nm 8 85 lb ft 3 Stator clamping screws 2 6 Nm 4 43 lb ft 4 Pick Up clamping screw 3 3 5 Nm 2 58 lb ft Removing the flywheel cover Unscrew and remove the two adjust ment plugs 1 Unscrew and remove the engine oil pre filter plug 2 Remove the engine oil pre filter Undo and remove the ten screws fixing the flywheel cover Remove the flywheel cover ...

Page 128: ...imozione rotore Remove the starter motor gear Fit the specific tool Undo and remove the hex socket screw Specific tooling 865259 Flywheel retainer Retrieve the washer Fit the tool and pull out the rotor Specific tooling 864868 Flywheel extractor ...

Page 129: ...une 125 Dune X 125 Euro 4 Engine ENG 129 Remove the rotor Remove the key Removing the stator Remove the two screws fastening the plate securing the stator cable Remove the two screws fastening the stator ...

Page 130: ...Dune 125 Dune X 125 Euro 4 Engine ENG 130 Remove the stator Freewheel removal Undo and remove the indicated retain er screw with the relative plate Remove the freewheel ...

Page 131: ...Engine ENG 131 Clutch side CLUTCH COVER Pos Description Type Quantity Torque Notes 1 Clutch cover fixing screw M6x35 10 12 Nm 8 85 lb ft 2 Oil filter cover M56x1 5 1 25 Nm 18 44 lb ft 3 Oil pressure sensor M10 1 13 Nm 9 59 lb ft ...

Page 132: ...5 5 4 Nm 2 95 lb ft 2 Crankshaft primary gear fastener nut M12 1 79 Nm 58 27 lb ft 3 Clutch nut 1 40 Nm 29 50 lbf ft Removing the clutch cover Undo and remove the ten screws of the clutch cover Remove the clutch cover Remove the gasket 1 and retrieve the locating dowels 2 WARNING REPLACE THE GASKET WHEN REASSEMBLING ...

Page 133: ...t a time operate in stages and diagonally and retrieve the washers and the clutch springs Remove the thrust bearing Remove the discs Release the screw by lowering the lock tab Block clutch bell rotation using the spe cific tool Unscrew and remove the clutch bell fixing nut Remove the clutch hub Specific tooling 00H05300041 Clutch lock ...

Page 134: ...e the shim and the clutchhous ing Remove the shim Checking the clutch plates Characteristic Driving plates thickness 2 85 2 95 mm 0 112 0 116 in Number of driving plates 5 Driven plates thickness 1 46 1 53 mm 0 057 0 06 in Number of driven plates 4 ...

Page 135: ...e primary drive gear and the clutch bell all together Check the worn guiding grooves ofthe clutch bell 1 max insertion depth A 0 5 mm 0 020 in Checking the clutch hub When the clutch hub is worn it can cre ate problems with sliding of the hous ing The hub should be replaced if the surface of the spring has exceeded the wear limits Max wear limit A 0 3 mm 0 012 in Check the clutch hub for damage an...

Page 136: ...replace the them all togeth er Measure the clutch spring length when unloaded if necessary replace the springs all together Characteristic Minimum wear limit in the release position of the individual clutch springs 31 6 mm 1 24 in Assembling the clutch Insert the shim Fit the clutch housing Fit the shim washer ...

Page 137: ...H05300041 Clutch lock Lift one side of the lock tab Insert the disc covered with friction material into the housing Continue inserting alternating a metal disc with one with friction material fin ishing with a friction material disc with a black tooth Place the thrust plate Fit the clutch springs Fit the screw washers Tighten the six screws operating in stages and diagonally ...

Page 138: ...5 Dune X 125 Euro 4 Engine ENG 138 Crankcase ENGINE CRANKCASE pos Description Type Quantity Torque Notes 1 Crankcase retainer screw M6x60 4 12 Nm 8 85 lb ft 2 Crankcase retainer screw M6x75 4 12 Nm 8 85 lb ft ...

Page 139: ...ncing countershaft removal Before taking out the balancing coun tershaft the clutch cover and flywheel cover must be removed Lock the countershaft with the specific tool Specific tooling 864486 Countershaft lock tool Unscrew and remove the nut and col lect the washer Remove the countershaft gear Remove the countershaft from the al ternator side ...

Page 140: ...ligning its reference to the primary gear Using the specific tool tighten the nut remember first to place the washer Specific tooling 864486 Countershaft lock tool Crankcase opening Beforehand remove the clutch cover and the clutch Remove the gear selector Install the countershaft blocking tool Specific tooling 864486 Countershaft lock tool ...

Page 141: ...he nut Collect the washer Remove the countershaft gear Remove the primary remaining gears Remove the head and cylinder Remove the chain guide slider un screwing and removing the fixing screw Remove the timing chain gear Remove the pump drive gear remov ing the seeger and recovering the washer ...

Page 142: ...uro 4 Engine ENG 142 Remove the base gear of the main shaft Remove the cotter Remove the oil pump unscrewing the three fixing screws Collect the gasket Remove the gear spider screw un screwing and removing the fixing screw ...

Page 143: ...ts beforehand Unscrew and remove the six screws on the outside of the crankcase 1 Unscrew and remove the longest screw 2 Unscrew and remove the five screws 3 Unscrew and remove the short screw 4 Remove the left crankcase Bearing removal Heat the crankcase surface with a heat gun Remove the bearing using the specific extractor ...

Page 144: ...val of countershaft roller bear ing cage 020364Y Crankcase check Before checking the crankcase halves thoroughly clean all the surfaces and the oil pipes For the crankcase half on the transmission side take particular care when handling the housing and hoses for the oil pump the duct with the by pass valve and the main bushings As already described in the lubrication chapter it is especially impor...

