Page 1 SERVICE STATION MANUAL ZP682837 Dune 125 - Dune X 125 - Euro 4...
Page 2 Only by requesting original spare parts can you be of purchasing products that were developed and tested during the design and development of the vehicle itself. All Malaguti original spare parts undergo quality control procedures to guarantee reliability and durability.
Page 3 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to Malaguti Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing motorcyle.
Page 4 Dune 125 Dune X 125...
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS....P7-41 S-TOOLS PECIAL TOOLS.......P43-46 MAIN AINTENANCE......P48-58 ELE SYS LECTRICAL SYSTEM.....P59-109 ENG VE NGINE FROM VEHICLE..P110-115 NGINE........P117-173 P SUPP OWER SUPPLY.....P175-177 SUSP USPENSIONS......P179-190 CHAS HASSIS........P192-221 BRAK SYS RAKING SYSTEM....P223-236 COOL SYS OOLING SYSTEM....P238-244 BODYW ODYWORK......P246-264 PRE DE DELIVERY.......P266-268...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
Dune 125 - Dune X 125 - Euro 4 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 Dune 125 - Dune X 125 - Euro 4 Characteristics KEEP OUT OF THE REACH OF CHILDREN. NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil CAUTION IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE- HICLE.
Page 9 Dune 125 - Dune X 125 - Euro 4 Characteristics BEFORE DISASSEMBLING COMPONENTS  Remove the dirt, mud, dust and foreign objects from the vehicle before disassembling com- ponents. Wherever required, use the special tools designed for this vehicle. DISASSEMBLING COMPONENTS ...
Page 10 That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Malaguti Dealer FOR THE CHECKS INDICATED IN THE "RECOMMENDED PRODUCTS" TABLE IN THE SCHEDULED MAIN- TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
Page 11: Vehicle Identification
Dune 125 - Dune X 125 - Euro 4 Characteristics Vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.
Page 12 Dune 125 - Dune X 125 - Euro 4 Characteristics Engine ENGINE Specification Desc./Quantity Engine type Single cylinder 4 stroke Engine capacity 124.2 cm³ (7.58 cu in) Bore x stroke (58 x 47) mm; (2.28 x 1.85) in Compression ratio 12.0 +/- 0.5: 1...
Page 13: Warning Lights
Dune 125 - Dune X 125 - Euro 4 Characteristics ELECTRICAL SYSTEM Specification Desc./Quantity Battery 12V - 6Ah Fuses 30A,10A Alternator 13V - 235W BULBS Specification Desc./Quantity Low-beam/high-beam headlight (1 dual-filament bulb) HS1 - 12V - 35W Daylight running light...
Page 14: Fuel System
Dune 125 - Dune X 125 - Euro 4 Characteristics Specification Desc./Quantity Front tyre pressure, rider only 1.9 bar (190 kPa) (27.56 PSI) Front tyre pressure, rider+ passenger 2.0 bar (190 kPa) (29.01 PSI) Rear (Dune 125) 130/80-17" 65P Rear (Dune X 125) 130/80-17"...
Page 15 Dune 125 - Dune X 125 - Euro 4 Characteristics RONT WHEEL pos. Description Type Quantity Torque Notes Wheel fastening pin 70/80 Nm (51.63/59 lb ft) SHC front brake disc fastening M6x20 10/12 Nm (7.38/8.85 lb ft) Loct. 243 screws...
Page 16 Dune 125 - Dune X 125 - Euro 4 Characteristics pos. Description Type Quantity Torque Notes Caps 15/25 Nm (11.06/18.44 lb ft) SHC wheel axle clamp fastening M8×25 15/18 Nm (11.06/13.27 lb ft) screws Hex head handlebar U-bolt flanged M8×35 20/24 Nm (14.75/17.70 lb ft)
Page 17 Dune 125 - Dune X 125 - Euro 4 Characteristics ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes M6×25 Balance hammer bolt 7/10 Nm (5.16/7.38 lb ft) SHC brake master cylinder M6×25 7/10 Nm (5.16/7.38 lb ft) fastening screws M6×25...
Page 18 Dune 125 - Dune X 125 - Euro 4 Characteristics IGHTS pos. Description Type Quantity Torque Notes Turninglight bolt M6 × 20 2/3 Nm (1.48/2.21 lb ft) Windshield bolt M6 × 20 2/3 Nm (1.48/2.21 lb ft) Instrument cover self-tapping St2.8 ×...
