Malaguti Dune X 125, Service Station Manual

Page: 224 / 272

Dune 125 - Dune X 125 - Euro 4
Braking system
BRAK SYS - 224
Brake Pedal Installation

Replace O-rings [A] with new ones, and
apply grease to the O-rings.

Apply grease to the shaft portion of the
brake pedal.

Install the brake pedal onto the frame
with the return spring and brake light
switch spring.

Face the return spring ends forward.

Replace the cotter pins of the brake
pedal pivot and rear master cylinder joint
pin with new ones.

Insert washer and cotter pin into the
shaft portion of the brake pedal, and
bend cotter pin end.

Insert a cotter pin into the joint pin, and
bend its ends.

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 remove the
brake hose [D] from the caliper (see
Brake Hose Replacement in the Periodic
Maintenance chapter)
CAUTION
IMMEDIATELY WASH AWAY ANY BEAKE FLUID SPILLS.
NOTE
If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before
the brake hose is removed (see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter)