Malaguti Dune X 125, Service Station Manual

Page: 235 / 272

Dune 125 - Dune X 125 - Euro 4
Braking system
BRAK SYS - 235

Bleed the brake line and the caliper.
Repeat this operation until no more air can
be seen coming out into the plastic hose.
1. Pump the brake lever until it becomes
hard, and apply the brake and hold it [A].
2. Quickly open and close [B] the bleed
valve while holding the brake applied.
3. Release the brake [C].
NOTE
THE FLUID LEVEL MUST BE CHECKED OFTEN DURING
THE BLEEDING OPERATION AND REPLENISHED WITH
FRESH BRAKE FLUID AS NECESSARY. IF THE FLUID IN
THE RESERVOIR RUNS COMPLETELY OUT ANY TIME
DURING BLEEDING, THE BLEEDING OPERATION MUST BE
DONE OVER AGAIN FROM THE BEGINNING SINCE AIR
WILL HAVE ENTERED THE LINE. TAP THE BRAKE HOSE
LIGHTLY FROM THE CALIPER TO THE RESERVOIR FOR
MORE COMPLETE BLEEDING.

Remove the clear plastic hose.

Install the diaphragm and reservoir cap.

Tighten:
Torque - Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)

Tighten the bleed valve, and install the
rubber cap. Torque - Caliper Bleed Valve: 5.4
N·m (0.55 kgf·m, 48 in·lb)

Check the fluid level (see Brake Fluid Level Inspection in the Periodic Maintenance
chapter).

After bleeding is done, check the brake for good braking power, no brake drag, and no
fluid leakage.
WHEN WORKING WITH THE DISC BRAKE, OBSERVE THE PRECAUTIONS LISTED BELOW. 1.
Never 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 moisture contamination of the fluid. 5. Don` t change the fluid in the
rain or when a strong wind is blowing. 6. Except for the disc pads and disc, use only disc brake
fluid, isopropyl alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause
deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely
and will eventually deteriorate the rubber used in the disc brake. 7. When handling the disc
pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or
oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one
which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned
satisfactorily. 8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be
completely wiped up immediately. 9. If any of the brake line fittings or the bleed valve is opened
at any time, the air must be bled from the brake line.