Page 19 Dune 125 - Dune X 125 - Euro 4 Characteristics IGHTS pos. Description Type Quantity Torque Notes Turninglight bolt M6 × 20 2/3 Nm (1.48/2.21 lb ft) Windshield bolt M6 × 30 2/3 Nm (1.48/2.21 lb ft) Instrument cover self-tapping St2.8 ×...
Page 20 Dune 125 - Dune X 125 - Euro 4 Characteristics LASTIC COVERS pos. Description Type Quantity Torque Notes Fuel tank shell bolt M6 × 25 8/10 Nm (5.90/7.38 lb ft) Fuel tank shroud bolt 2/3 Nm (1.48/2.21 lb ft) M5 × 9 Fuel tank shroud connecting M5 ×...
Page 21 Dune 125 - Dune X 125 - Euro 4 Characteristics RAME pos. Description Type Quantity Torque Notes Headlight bracket bolt M6 × 16 5/7 Nm (3.69/5.16 lb ft) Headlight bracket bolt 8/10 Nm (5.90/7.38 lb ft) M6 × 30 Engine bracket bolt M10 ×...
Page 22 Dune 125 - Dune X 125 - Euro 4 Characteristics ANISTER ASSEMBLY pos. Description Type Quantity Torque Notes Canister bracket bolt M6 × 10 5/7 Nm (3.69/5.16 lb ft) ILTER BOX pos. Description Type Quantity Torque Notes Air filter box fastening screw M5×12...
Page 23 Dune 125 - Dune X 125 - Euro 4 Characteristics LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Ignition coil Assy bracket bolt M6 × 16 5/7 Nm (3.69/5.16 lb ft) Ignition coil Assy bolt 4/6 Nm (2.95/4.43 lb ft) M3 ×...
Page 24 Dune 125 - Dune X 125 - Euro 4 Characteristics UEL TANK pos. Description Type Quantity Torque Notes M6 × 16 Coolant tank bolt 8/10 Nm (5.90/7.38 lb ft) Fuel tank bolt M6 × 30 8/10 Nm (5.90/7.38 lb ft) 2.7/3.3 Nm (1.99/2.43 lb...
Page 25 Dune 125 - Dune X 125 - Euro 4 Characteristics OCK ASSY pos. Description Type Quantity Torque Notes 18/20 Nm (13.28/14.75 M8 × 20 Electric Lock bolt lb ft) 18/20 Nm (13.28/14.75 Electric Lock bolt M8 × 20 lb ft) Electric Lock cover bolt M5 ×...
Page 26 Dune 125 - Dune X 125 - Euro 4 Characteristics XHAUST SYSTEM pos. Description Type Quantity Torque Notes Muffer bent pipe cover bolt 5/6 Nm (3.69-4.43 lb ft) 5/6 Nm (3.69-4.43 lb ft) Muffer cover bolt 8/10 Nm (5.90-7.38 lb Muffler fixing clamp 18/22 Nm (13.28-16.23...
Page 27 Dune 125 - Dune X 125 - Euro 4 Characteristics EAR FORK pos. Description Type Quantity Torque Notes 55/65 Nm (10.56/47.94 M12 × 58 Rear shock absorber bolt lb ft) 55/65 Nm (10.56/47.94 Rear shock absorber bolt M12 × 50...
Page 28 Dune 125 - Dune X 125 - Euro 4 Characteristics ear Brake Pedal pos. Description Type Quantity Torque Notes Rear brake disc fastening torx button 17/19 Nm (14.75/16.23 head screws lb ft) Speed sensor fastening screws M6 × 35 8/10 Nm (5.90/7.38 lb ft) SYSTEM pos.
Page 29 Dune 125 - Dune X 125 - Euro 4 Characteristics Engine RANKSHAFT pos. Description Type Quantity Torque Notes Gear fixing screw 40 Nm (29.50 lb ft) YLINDER ISTON pos. Description Type Quantity Torque Notes Chain tensioner fastener screw 12 Nm (8.85 lb ft) ×...
Page 30 Dune 125 - Dune X 125 - Euro 4 Characteristics HROTTLE BODY pos. Description Type Quantity Torque Notes Sleeve fixing screw 12 Nm (8.85 lb ft) × Sleeve fixing clamp 0.8 Nm (0.59 lb ft) Injector mounting fixing screw 10 Nm (7.38 lb ft) ×...