Page 145: ...eter RED BLUE Crankshaft type 1 Type 1 crankcase diameter RED BLUE Type 2 crankcase diameter BLUE BLUE Bearing fitting Heat up the crankcase using the thermal gun Fit the bearing in the seat with the aid of the specific tool List of tools for refitting to be coupled with sleeve 020376Y RIGHT CRANKCASE Insertion of main shaft bearing 020439Y 020359Y Removal of the main shaft bearing 020358Y Inserti...

Page 146: ...364Y NOTE insertion of the roller bearing cages in line with the crankcase is recommended from the inside to the outside Crankcase closing After installing the gearbox fit a new gasket Join the two crankcase halves togeth er using the locating dowels to align correctly Fit and tighten the short screw 1 Fit and tighten the five screws 2 Fit and tighten the long screw 3 Move to the left hand side of...

Page 147: ...ten the screw Fit a new oil pump gasket Fit the oil pump screwing the three screws Insert the countershaft gear and posi tion the washer Use the specific tool to tighten the nut Apply the cotter to the main shaft Position the base gear of the primary aligning the two references ...

Page 148: ... the pump drive gear Insert the washer and apply the fixing seeger Insert the timing chain gear paying at tention to the direction The engraving must face upward Fit the timing chain Position the chain guide slider Position and screw the fixing screw ...

Page 149: ...f the primary gears Tighten the fixing nut Remove the countershaft locking tool Fit the gear selector Head and timing HEAD COVER pos Description Type Quantity Torque Notes 1 Spark plug M10 1 13 Nm 9 59 lb ft 2 Head cover fastener screw M6 4 11 Nm 8 11 lb ft ...

Page 150: ...Nm 8 85 lb ft 2 Drainage side stud bolt retainer M8x40 2 12 Nm 8 85 lb ft 3 Camshaft cover fastener screw M6x40 4 11 Nm 8 11 lb ft 4 Head fastener screw M8x166 4 27 Nm 90 19 91 lb ft 90 5 Thermostat cover fastener screw M6x20 2 11 Nm 8 11 lb ft 6 Head dowels retainer M8x10 2 6 5 Nm 4 79 lb ft 7 Thermostat retainer 1 9 Nm 6 64 lb ft ...

Page 151: ...Chain tensioner pad fastener screw M6x16 1 10 Nm 7 38 lb ft Loctite 243 2 Timing system gear fastener screw M8x40 2 27 Nm 19 91 lb ft Loctite 243 Removing the head cover Remove the adjuster screw covers 1 Unscrew and remove the four cylinder head screws 2 Remove the cylinder head 3 Remove the gasket 4 ...

Page 152: ... the crankshaft from the hole on the cover 1 Take the piston to TDC The sign 2 must be aligned with the sign 3 Insert the specific pins 4 on the valves cam tower Specific tooling 864567 Camshaft timing adjustment lock pins Remove the starter motor beforehand Loosen and remove the tensioner screw 5 ...

Page 153: ...ing Unscrew and remove the two screws 6 and remove the entire tensioner control Lock the timing gear using thespecific tool Specific tooling 865260 Camshaft sprocket lock tool Unscrew and remove the gear Repeat the operation with the other gear Cylinder head ...

Page 154: ... ENG 154 Removing the overhead camshaft Remove the two pins from the cam tower Remove the eight screws 1 Remove the cam tower 2 Remove the two camshafts intake side and exhaust side Undo and remove the six screws fas tening the head 3 ...

Page 155: ...ve the head Place the head on supporting surface Number the valves and their bucket tappets in order to position them cor rectly upon refitting Remove the valve bucket tappets Compress the valve spring using the specific tool Specific tooling 020382Y011 Valve removal installation tool ...

Page 156: ...eter Bearing A 19 980 19 959 mm 0 7866 0 7858 in Minimum diameter allowed Bearing A 19 95 mm 0 7854 in Inlet cam height 31 488 mm 1 23968 in Exhaust cam height 30 864 mm 1 21511 in Check that the holes used for timing and their shoulders are not worn If values measured are not within the specified limits or there are signs of wear replace the defective components with new ones Characteristic Maxim...

Page 157: ...lowed Exhaust 3 95 mm 0 1555 in Standard clearance Intake 0 15 0 20 mm 0 0059 0 0079 in Standard clearance Exhaust 0 20 0 25 mm 0 0079 0 0098 in Maximum clearance admitted Intake 0 060 mm 0 0023 in Maximum clearance admitted Exhaust 0 070 mm 0 0027 in Remove the head cover Bring the engine to reach the top dead centre and lock it at that position using the specific tool 4 Specific tooling 864567 C...

Page 158: ...t of the valves in ques tion Remove the bucket tappet of thevalve in question and read the calibration val ue for that bowl found inside the buck et tappet itself Replace the bucket tappet with new one of a size suitable to restore the correct clearance Characteristic Standard clearance Intake 0 15 0 20 mm 0 0059 0 0079 in Standard clearance Exhaust 0 20 0 25 mm 0 0079 0 0098 in ...

Page 159: ... Inspecting the valve sealings Fit the valves into the cylinder head Alternatively test the intake and exhaust valves This test should be carried out by filling the mani fold with petrol and checking that the head does not excessively ooze through the valves Measure the sealing surface width on the valve seats VALVE SEALING SURFACE Specification Desc Quantity Inlet valve seal surface 2 30 0 15 mm ...

Page 160: ... in Replace the head if the values corre sponding to the width of the mark on the valve seat or the valve guide diam eter exceed the specified limits Check the width of the mark on the valve seat V Characteristic Wear limit for the width of the mark on the valve seat V Intake 1 6 mm 0 0630 in Outlet 1 8 mm 0 0708 in Inspecting the springs and half cones Check that the spring upper supporting caps ...

Page 161: ...n the two oil seals on the cylinder head Fit the valves the springs and the caps Using the specific tool compress the springs and fit the cotters in their seats Specific tooling 020382Y011 Valve removal installation tool Timing Checking the chain tensioner Remove the centre screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensio...

