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Dune 125 - Dune X 125 - Euro 4

Electrical system

ELE SYS - 93

Short-circuit to positive:



Disconnect the injector connector, turn

the key to ON and activate the compo-

nent through the diagnostic tool.



Verify the absence of voltage at the in-

jector connector PIN 1; if present re-

store the wiring harness, otherwise

proceed with the following checks.

Short circuit to negative:



Disconnect the injector connector, turn

the key to ON and activate the compo-

nent through 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 continuity restore the wiring

harness.

Fuel pump

CAUTION

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.

Содержание Dune X 125

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

Страница 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...

Страница 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...

Страница 4: ...Dune 125 Dune X 125...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 272: ......

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