Page 31 Dune 125 - Dune X 125 - Euro 4 Characteristics LUTCH COVER pos. Description Type Quantity Torque Notes Clutch cover fixing screw 12 Nm (8.85 lb ft) × Oil filter cover 25 Nm (18.44 lb ft) × Oil pressure sensor 13 Nm (9.59 lb ft)
Page 32 Dune 125 - Dune X 125 - Euro 4 Characteristics LYWHEEL COVER pos. Description Type Quantity Torque Notes Flywheel cover fastener screw 12 Nm (8.85 lb ft) Timing control cap 4 Nm (2.95 lb ft) Oil dipstick 5 Nm (3.69 lb ft) ×...
Page 33 Dune 125 - Dune X 125 - Euro 4 Characteristics LUTCH pos. Description Type Quantity Torque Notes Clutch spring screw 4 Nm (2.95 lb ft) Crankshaft primary gear fastener nut 79 Nm (58.27 lb ft) Clutch nut 40 Nm (29.50 lbf ft)
Page 34 Dune 125 - Dune X 125 - Euro 4 Characteristics ATER PUMP pos. Description Type Quantity Torque Notes Water pump fastener screw 3.5 Nm (2.58 lb ft) Water pump rotor fastener screw 5 Nm (3.69 lb ft) CHAR - 34...
Page 35 Dune 125 - Dune X 125 - Euro 4 Characteristics pos. Description Type Quantity Torque Notes Loctite Oil pump fastener screw M5x35 4 Nm (2.95 lb ft) Oil cap retainer 25 Nm (18.44 lb ft) EAR SELECTOR pos. Description Type...
Page 36 Dune 125 - Dune X 125 - Euro 4 Characteristics NGINE RANKCASE pos. Description Type Quantity Torque Notes Crankcase retainer screw M6x60 12 Nm (8.85 lb ft) Crankcase retainer screw M6x75 12 Nm (8.85 lb ft) CHAR - 36...
Page 37 Dune 125 - Dune X 125 - Euro 4 Characteristics ALVES pos. Description Type Quantity Torque Notes Head fastener screw M6x130 12 Nm (8.85 lb ft) Drainage side stud bolt retainer M8x40 12 Nm (8.85 lb ft) Camshaft cover fastener screw M6x40 11 Nm (8.11 lb ft)
Page 38 Dune 125 - Dune X 125 - Euro 4 Characteristics GNITION UNIT pos. Description Type Quantity Torque Notes Flywheel rotor fixing nut M14x1.5 86 Nm (63.43 lb ft) Rotor fastener screw 12 Nm (8.85 lb ft) Stator clamping screws 6 Nm (4.43 lb ft) Pick-Up clamping screw 3.5 Nm (2.58 lb ft)
Page 39 Dune 125 - Dune X 125 - Euro 4 Characteristics OMPONENTS OF GEARBOX pos. Description Type Quantity Torque Notes Gear sensor retainer 3 Nm (2.21 lb ft) CHAR - 39...
Page 40 Dune 125 - Dune X 125 - Euro 4 Characteristics INKAGE pos. Description Type Quantity Torque Notes Loctite Pinion fastening screws 4-5 Nm (2.95-3.69 lb ft) 2.5-3.5 Nm (1.84-2.58 Pinion cover fastening screws lb ft) 9-11 Nm (6.64-8.11 lb Gearbox lever fixing screws...
Page 41 Dune 125 - Dune X 125 - Euro 4 Characteristics 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) CHAR - 41...
Page 42 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 43 XSM 125 - XTM 125 - Euro 4 Special tools PECIAL TOOLS Stores code Description AP8140266 Dial gauge mount 865259 Flywheel retainer 866380 Water pump tool set 864868 Flywheel extractor 864567 Camshaft timing adjustment lock pins 864486 Countershaft lock tool S-TOOLS - 43...
Page 44 XSM 125 - XTM 125 - Euro 4 Special tools Stores code Description 00H05600351 Oil seal guide 020382Y011 Valve removal/installation tool 020287Y Tool for installing seal rings 865261 Piston retainer 00H05300041 Clutch lock 865260 Camshaft sprocket lock tool 020376Y Sleeve for adaptors S-TOOLS - 44...