Page 162: ...der and the ten sioner pad are not excessively worn Check that the chain assembly the camshaft driving pulleys and the sprocket wheel are not worn Replace the parts if signs of wear are found Cylinder piston assembly Removing the cylinder Remove the head gasket 1 Remove the guide shoe 2 ...

Page 163: ...e water hose clamp 3 Remove the cylinder 4 Remove the gasket 5 Disassembling the piston Apply the tool under the piston 1 Cover the base of the cylinder with a cloth Specific tooling 865261 Piston retainer Remove the retainer ring which locks the pin 2 ...

Page 164: ... pin axis Take the measurement at 6 mm 0 24 in from the base at the position shown in the figure Carefully clean the sealing rings hous ings Measure the sealing rings grooves coupling clearance using suitable sen sors as shown in the diagram If clearances measured exceed the limits specified in the table the piston should be replaced by a new one NOTE MEASURE CLEARANCE BY INSERTING THE BLADE OF TH...

Page 165: ...er measure the cyl inder inside diameter at three different points according to the directions shown in the figure Check that the coupling surface with the head is not worn or misshapen CAUTION THE MARKING IS LOCATED ON THE PISTON CROWN Characteristic Maximum run out allowed 0 05 mm CYLINDER PISTON COUPLING CLEARANCE 125 CM Coupling categories with cast iron cylinder NAME ABBREVIA TION CYLINDER PI...

Page 166: ...in Oil scraper ring 0 2 0 7 mm 0 0079 0 027 in Top ring maximum value 0 45 mm 0 18 in Middle ring maximum value 0 45 mm 0 18 in Checking the connecting rod small end Measure the inside diameter of the connecting rod small end using a spe cific micrometer NOTE IF THE DIAMETER OF THE CONNECTING ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ADMISSIBLE SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANK...

Page 167: ...t a dial gauge on the specific tool Bring the piston to TDC Place the dial gauge against one side of the cylinder and fasten securely to ensure that the zero position is read correctly Specific tooling AP8140266 Dial gauge mount Move the dial gauge diagonally and measure the protrusion of the piston relative to the reference surface Calculate the thickness of the gasket necessary and select the ap...

Page 168: ...nstalling seal rings Fit a new gasket between the cylinder and the head Place the two dowels Install the head Selecting the base gasket BASE GASKET SELECTION Specification Desc Quantity Size measured 0 95 1 09 mm 0 037 0 042 in Gasket 0 3 0 05 mm 0 012 0 001 in Size measured 1 1 1 25 mm 0 043 0 049 in Gasket 0 4 0 05 mm 0 015 0 001 in Size measured 1 26 1 45 mm 0 049 0 057 in Gasket 0 5 0 05 mm 0 ...

Page 169: ... IS GENERALLY CLEAN AND USE A JET OF COMPRESSED AIR FOR CLEANING Tighten the four central screws 2 3 crosswise Lastly tighten the two side screws 1 Insert the timing control chain on the crankshaft Insert the chain tensioner pad of the head and lock it with the fixing screw Insert the camshafts in their seats on the head remember to position the camshaft marked with the letter A on the intake side...

Page 170: ...n of rotation Keep the camshafts locked with the pins and screw but do not tighten the screws fixing the gears using Loctite 243 Fit the chain tensioner on the cylinder using a new gasket and tighten the two screws 1 to the prescribed torque Insert the spring with the central screw 2 and o ring and tighten the cap to the prescribed torque Tighten the screws fixing the camshaft gears to the prescri...

Page 171: ...earance and adjust it if required Refit the tappet cover Lubrication OIL PUMP pos Description Type Quantity Torque Notes 1 Oil pump fastener screw M5x35 3 4 Nm 2 95 lb ft Loctite 243 2 Oil cap retainer 1 25 Nm 18 44 lb ft Oil pump Removing Remove the Seeger ring ...

Page 172: ...nents to inspect them Inspection Measure distance between rotors with a feeler gauge at the positions shown in the picture Characteristic Oil intake rotor Thickness 13 5 mm 0 53 in Oil supply rotor Thickness 8 5 mm 0 33 in Standard values Radial clearance 1 between points of the rotor 0 04 mm 0 0015 in ...

Page 173: ... clearance 3 between rotor 1 and the pump body 0 04 mm 0 0015 in Radial clearance 3 between rotor 2 and the pump body 0 05 mm 0 0019 in Installing Refit the oil pump proceeding in re verse order of disassembly Payatten tion to the direction of the rotor the dot should stay on the opposite part of the resting face ...

Page 174: ...POWER SUPPLY INDEX OF TOPICS P SUPP ...

Page 175: ...ircuit diagram Key 1 Fuel tank 2 Fuel pump Fuel pump Injection Diagram Key 1 ECU control unit position 2 Ignition switch 3 Fuel pump 4 Instrument panel 5 Air temperature sensor 6 Throttle valve position sensor 7 Injector 8 Coolant temperature sensor ...

Page 176: ...ro 4 9 Lambda probe position 10 Engine speed sensor 11 Electric fan Removing the throttle body Remove the filter box Loosen the nut 1 Remove the gas control cable from the points indicated in the figure Loosen the clamp 2 P SUPP 176 ...

Page 177: ...125 Dune X Euro 4 Power supply P SUPP 177 Remove the throttle body from the sleeve indicated in the figure Unscrew the screw 3 and remove the bracket 4 Disconnect the connector 5 Removing the throttle body 6 ...

Page 178: ...SUSPENSIONS INDEX OF TOPICS SUSP ...

Page 179: ...lb ft 3 Clutch control fastening screws M6 25 2 6 8 Nm 4 43 5 90 lb ft 4 Front brake upper pump brake hose bolt M10 1 1 28 33 Nm 20 66 24 35 lb ft 5 PUMP FR DISC BRAKE M8 30 2 17 19 Nm 12 54 14 01 lb ft Loct 243 6 Throttle cable bolt M5 8 1 5 6 Nm 3 69 4 43 lb ft 7 Brake oil line clamp bolt M6 16 1 7 10 Nm 5 16 7 38 lb ft 8 Brake oil line clamp screw ST5 1 14 1 3Nm 2 21 lb ft 9 Front brake upper p...

