Malaguti Dune X 125 Page 163 Service Station Manual Download

Page: 163 / 272

Dune 125 - Dune X 125 - Euro 4

Engine

ENG - 163



Remove the 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).

Summary of Contents for Dune X 125

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

Page 2: ...tself 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 on...

Page 3: ...ations 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 c...

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...

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

Page 7: ...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 rema...

Page 8: ...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 C...

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...

Page 10: ...HESE 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...

Page 11: ...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 sid...

Page 12: ...perates 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...

Page 13: ...tion 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...

Page 14: ...tening 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...

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...

Page 16: ...ing 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...

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...

Page 18: ...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...

Page 19: ...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...

Page 20: ...8 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...

Page 21: ...acket 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 0...

Page 22: ...LY 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...

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...

Page 24: ...lant 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...

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...

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...

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 adju...

Page 28: ...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...

Page 29: ...istics 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 fas...

Page 30: ...ROTTLE 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 f...

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 To...

Page 32: ...lywheel 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...

Page 33: ...escription 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 Q...

Page 34: ...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...

Page 35: ...stener 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 faste...

Page 36: ...5 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 8...

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 Thermosta...

Page 38: ...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 f...

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: ...in 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 5...

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: ...ools 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 Cams...

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 Pisto...

Page 45: ...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 m...

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: ...n 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...

Page 49: ...amps 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...

Page 50: ...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 cont...

Page 51: ...L 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...

Page 52: ...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 SPEC...

Page 53: ...pecified 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 M...

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...

Page 55: ...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 F...

Page 56: ...AKE 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 Rec...

Page 57: ...LL 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 T...

Page 58: ...n 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...

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 fus...

Page 62: ...ables 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 lock...

Page 63: ...ctly 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 Cen...

Page 64: ...ectrical 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...

Page 65: ...stem 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 regu...

Page 66: ...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 pie...

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 st...

Page 68: ...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 r...

Page 69: ...m 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...

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

Page 71: ...ECK 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 corr...

Page 72: ...g 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...

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...

Page 74: ...on 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 p...

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...

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 valu...

Page 77: ...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 en...

Page 78: ...f 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...

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 be...

Page 80: ...e 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...

Page 81: ...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...

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: ...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...

Page 84: ...AILLIGHT 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 1...

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 Posit...

Page 86: ...cate 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 conne...

Page 87: ...ion 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 es...

Page 88: ...in electrical 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 k 100 Resistance PIN B...

Page 89: ...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 s...

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 underneat...

Page 91: ...ore 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...

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 cor...

Page 93: ...ugh 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 circui...

Page 94: ...ugh 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 batte...

Page 95: ...tion 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 TRO...

Page 96: ...age 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...

Page 97: ...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 senso...

Page 98: ...uity 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 t...

Page 99: ...e 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...

Page 100: ...ay 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...

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 PI...

Page 102: ...ing 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...

Page 103: ...a 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 g...

Page 104: ...relli 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 severa...

Page 105: ...pper 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 No...

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 sens...

Page 107: ...ol 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...

Page 108: ...ning 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 b...

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

Page 110: ...in 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...

Page 111: ...e 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...

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 Und...

Page 113: ...25 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 s...

Page 114: ...25 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 Lo...

Page 115: ...d 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 engi...

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

Page 117: ...R 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 f...

Page 118: ...ent 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...

Page 119: ...ESSARY 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 s...

Page 120: ...t 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 Remo...

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 Ch...

Page 125: ...rmly 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 Quant...

Page 126: ...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 fastene...

Page 127: ...astener 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 Unsc...

Page 128: ...mozione 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 roto...

Page 129: ...ne 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 stat...

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: ...ngine 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 se...

Page 132: ...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...

Page 133: ...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 rotatio...

Page 134: ...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...

Page 135: ...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...

Page 136: ...eplace 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 c...

Page 137: ...05300041 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 ishin...

Page 138: ...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 8...

Page 139: ...cing 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 Counter...

Page 140: ...igning 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 t...

Page 141: ...e 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...

Page 142: ...ro 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 remo...

Page 143: ...s 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...

Page 144: ...al 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...

Page 145: ...ter 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 a...

Page 146: ...64Y 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 cra...

Page 147: ...en 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...

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...

Page 149: ...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...

Page 150: ...m 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 co...

Page 151: ...hain 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 cover...

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...

Page 153: ...ng 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 ge...

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...

Page 155: ...e 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...

Page 156: ...ter 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...

Page 157: ...owed 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 Max...

Page 158: ...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...

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 t...

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 Cha...

Page 161: ...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 remova...

Page 162: ...er 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...

Page 163: ...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 reta...

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 s...

Page 165: ...r 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 MAR...

Page 166: ...n 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...

Page 167: ...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...

Page 168: ...stalling 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...

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 Ins...

Page 170: ...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 t...

Page 171: ...arance 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...

Page 172: ...ents 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 Thi...

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 dis...

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

Page 175: ...rcuit 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 positio...

Page 176: ...o 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 figur...

Page 177: ...25 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...

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

Page 179: ...b 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 f...

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 f...

Page 181: ...e 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...

Page 182: ...E 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 th...

Page 183: ...PLY 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 OI...

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: ...k 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 USIN...

Page 186: ...l 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 minute...

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: ...l 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 atin...

Page 189: ...spensions 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 Re...

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...

Page 193: ...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...

Page 194: ...heel 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 S...

Page 195: ...emoval 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 Loose...

Page 196: ...IAL 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 BEA...

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 latera...

Page 198: ...8 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 M...

Page 199: ...O 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...

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: ...emove 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 COM...

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 Repl...

Page 204: ...D 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...

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 a...

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 AL...

Page 208: ...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 Q...

Page 209: ...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 s...

Page 210: ...nt 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 des...

Page 211: ...maged 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 F...

Page 212: ...sion 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 ins...

Page 213: ...te 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 ve...

Page 214: ...0 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...

Page 215: ...rests 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 PASS...

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 t...

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 Remo...

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: ...uffer 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...

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 mu...

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: ...der 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 AL...

Page 224: ...djust 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...

Page 225: ...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 FLU...

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 ever...

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 re...

Page 228: ...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...

Page 229: ...tion 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...

Page 230: ...on 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 b...

Page 231: ...ashers 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...

Page 232: ...ston 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 l...

Page 233: ...sure 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...

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 A...

Page 235: ...euse 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 t...

Page 236: ...YS 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 Conditio...

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: ...nnect 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 figu...

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...

Page 241: ...E 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...

Page 242: ...he 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 u...

Page 243: ...LANT 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...

Page 244: ...uro 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...

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

Page 246: ...crew 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 vi...

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...

Page 248: ...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 Un...

Page 249: ...t 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 i...

Page 250: ...50 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 Si...

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: ...cense 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 an...

Page 253: ...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 clam...

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: ...lhouse 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 Unscr...

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...

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: ...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 U...

Page 263: ...odywork 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 Unsc...

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: ...tainers 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...

Page 267: ...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...

Page 268: ...ng 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 Clut...

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...

Page 272: ......

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