Page 45 XSM 125 - XTM 125 - Euro 4 Special tools Stores code Description 020359Y 42 x 47 mm Adaptor 020358Y 37 x 40 mm Adaptor 020357Y 32 x 35-mm Adaptor 020439Y 17 mm punch for secondary shaft oil seal 020891Y 25 mm (0.98 in) adapter 020363Y 20 mm diam.
Page 46 XSM 125 - XTM 125 - Euro 4 Special tools Stores code Description 020375Y 28x30 mm punch 020483Y 30-mm guide 020364Y 25 mm adapter S-TOOLS - 46...
Page 47 INDEX OF TOPICS MAIN AINTENANCE...
Page 48: Scheduled Maintenance Table
Dune 125 - Dune X 125 - Euro 4 Maintenance Scheduled maintenance table Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum function and performance. Services must be performed as soon as the specified mileage and time intervals are reached. Services must be performed punctually at the correct intervals to maintain the validity of the warranty.
Page 49 Dune 125 - Dune X 125 - Euro 4 Maintenance Km x 1,000 (mi x 1,000) EVERY EVERY (0.6) (3.7) (7.5) (11.2) (14.9) (18.6) (22.4) (26.1) (29.8) MONTH MONTH Valve clearance adjustment Screw tightness Front suspension: oil (5) Indicator lamps...
Page 50 Dune 125 - Dune X 125 - Euro 4 Maintenance km (mi) x1000 1 (0.6) 6 (3.7) 12 (7.5) 18 (11.2) 24 (14.9) 30 (18.6) 36 (22.4) 42 (26.1) 48 (29.8) Final drive (1)(7) Fuel and oil pipes + filters...
Page 51: Engine Oil
Dune 125 - Dune X 125 - Euro 4 Maintenance  Fit the cap on the spark plug as far as it will go. CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE EN- GINE IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 12,000 KM.
Page 52 Dune 125 - Dune X 125 - Euro 4 Maintenance  Unscrew and remove the dipstick-cap again and check that the engine oil lev- el is between the two markings: MAX = maximum level; MIN = minimum level.  The oil level should be almost at the "MAX"...
Page 53 Dune 125 - Dune X 125 - Euro 4 Maintenance OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT; BE CAREFUL NOT TO GET BURNED WHEN CARRYING OUT THE OPERATIONS DESCRIBED BELOW.  Keep the vehicle upright with both wheels on the ground.
Page 54: Engine Oil Filter
Dune 125 - Dune X 125 - Euro 4 Maintenance 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) ...
Page 55: Braking System
Dune 125 - Dune X 125 - Euro 4 Maintenance  Remove the cover (3).  Remove the filter element (4) CLEANING - AIR FILTER NEVER USE SCREWDRIVERS OR OTHER TOOLS TO WORK ON THE FILTER.  Clean the filter element (4) with com- pressed air, blowing from the inside of the filter outwards.
Page 56 Dune 125 - Dune X 125 - Euro 4 Maintenance Top-up RISK OF BRAKE FLUID SPILLING. DO NOT OPERATE THE BRAKE LEVER IF THE BRAKE FLUID RESERVOIR CAP IS LOOSE OR HAS BEEN REMOVED. CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR.
Page 57: Clutch System
Dune 125 - Dune X 125 - Euro 4 Maintenance Rear braking system  Unscrew and remove the screws (5) on the rear braking circuit fluid tank (6).  Lift and remove the cover (7)  Lift and remove the Teflon lid (8) and the gasket (9).
Page 58 Dune 125 - Dune X 125 - Euro 4 Maintenance Adjusting the lever Adjustment clutch when the engine stops or the vehicle tends to move forward even when clutch lever is operated and the gear engaged, or if the clutch "slides", resulting in acceleration delay con- sidering the engine revs.
Page 59 Dune 125 - Dune X 125 - Euro 4 Electrical system INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM ELE SYS - 59...
Page 60 Dune 125 - Dune X 125 - Euro 4 Electrical system Components arrangement ELE SYS - 60...
Page 61 Dune 125 - Dune X 125 - Euro 4 Electrical system KEY: 1. Speed sensor 2. Stop switch 3. Taillight 4. Injector 5. Battery 6. Main fuses 7. Fan relay 8. Light relay 9. Front light assembly 10. Starter relay 11.