Page 180: ... SHC wheel axle clamp fastening screws M8 25 1 15 18 Nm 11 06 13 27 lb ft 3 Hex head handlebar U bolt flanged fastening screws M8 35 4 20 24 Nm 14 75 17 70 lb ft 4 NUT M25 1 1 50 60 Nm 36 87 44 12 lb ft 5 SHC steering yoke fastening screws M8 35 2 20 24 Nm 14 75 17 70 lb ft 6 SHC steering yoke fastening screws M8 35 2 20 24 Nm 14 75 17 70 lb ft ...

Page 181: ...ue Notes 1 Caps 2 15 25 Nm 11 06 18 44 lb ft 2 SHC wheel axle clamp fastening screws M6 25 3 4 6 Nm 2 95 4 42 lb ft 3 Hex head handlebar U bolt flanged fastening screws M8 30 6 20 25 Nm 14 75 18 44 lb ft 4 NUT M24 1 1 50 60 Nm 36 87 44 12 lb ft 5 SHC steering yoke fastening screws M8 35 2 20 24 Nm 14 75 17 70 lb ft 6 SHC steering yoke fastening screws M8 35 2 20 24 Nm 14 75 17 70 lb ft ...

Page 182: ...HE LEFT HAND FORK Remove the left hand fork cover Undo and remove the screw 1 Unscrew and remove the screws 2 Remove the front brake calliper 3 from the fork together with the support bracket Loosen the screws 4 Loosen the clamp 5 Remove the left hand fork 6 4 ...

Page 183: ...PPLY TO BOTH Remove the complete fork stem Carefully clean the entire fork stem be fore removing it CAUTION BEFORE CARRYING OUT THE OPERATIONS BELOW GET A 500 cm 30 51 cu in CONTAINER TO COLLECT THE OIL Unscrew 3 and take out 4 Drain the oil into a suitably sized con tainer to collect fluids by pumping out the oil a few times DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SE...

Page 184: ...Dune 125 Dune X 125 Euro 4 Suspensions SUSP 184 Disassembling the fork Remove the dust guard 1 Remove the retainer circlip 2 Remove the oil seal 3 Remove the spacer 4 ...

Page 185: ...ck that bending of the bearing tube is below the limit value If it is over the limit replace the stem CAUTION A BENT TUBE SHOULD NEVER BE STRAIGHTENED BECAUSE THIS WEAKENS ITS STRUC TURE AND MAKES USING THE VEHICLE DANGEROUS Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check for damage and or cracks if it is damaged replace it Spring Check that the spring is in good condition where possib...

Page 186: ...ll in sequence Filling oil Place the fork upright in a vice fitted with protection jaws Push the stem into the sleeve as far as it will go Pour part of the fork oil into the stanchion Wait a few minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times ...

Page 187: ...Dune 125 Dune X 125 Euro 4 Suspensions SUSP 187 Installing the fork legs Insert the left hand fork 1 Tighten the screws 2 Insert the left hand fork 3 Tighten the screws 4 ...

Page 188: ...el Secure the front brake calliper 7 with support bracket by tightening the screw 8 Check that the forks are working cor rectly by applying the front brake and pushing repeatedly on the forks Oper ating must be progressive and there must not be any traces of oil on the stanchions CAUTION BEFORE USING THE VEHICLE CHECK THAT IT IS COR RECTLY SET Rear ...

Page 189: ...uspensions SUSP 189 Removing Lift the vehicle using a hoist and support it in the centre using a support Remove the nut 1 Remove the washer 2 Remove the screws 3 Remove the washer 4 Remove the nut 5 Remove the washer 6 3 2 6 5 4 1 ...

Page 190: ...Dune 125 Dune X 125 Euro 4 Suspensions SUSP 190 Remove the screw and washer 7 Remove the shock absorber 8 7 8 ...

Page 191: ...CHASSIS INDEX OF TOPICS CHAS ...

Page 192: ... bracket bolt M6 30 2 8 10 Nm 5 90 7 38 lb ft 3 Engine bracket bolt M10 100 4 37 39 Nm 27 29 28 76 lb ft 4 Engine shroud bolt M5 16 3 2 3 Nm 1 48 2 21 lb ft 5 Front Pedal bolt M8 40 2 17 19 Nm 12 54 14 01 lb ft 6 Front fender bolt M6 25 1 8 10 Nm 5 90 7 38 lb ft 7 Engine bracket bolt M10 25 2 37 39 Nm 27 29 28 76 lb ft 8 Side bracket bolt M8 1 17 19 Nm 12 54 14 01 lb ft ...

Page 193: ...4 Chassis CHAS 193 Wheels Front wheel FRONT WHEEL pos Description Type Quantity Torque Notes 1 Wheel fastening pin M14 1 70 80 Nm 51 63 59 lb ft 2 SHC front brake disc fastening screws M6x20 6 10 12 Nm 7 38 8 85 lb ft Loct 243 ...

Page 194: ...wheel axle clamp fastening screws M8 25 1 15 18 Nm 11 06 13 27 lb ft 3 Hex head handlebar U bolt flanged fastening screws M8 35 4 20 24 Nm 14 75 17 70 lb ft 4 NUT M25 1 1 50 60 Nm 36 87 44 12 lb ft 5 SHC steering yoke fastening screws M8 35 2 20 24 Nm 14 75 17 70 lb ft 6 SHC steering yoke fastening screws M8 35 2 20 24 Nm 14 75 17 70 lb ft ...