Page 62 Dune 125 - Dune X 125 - Euro 4 Electrical system Electrical system installation Scope and applicability The purpose of this document is to define the correct cable harness routing layout to ensure the reliability of the vehicle. Materials used and corresponding quantities The electrical system consists of the following wiring harnesses and parts: 1 x main cable harness.
Page 63 Dune 125 - Dune X 125 - Euro 4 Electrical system TURN INDICATORS  Make sure the turn indicators connector (1) is correctly connected to the turn indicators. CABLE ROUTING ON RH SIDE  Secure the wiring harnesses on the RH...
Page 64 Dune 125 - Dune X 125 - Euro 4 Electrical system A1-OIL PRESSURE SENSOR  The oil pressure sensor wiring harness (2) must pass through the metal cable gland of the frame (3). A2-OIL PRESSURE SENSOR  The oil pressure sensor wiring harness (2) must pass under the water pipe (4).
Page 65 Dune 125 - Dune X 125 - Euro 4 Electrical system 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 ...
Page 66 Dune 125 - Dune X 125 - Euro 4 Electrical system MAIN WIRING HARNESS  Place the main wiring harness (1) in- side the chassis making sure that the red taping is placed near the metal flanges which must be covered with a piece of PVC pipe.
Page 67 Dune 125 - Dune X 125 - Euro 4 Electrical system  Secure the ECU connector using the special metal plate. FLYWHEEL  The flywheel wiring harness must be fastened other wiring harnesses by a clamp. STARTER MOTOR  Make sure that the starter motor earth cable is fastened correctly.
Page 68 Dune 125 - Dune X 125 - Euro 4 Electrical system STARTER MOTOR  Connect the starter 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 ...
Page 69 Dune 125 - Dune X 125 - Euro 4 Electrical system 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...
Page 70 Dune 125 - Dune X 125 - Euro 4 Electrical system General wiring diagram ELE SYS - 70...
Page 71 Dune 125 - Dune X 125 - Euro 4 Electrical system Checks and inspections GENERAL NOTIONS FOR TROUBLESHOOTING ELECTRICAL FAULTS THE SECTIONS RELATIVE TO THE ELECTRICAL SYSTEM CONTAIN DRAWINGS OF CONNEC- TORS; NOTE THAT THE DRAWING ALWAYS DEPICT THE CONNECTOR/COMPONENT VIEWED FROM THE WIRING HARNESS SIDE, I.E.
Page 72 Dune 125 - Dune X 125 - Euro 4 Electrical system IN THE CASE OF SPORADIC FAULTS, MOVE OR WIGGLE THE RELATIVE WIRING HARNESS SLIGHTLY WHILE PERFORMING EACH OF THE CHECKS INDICATED FOR TROUBLESHOOT- ING. 3. Pull cables gently from the back of the connector to check that the terminals are fitted correctly on the connector and that the wires are fastened correctly to the terminals.
Page 73 Dune 125 - Dune X 125 - Euro 4 Electrical system Diagnosis Oil pressure  The red oil warning lamp (1) illuminates if the pressure in the oil circuit is too low.  If this occurs, determine the cause of the low oil level.
Page 74 Dune 125 - Dune X 125 - Euro 4 Electrical system Instrument function button  Function switch button II(5).  Function switch button I(6). Instrument function button operation instructions RESETTING THE SCHEDULED MAINTENANCE ICON  Elimination warning ： only connect...
Page 75 Dune 125 - Dune X 125 - Euro 4 Electrical system Ignition circuit Characteristic Spark plug NGK CR9EKB or NGK 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.
Page 76 Dune 125 - Dune X 125 - Euro 4 Electrical system Measurement of resistance (with engine off)  For a correct detection of the alternator resistance, an ambient temperature measurement must be carried out and afterwards a heat stabilisation (after...
Page 77 Dune 125 - Dune X 125 - Euro 4 Electrical system  Effective resistance stage 1 = 0.67-0.47 = 0.20 Ohm  If there is a significant difference between one stage and another (other than 0.20 Ohm), this means that the alternator is defective and must be replaced.
Page 78 Dune 125 - Dune X 125 - Euro 4 Electrical system  If there is a significant difference between one stage and another (other than 15 V), this means that the alternator is defective and must be replaced. CAUTION WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 4-5 V LESS THAN THOSE DETECTED WITH THE ENGINE COLD.
Page 79 Dune 125 - Dune X 125 - Euro 4 Electrical system OLD SHORT CIRCUIT CURRENT 2000 4000 6000 8000 RMS DC current (Arms) (average of the 3 stage 12 - 18 12 - 18 12 - 18 12 - 18...
Page 80 Dune 125 - Dune X 125 - Euro 4 Electrical system Key: 1. Multiple connectors 2. MIU G3 control unit 3. Gear in neutral switch 4. Clutch switch 5. Right light switch 6. Ignition switch 7. Starter motor relay 8. Starter motor 9.
Page 81 Dune 125 - Dune X 125 - Euro 4 Electrical system STARTER COMMAND Function Commands engine starting through the injection control unit. Operation / Operating principle The starter button, brake switches, No. 25 starter relay and the injection control unit are involved, via PINs 5 and 10.
Page 82 Dune 125 - Dune X 125 - Euro 4 Electrical system Horn control Testing voltage: 13 V (nominal 12 V) Input: < 3.5 A Lights list ELE SYS - 82...
Page 83 Dune 125 - Dune X 125 - Euro 4 Electrical system Lights list Key: 1.Instrument panel 2.Flasher unit 3.Left light switch 4.Right light switch 5.Ignition switch 6.Rear stop switch 7.Front stop switch 8.Multiple connectors 9.Rear right turn indicator 10.Licence plate light 11.Rear left turn indicator...
Page 84 Dune 125 - Dune X 125 - Euro 4 Electrical system HEADLAMP Low-beam/high-beam headlight (1 dual-filament bulb): HS1 - 12 V - 35 W Daylight running light 12 V - 5 W TAILLIGHT  Rear daylight running light /stop light: ...
Page 85 Dune 125 - Dune X 125 - Euro 4 Electrical system Battery Function Provides electrical power to vehicle: the battery (YTX7L-BS) must be activated and charged. Level in electrical circuit diagram: Start, ECU base power circuit, injection utilities re- lay, turn indicators, battery charging, high beam...
Page 86 Dune 125 - Dune X 125 - Euro 4 Electrical system Value determined from signal read without taking considering whether recovery mode is implemen- Diagnostics tool - Logic errors Battery voltage P0560  Too high/Too low Error cause  If too high: excessively high voltage detected at PIN 9 If too low: excessively low voltage detected at PIN 9 Instrument cluster does not indicate this error even if in ATT state.
Page 87 Dune 125 - Dune X 125 - Euro 4 Electrical system Engine rpm sensor Function It informs crankshaft position and speed to the Marelli control unit Operation / Operating principle Inductive sensor: sinusoidal-type generated voltage; two teeth are missing on the flywheel for the ref-...
Page 88 Dune 125 - Dune X 125 - Euro 4 Electrical system Engine temperature sensor Function Serves the purpose of communicating the engine temperature to the control unit in order to optimise performance. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).
Page 89 Dune 125 - Dune X 125 - Euro 4 Electrical system ELECTRICAL ERRORS Engine temperature sensor P0115 - open circuit or shorted to positive / shorted to negative. Cause of error Open circuit or short circuit to positive: interruption of the circuit or excessive voltage at PIN 13 of the control unit connector.
Page 90 Dune 125 - Dune X 125 - Euro 4 Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich. Operation / Operating principle Based on the difference of oxygen in the exhaust...
Page 91 Dune 125 - Dune X 125 - Euro 4 Electrical system Short-circuit to positive: excessive voltage at PIN 11 or PIN 12 of the control unit connector. Open circuit or short-circuit to negative: interruption of the circuit or null voltage between control unit connector PIN 11 and 12.
Page 92 Dune 125 - Dune X 125 - Euro 4 Electrical system  Verify continuity of the wiring harness between the sensor connector and the control unit connector: control unit PIN 31 - sensor PIN B. If necessary, restore the wiring harness.
Page 93 Dune 125 - Dune X 125 - Euro 4 Electrical system 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;...
Page 94 Dune 125 - Dune X 125 - Euro 4 Electrical system ELECTRICAL ERRORS Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit. Error cause Shorted to positive: excessive voltage at PIN 22 of the control unit connector.
Page 95 Dune 125 - Dune X 125 - Euro 4 Electrical system - control unit PIN 22. Restore the ca- bling if necessary. Coil Check A tester can be used for the check. In every case the continuity of the primary and secondary wind- ings must be checked.