Page 195: ...Removal Lift the front of the vehicle using a hoist make it safe by using belts and support it in the centre using a support Remove the cap 1 Unscrew the nut 2 and remove it Retrieve the washer 3 Loosen the screws 4 Remove the front wheel axle 5 ...

Page 196: ...DIAL AND AXIAL PLAY Check the radial and axial play Axial play minimal axial play is permitted Radial none If one or both bearings are not conformant Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE Check the condition of the seals replace if damaged or excessively worn ALWAYS REPLACE BOTH SEALS TOGETHER ALWAYS REPLACE THE SEALS ...

Page 197: ... worn or damaged bearings If eccentricity is not within the indicated limits after replacing the bearings re place the wheel Characteristic Maximum radial A eccentricity 0 6 mm 0 0236 in Maximum lateral B eccentricity 0 5 mm 0 0197 in Installing Repeat the front wheel removal procedure in reverse order making sure that the compo nents are positioned correctly and that the correct tightening torque...

Page 198: ...98 Rear wheel REAR WHEEL pos Description Type Quantity Torque Notes 1 Rear axle M14 1 70 80 Nm 51 63 59 lb ft 2 Rear brake disc bolt M8 24 2 3 15 18 Nm 11 06 13 27 lb ft Loct 243 3 Rear sprocket bolt M8 30 6 17 19 Nm 12 54 14 01 lb ft Loct 243 ...

Page 199: ...TO AMBIENT TEMPERATURE TO PREVENT THE RISK OF BURNS CAUTION DURING REMOVAL TAKE CARE NOT TO DAMAGE THE PIPE THE DISC AND THE BRAKE PADS Lift the front of the vehicle using a hoist make it safe by using belts and support it in the centre using a support Remove the chain guard Remove the protective rubber 1 Remove the protective rubber 2 ...

Page 200: ...Dune 125 Dune X 125 Euro 4 Chassis CHAS 200 Unscrew the nut 3 and remove it Retrieve the washer 4 Remove the wheel axle 5 ...

Page 201: ...Dune 125 Dune X 125 Euro 4 Chassis CHAS 201 Remove the chain 6 from the crown Retrieve the washer 7 Remove the rear wheel 8 ...

Page 202: ...Remove the rear wheel Remove the spacer 1 Block the nuts at the rear and unscrew and remove the screws 2 at the points indicated in the figure Remove the crown 3 Checking CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR ...

Page 203: ... is permitted Radial none If one or both bearings do not fall within the control parameters Replace both wheel bearings WHEEL AXLE Use a dial gauge to measure the ec centricity of the wheel axle 1 Replace the wheel axle 1 if the eccentricity measured exceeds the specified limit Characteristic Maximum eccentricity 0 2 mm 0 0079 in WHEEL RIM Use a dial gauge to check that the ra dial A and axial B e...

Page 204: ...ED TOGETHER AS A SET CAUTION WHEN REPLACING THE SPROCKET REPLACE THE PRE IMPREGNATED SCREWS WITH NEW ONES BEFORE FITTING THE SCREWS CAREFULLY CLEAN THE THREADED HOLES REMOV ING ANY RESIDUES Installing Repeat the removal procedure in re verse order taking care to insert the spacer correctly on the left hand side as indicated in figure Tighten the nuts applying the predetermined torque CAUTION AFTER...

Page 205: ... 55 65 Nm 10 56 47 94 lb ft 2 Rear shock absorber bolt M12 50 1 55 65 Nm 10 56 47 94 lb ft 3 Flat fork shaft M12 2 70 75 Nm 51 62 55 56 lb ft 4 Chain guard bolt M6 12 2 5 7 Nm 3 69 5 16 lb ft 5 Chain adjuster bolt M6 2 5 7 Nm 3 69 5 16 lb ft 6 Chain slider bolt M4 8 19 2 3 Nm 2 21 lb ft 7 Chain guide bolt M6 12 2 5 7 Nm 3 69 5 16 lb ft Loct 243 ...

Page 206: ...Dune 125 Dune X 125 Euro 4 Chassis CHAS 206 Removing Remove the rear mudguard Remove the rear wheel Remove the cap 1 Remove the cap 2 Holding the pin 3 in place unscrew the nut 4 ...

Page 207: ... Euro 4 Chassis CHAS 207 CAUTION Remove the nut 5 Extract the pin 6 and remove it Remove the swingarm 7 Checking CHECK THAT NO COMPONENT IS NOTICEABLY DISTORTED DAMAGED CRACKED AND OR DENTED REPLACE ALL DAMAGED COMPONENTS ...

Page 208: ...o install the swingarm follow the operations described for removal in reverse order being careful to tighten the ring nuts nuts and screws to the prescribed torque Pinion LINKAGE pos Description Type Quantity Torque Note 1 Pinion fastening screws M5 2 4 5 Nm 2 95 3 69 lb ft Loctite 270 2 Pinion cover fastening screws M5 2 2 5 3 5 Nm 1 84 2 58 lb ft 3 Gearbox lever fixing screws M6 1 9 11 Nm 6 64 8...

Page 209: ...4 Chassis CHAS 209 Removing REMOVING THE PINION GUARD Unscrew and remove the two screws 1 Remove the pinion guard 2 REMOVING THE PINION Remove the chain Remove the pinion guard Unscrew and remove the screws 1 Remove the plate 2 ...

Page 210: ...ont sprocket and drive chain CAUTION TO PREVENT NEW COMPONENTS FROM WEARING PREMATURELY REPLACE ALL THREE TOGETHER AS A SET Installing To install the front sprocket follow the procedure for removal described previously in reverse order tightening the screws to the specified torque Drive chain Removing Using a commercially available chain tool partially remove the two pins 1 of a link ...