Page 96 Dune 125 - Dune X 125 - Euro 4 Electrical system Troubleshooting Shorted to positive:  Disconnect the coil connector, turn the key to ON and activate the component through the diagnostics instrument.  Verify the presence of voltage on the coil connector PIN 2: if present, restore the cabling, otherwise replace the coil.
Page 97 Dune 125 - Dune X 125 - Euro 4 Electrical system NOTE NO ERRORS Neutral sensor Function Indicates the gear position to the instrument panel: if it is in neutral or in gear Operation / Operating principle For neutral gear, the circuit is closed to ground connection: the instrument panel turns on the neutral...
Page 98 Dune 125 - Dune X 125 - Euro 4 Electrical system  If there is no continuity, restore the wir- ing harness.  If OK, replace the instrument panel if the vehicle performs properly. Warning light "N" always on Error cause ...
Page 99 Dune 125 - Dune X 125 - Euro 4 Electrical system Electrical specifications  Clutch engaged: closed circuit (con- tinuity)  Clutch released: open circuit (infinite resistance) Pin-out 1. 12 V Voltage (brown/white) 2. Ground (blue/green) Diagnostic tool - Parameters and statuses ...
Page 100 Dune 125 - Dune X 125 - Euro 4 Electrical system Electric fan circuit Function Activates coolant radiator fan Operation / Operating principle When the ECU detects a temperature of approxi- mately 101°C, it closes the connection between the fan control relay excitation circuit and ground Level in electrical circuit diagram: Electric fan.
Page 101 Dune 125 - Dune X 125 - Euro 4 Electrical system  Disconnect the fan control relay (No. 42 in electrical circuit diagram), turn the ignition switch to ON and measure the voltage at PIN 1 of the relay connector leading to the wiring harness side: if the voltage is 12V, repair the wiring harness, if the voltage is zero, replace the relay.
Page 102 Dune 125 - Dune X 125 - Euro 4 Electrical system 1. Voltage 0 V with engine kill in STOP; 12V if engine kill in RUN (pink/yellow cable) 2. Always voltage 12 V (with key on) (red/yellow cable) Diagnostic tool - Parameters and statuses ...
Page 103 Dune 125 - Dune X 125 - Euro 4 Electrical system green-black 1. Coil output ( 2. NO light green-red 3. Neutral signal input ( 4. RUN-OFF input (brown-yellow) 5. Start button input (yellow-red) white-red 6. Ignition switch (+) input ( 7.
Page 104 Dune 125 - Dune X 125 - Euro 4 Electrical system Diagnostic tool - Control unit info screen page In this screen page are read the general data re- garding the control unit, for example: type of soft- ware, mapping, control unit programming data ...
Page 105 Dune 125 - Dune X 125 - Euro 4 Electrical system  Engine status - (Undetermined, Po- wON/Engine off, KeyON/engine off, Rotation, Engine Stall, Pwr latch in pro- gress, Pow.Latch Term, Stop, Syn- chronis. 4 strokes)  er, partial position) Throttle valve status - (---, idle, full pow ...
Page 106 Dune 125 - Dune X 125 - Euro 4 Electrical system  Fan activation  Lambda probe heater 1  Fuel manifold test  Injector control  Headlights relay  Stepper  Fuel pump  General warning light Diagnostic tool - Errors screen page This display shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO).
Page 107 Dune 125 - Dune X 125 - Euro 4 Electrical system   Sensor potentiometer throttle valve position P0120 - short circuit to positive, open circuit / short circuit to negative Cause of error  Malfunction of sensor inside the control unit Troubleshooting ...
Page 108 Dune 125 - Dune X 125 - Euro 4 Electrical system Dashboard Key: 1.EFI warning light （ brown-white ） 2.Oil level or pressure warning light （ blue-black ） 3.No 4.Rotating speed （ yellow-pink ） 5.Speed （ blue-white ） 6.Side stand status indicator （ white-green ）...
Page 109 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 110 Dune 125 - Dune X 125 - Euro 4 Engine from vehicle Vehicle preparation  Support the front of the vehicle using a hoist, make it safe by using belts and support it in the centre using a support. ...
Page 111 Dune 125 - Dune X 125 - Euro 4 Engine from vehicle  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-...