Page 211: ...amaged rollers Loosened pins Dry corroded crushed or seized links Excessive wear Excessively worn or damaged front or rear sprocket teeth CAUTION IF ANY DAMAGED CHAIN ROLLERS AND OR LOOSENED PINS ARE FOUND THE ENTIRE CHAIN SET FRONT SPROCKET REAR SPROCKET AND CHAIN MUST BE REPLACED LUBRICATE THE CHAIN EVERY 500 km 310 69 mi ESPECIALLY IF ANY DRY OR RUSTY PARTS ARE NOTED CRUSHED OR SEIZED LINKS MUS...

Page 212: ...nsion the chain Place the Ognibene 529510001 ruler on the chain rollers in a section formed by eight chain steps Check that the measurement notches between the mobile part and the fixed part of the instrument match 1 2 step New chain the notch of the mobile measuring in strument coincides with the first notch on the right of the fixed part of the in strument Chain to be replaced the notch of the m...

Page 213: ...ete with pins on the chain Put the outer plate 2 into position Using a general purpose riveter 3 riv et the chain pins in several points Adjusting To check the clearance Shut off the engine Rest the vehicle on the side stand Select neutral Check that the vertical oscillation at a point between the pinion and the sprocket on the lower branch of the chain is 35 40 mm 1 38 1 57 in ...

Page 214: ...00 km 310 69 mi SEE SCHEDULED MAINTENANCE TABLE If the deflection is uniform but greater or less than 35 40 mm 1 38 1 57 in adjust the chain tension Pedaline FRAME pos Description Type Quantity Torque Notes 1 Headlight bracket bolt M6 16 2 5 7 Nm 3 69 5 16 lb ft 2 Headlight bracket bolt M6 30 2 8 10 Nm 5 90 7 38 lb ft 3 Engine bracket bolt M10 100 4 37 39 Nm 27 29 28 76 lb ft 4 Engine shroud bolt ...

Page 215: ...trests Unscrew the nut 1 and remove it Retrieve the washer 2 Remove the pin 3 Remove the left hand rider footrest 4 Repeat the entire procedure to remove the right hand rider footrest REMOVING THE PASSENGER FOOTRESTS The following procedure is only shown from the left hand side of the vehicle but is valid for both footrests Remove the cotter pin 1 Remove the washer 2 Remove the pin 3 ...

Page 216: ... Remove the left hand passenger foot rest 4 Repeat the entire procedure to remove the right hand passenger footrest REMOVING THE REAR BRAKE LEVER Remove the clip 1 Remove the pin 2 Block the nut 3 so that it cannot rotate and remove the screw 4 ...

Page 217: ... 217 Remove the rear brake lever 5 REMOVING THE GEAR SHIFT LEVER Unscrew and remove the gear lever 1 Remove the gear lever 2 Main stand Remove the cotter pin 1 Remove the washer 2 Remove the pin 3 Remove the springs 4 Remove the main stand 5 ...

Page 218: ...Dune 125 Dune X 125 Euro 4 Chassis CHAS 218 Side stand Remove the the nut 1 Remove the the turn off switch 2 Remove the bolt 3 Remove the side stand 4 Remove the springs 5 ...

Page 219: ...Muffer bent pipe cover bolt M5 2 5 6 Nm 3 69 4 43 lb ft 2 Muffer cover bolt M5 4 5 6 Nm 3 69 4 43 lb ft 3 Muffler fixing clamp M6 1 8 10 Nm 5 90 7 38 lb ft 4 Muffer bolt M8 20 2 18 22 Nm 13 28 16 23 lb ft 5 Muffer bent pipe bolt M8 2 18 22 Nm 13 28 16 23 lb ft 6 Oxygen Sensor bolt M12 1 17 20 Nm 12 54 14 75 lb ft ...

Page 220: ... pipe Loosen the clamp 1 Unscrew the screws 2 blocking at the rear the nuts at the points indicated in the figure Retrieve the washers 3 Remove the muffler 4 Removing the exhaust manifold Remove the muffler Remove the lambda probe Unscrew and remove the screws 1 ...

Page 221: ...Dune 125 Dune X 125 Euro 4 Chassis CHAS 221 Remove the exhaust manifold 2 Removing the lambda sensor Remove the horn Disconnect the connector 1 Undo and remove the probe 2 ...

Page 222: ...BRAKING SYSTEM INDEX OF TOPICS BRAK SYS ...

Page 223: ...nder Push Rod Locknut 17 N m 1 7 kgf m 13 ft lb Check the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter NOTE FIRST HAND TIGHTEN TIGHTEN ALL THE SCREWS THEN TIGHTEN TO THE DEFINITIVE TORQUE IN A CROSSED PATTERN IN THE SEQUENCE A D B E C F USUALLY IT IS NOT NECESSARY TO ADJUST THE PEDAL POSTION BUT ALWAYS ADIUST IT WHEN THE PUSH ROD LOCK...

Page 224: ...Adjust the brake pedal position see Brake Pedal Position Adjustment Check the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Calipers Front Caliper Removal Loosen the banjo bolt A at the brake hose lower end and tighten it loosely Unscrew the caliper mounting bolts B and detach the caliper C from the disc Unscrew the banjo bolt and remo...

Page 225: ...e Banjo Bolt 25 N m 2 5 kgf m 18 ft lb Bleed the brake line see Brake Line Bleeding Check the brake for good braking power no brake drag and no fluid leakage WARNING IMMEDIATELY WASH AWAY ANY BEAKE FLUID SPILLS DO NOT ATTEMPT TO DRIVE THE MOTOCYCLE UNTIL A FULL BRAKE LEVER OR PEDAL IS OBTAINED BY PUMPING THE BRAKE LEVER PEDAL UNTIL THE PADS ARE AGAINST THE DISC THE BRAKES WILL NOT FUNCTION ON THE ...

Page 226: ... the pad Brakes overheat Considerable difference in inner and outer pad wear Seal and piston are stuck together If the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed Front Caliper C Rear Caliper D Caliper Dust Boot and Friction Boot Damage Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise da...

Page 227: ... brake and brake fluid temperature Check to see that the caliper holder shafts are not badly worn or stepped and that the rubber friction boots are not damaged If the rubber friction boot is damaged replace the rubber friction boot To replace the friction boot remove the pads and the caliper bracket If the caliper holder shaft is damage replace the caliper bracket or holder shaft front caliper Tor...

Page 228: ...y hand as far as they will go Install the anti rattle spring in its correct position Install the pad on the piston side first then install the other pad Tighten the brake pad pins temporary Install the front brake caliper see Caliper Installation Tighten Torque Front Caliper Brake Pad Pins 17 N m 1 7 kgf m 13 ft Ib WARNING DO NOT ATTEMPT TO DRIVE THE MOTOCYCLE UNTIL A FULL BRAKE LEVER IS OBTAINED ...

Page 229: ...ition Install the pad on the piston side first then install the other pad Tighten the brake pad pins temporary Install the rear brake caliper see Caliper Installation Tighten Torque Rear Caliper Brake Pad Pins 17 N m 1 7 kgf m 13 ft Ib WARNING DO NOT ATTEMPT TO DRIVE THE MOTOCYCLE UNTIL A FULL BRAKE LEVER IS OBTAINED BY PUMPING THE BRAKE LEVER UNTIL THE PADS ARE AGAINST THE DISC THE BRAKE WILL NOT...

Page 230: ...ion Install the front master cylinder so that the punch mark A of the handlebar is aligned with the mating surface B of the master cylinder clamp to level the reservoir The master cylinder clamp must be installed with the arrow mark A upward Tighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Front Master C...

Page 231: ...washers on each side of hose fitting with new ones Tighten Torque Rear Master Cylinder Mounting Bolts 10 N m 1 0 Kgf m 89 in lb Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 Ft lb Replace the cotter pin A with a new one Install the joint pin B and washer C Insert the cotter pin and bend the pin ends Bleed the brake line see Brake Line Bleeding Check the brake for good braking power no brake drag and ...

Page 232: ...iston shows any damage replace them Inspect the primary cup C and secondary cup D If a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups If fluid leakage is noted at the brake lever the piston assembly should be replaced to renew the cups Check the dust covers E for damage If they are damaged replace them Check the piston return springs F for a...

Page 233: ...asure the thickness of each disc A at the point where it has worn the most If the disc has worn past the service limit replace it Measuring Area B Brake Discs Thickness Standard Front 3 4 3 7 mm 0 13 0 15 in Rear 3 4 3 7 mm 0 13 0 15 in Service Limit Front 3 0 mm 0 12 in Rear 3 0 mm 0 12 in Brake Disc Warp Raise the wheel off the ground with jack see Front Rear Wheel Removal in the Wheels Tires ch...

Page 234: ... the air This will make the lever or pedal feel spongy and there will be a loss in braking power BE SURE TO BLEED THE AIR FROM THE BRAKE LINE WHENEVER BRAKE LEVER OR PEDAL ACTION FEELS SOFT OR SPONGY AFTER THE BRAKE FLUID IS CHANGE OR WHENEVER A BRAKE LINE FITTING HAS BEEN LOOSENED FOR ANY REASON NOTE THE PROCEDURE YO BLEED THE FRONT BRAKE LINE IS AS FOLLOWS BLEEDING THE REAR BRAKE LINE IS THE SAM...

Page 235: ...reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid mo...

Page 236: ...SYS 236 Brake Hose Brake Hose Removal Installation Refer to the Brake Hose Replacement in the Periodic Maintenance chapter Brake Hose Inspection Refer to the Brake Hose Damage and Installation Condition Inspection in the Periodic Maintenance chapter ...

Page 237: ...COOLING SYSTEM INDEX OF TOPICS COOL SYS ...

Page 238: ...Dune 125 Dune X 125 Euro 4 Cooling system COOL SYS 238 Electric fan Remove the radiator Unscrew and remove the screws 1 Retrieve the grooved washers 2 and washers 3 Remove the electric fan 4 ...

Page 239: ...onnect the pipe 2 Collect the coolant that flows out in a suitably sized container CAUTION DO NOT DISPOSE OF THE FLUID INTO THE ENVIRON MENT Reconnect the pipe 2 and tighten the clamp shown in the figure Refill the system with the quantity de scribed in the technical characteristics CAUTION CHECK THAT THE COOLANT LEVEL IS BETWEEN THE REFERENCE MARKS MIN AND MAX Water pump ...

Page 240: ... of the water pump spindle assembly Support the clutch cover on a press and with the specific tool B remove the water pump shaft group acting from the external part to the internal one Specific tooling 866380 tool description Turn the clutch cover and acting from the internal part to the external one with the specific tool C take out the seal ring Specific tooling 866380 tool description ...

Page 241: ...HE SEALING RING WHENEVER IT IS NECESSARY TO REMOVE THE WATER PUMP Place the new bearings on the press and with the specific tool B push the shaft until it stops Specific tooling 866380 tool description Warm up the clutch cover to facilitate the insertion of the shaft with the bear ings Place the specific tools B and A as in the figure in order to push with the press the shaft and the bearings unti...

Page 242: ...the cover Use the specific tool B as an endstop in order to push the gear with the press until it is in line with the shaft Specific tooling 866380 tool description Place the sealing ring and push it until it stops with the specific tool C by us ing the press Specific tooling 866380 tool description Install the clutch cover Install the rotor and the water pump cover Removing the radiator ...

Page 243: ...OLANT OR VAPOURS MAY CAUSE SERIOUS BURNS COLLECT THE COOLANT IN A SPECIAL CONTAINER COOLANT IS HARMFUL AVOID CONTACT WITH THE SKIN AND EYES Remove the side fairings Unscrew and remove the cap 1 Loosen the clamp shown in the figure 2 and disconnect the pipe 3 Retrieve the spacers 4 Extract the radiator from the points shown in the figure ...

Page 244: ...Euro 4 Cooling system COOL SYS 244 Remove the radiator 5 Removing the expansion tank Remove the side fairings Remove the radiator cover Unscrew and remove the screws 1 Disconnect the two pipes 2 Remove the expansion tank 3 ...

Page 245: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 246: ...screw and remove the screws 2 Unscrew and remove the screws 3 Remove the side cover 4 Driving mirrors The following procedure is only shown from the RH side of the vehicle but is valid for both rear view mirrors Remove the protective rubber 1 Using a suitable wrench unscrew the threaded pin 2 Remove the right rear view mirror 3 Repeat the entire procedure to remove the left rear view mirror ...

Page 247: ... 125 Dune X 125 Euro 4 Bodywork BODYW 247 Instrument panel Unscrew and remove the screws 1 Disconnect the connector 2 Remove the top fairing headlamp 3 Disconnect the connector 4 Remove the instrument panel ...

Page 248: ...4 Bodywork BODYW 248 Headlight assy Disconnect the connector Remove the top fairing Remove the daylight running light 1 Unscrew and remove the screws 2 Remove the pin 3 Remove the front light 4 Horn Undo and remove the screw 1 ...

Page 249: ...ct the connectors 2 Remove the horn 3 Turn indicators REMOVING THE FRONT TURN INDICATORS Remove the top fairing They cannot rotate and unscrew and remove the screws 1 Remove the right hand front turn indi cator 2 Remove the left hand front turnindica tor 3 ...

Page 250: ...250 REMOVING THE REAR TURN INDICATORS Remove the license plate holder brack et Unscrew and remove the screws 1 Remove the right hand rear turn indi cator 2 Remove the left hand rear turn indicator 3 Side fairings Unscrew and remove the screws 1 ...

Page 251: ...Dune 125 Dune X 125 Euro 4 Bodywork BODYW 251 Undo and remove the screw 2 Unscrew and remove the screw 3 Remove the left side engine fairing 4 ...

Page 252: ...icense plate holder Remove the rear light cluster Unscrew and remove the screws 1 Remove the license plate holder Remove the rear turn indicators Remove the licence plate light Rear mudguard Unscrew and remove the screws 1 Remove the rear mudguard 2 ...

Page 253: ...s Remove the tail fairing Remove the battery Remove the exhaust system Remove the rear mudguard Remove the rear wheelhouse Remove the rear shock absorber Unscrew and remove the screws 1 Loosen the clamp 2 Disconnect the pipe 3 Loosen the clamp 4 Loosen the clamp 5 Remove the sleeve 6 ...

Page 254: ...Dune 125 Dune X 125 Euro 4 Bodywork BODYW 254 To unload the filter box 7 Remove the filter box 7 ...

Page 255: ...Dune 125 Dune X 125 Euro 4 Bodywork BODYW 255 Lower cowl Unscrew and remove the screws 1 Undo and remove the screw 2 Remove the engine fairing lug 3 ...

Page 256: ...Dune 125 Dune X 125 Euro 4 Bodywork BODYW 256 Fuel tank Undo and remove the screw 1 Remove the battery Remove the battery box 3 ...

Page 257: ...Dune 125 Dune X 125 Euro 4 Bodywork BODYW 257 Remove the screw 4 Remove the fuel tank 5 REMOVING THE FUEL PUMP Remove the fuel tank Unscrew and remove the screws 1 Remove the fuel pump 2 ...

Page 258: ...elhouse Remove the side fairing panels Remove the tail fairing Remove the rear light cluster Remove the rear mudguard Remove the electrical components shown in the figure from the rear wheelhouse Unscrew and remove the screws 1 Remove the rear wheelhouse 2 ...

Page 259: ... Dune X 125 Euro 4 Bodywork BODYW 259 Front mudguard Unscrew and remove the screws 1 Remove the front mudguard 2 Radiator cover Remove the front mudguard Undo and remove the screw 1 Undo and remove the screw 2 ...

Page 260: ...Dune 125 Dune X 125 Euro 4 Bodywork BODYW 260 Undo and remove the screw 3 Undo and remove the screw 4 Undo and remove the screw 5 Undo and remove the screw 6 ...

Page 261: ...Dune 125 Dune X 125 Euro 4 Bodywork BODYW 261 Unscrew and remove the screws 7 Remove the radiator cover 8 ...

Page 262: ...e the saddle Remove the side fairing panels Unscrew and remove the screws 1 Disconnect the battery cables Remove the battery 2 Detach and remove the fuses shown in the figure from the battery support Unscrew and remove the screws 3 Remove the battery support 4 ...

Page 263: ...Bodywork BODYW 263 Tail guard Remove the saddle Remove the side fairing panels Unscrew and remove the screws 1 Unscrew and remove the screws 2 Unscrew and remove the screws 3 in the left and right Unscrew and remove the screws 4 ...

Page 264: ...Dune 125 Dune X 125 Euro 4 Bodywork BODYW 264 Remove the tail guard 5 ...

Page 265: ...Dune 125 Dune X 125 Euro 4 Bodywork BODYW 265 PRE DELIVERY INDEX OF TOPICS PRE DE ...

Page 266: ...etainers steering assembly Plastic parts fixing screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator i...

Page 267: ...T WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY OF CLEAN WATER IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS IF THE FLUID GETS IN CONTACT WITH 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 OT...

Page 268: ...ing Possible leaks Radiator electric fan operation if present Functional inspection Hydraulic braking system Clutch travel Rear brake lever travel see chapter installing rear brake master cylinder Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Check documentation Check the chassis and engine numbers Licence plate fitting Locks chec...

Page 269: ...Dune 125 Dune X 125 Euro 4 Pre delivery PRE DE 269 OBD LIST The OBD list are the following ...

Page 270: ...Dune 125 Dune X 125 Euro 4 Pre delivery PRE DE 270 ...

Page 271: ...Dune 125 Dune X 125 Euro 4 Pre delivery PRE DE 271 ...

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