Page 112 Dune 125 - Dune X 125 - Euro 4 Engine from vehicle  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) and disconnect the pipe (12) ...
Page 113 Dune 125 - Dune X 125 - Euro 4 Engine from vehicle  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) ...
Page 114 Dune 125 - Dune X 125 - Euro 4 Engine from vehicle  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) ...
Page 115 Dune 125 - Dune X 125 - Euro 4 Engine from vehicle  Unscrew and 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 ...
Page 116 INDEX OF TOPICS NGINE...
Page 117 Dune 125 - Dune X 125 - Euro 4 Engine Gearbox EAR SELECTOR pos. Description Type Quantity Torque Notes Selector sprocket fastener screw 4 Nm (2.95 lb ft) Lever fastener screw 9 Nm (6.64 lb ft) Clutch lever fastener screw 9 Nm (6.64 lb ft)
Page 118 Dune 125 - Dune X 125 - Euro 4 Engine OMPONENTS OF GEARBOX pos. Description Type Quantity Torque Notes Gear sensor retainer 3 Nm (2.21 lb ft) Diagram Filtro olio  Place a recipient with a capacity of at least 900 cm³ (54.91 cu.in) under the drain plug (1) on the clutch side.
Page 119 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the oil filter (4) and clean thor- oughly before refitting. NOTE CHECK AND, IF NECESSARY, REPLACE THE FILTER SEAL WASHER Gearbox shafts Disassembling the gearbox  Remove the desmodromic drum ...
Page 120 Dune 125 - Dune X 125 - Euro 4 Engine Removing the primary shaft CAUTION THE PRIMARY SHAFT CANNOT BE DISASSEMBLED. IF NECESSARY, REPLACE THE ENTIRE PRIMARY SHAFT. Removing the secondary shaft CAUTION FIT NEW CIRCLIPS WHEN REASSEMBLING Disassemble the secondary shaft as follows: ...
Page 121 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the spacer washer (4)  Remove the fifth speed gear (5).  Remove the circlip (6).  Remove the spacer washer (7) ENG - 121...
Page 122 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the third speed gear (8).  Remove the fourth speed gear (9).  Remove the sixth speed gear (10).  Remove the spacer washer (11) ENG - 122...
Page 123 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the spacer washer (12)  Remove the second speed gear (13).  Remove the bush (14).  Remove the shim washer (15) ENG - 123...
Page 124 Dune 125 - Dune X 125 - Euro 4 Engine Desmodromic demounting  Remove the fork carrier shaft (1)  Remove the desmodromic shaft (2)  Remove the forks (3) Checking the desmodromic drum Check the desmodromic shaft and drum for any signs of damage, scratches or wear, and replace if necessary.
Page 125: Starter Motor
Dune 125 - Dune X 125 - Euro 4 Engine  Check that the fork moves uniformly and without impediment; check for damage, dents and signs of wear on the roller (1) and on the teeth (2) of the fork.
Page 126 Dune 125 - Dune X 125 - Euro 4 Engine Removing the starter motor  Undo and remove the two fixing screws (1).  Remove the starter motor (2). NOTE THE STARTER MOTOR CAN ALSO BE REMOVED IF THE ENGINE IS FITTED TO THE VEHICLE.
Page 127 Dune 125 - Dune X 125 - Euro 4 Engine GNITION UNIT pos. Description Type Quantity Torque Notes Flywheel rotor fixing nut M14x1.5 86 Nm (63.43 lb ft) Rotor fastener screw 12 Nm (8.85 lb ft) Stator clamping screws 6 Nm (4.43 lb ft) Pick-Up clamping screw 3.5 Nm (2.58 lb ft)
Page 128 Dune 125 - Dune X 125 - Euro 4 Engine Rimozione 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.
Page 129 Dune 125 - Dune X 125 - Euro 4 Engine  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...
Page 130 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the stator. Freewheel removal  Undo and remove the indicated retain- er screw with the relative plate.  Remove the freewheel. ENG - 130...
Page 131 Dune 125 - Dune X 125 - Euro 4 Engine Clutch side LUTCH COVER Pos. Description Type Quantity Torque Notes Clutch cover fixing screw M6x35 12 Nm (8.85 lb ft) Oil filter cover M56x1.5 25 Nm (18.44 lb ft) Oil pressure sensor 13 Nm (9.59 lb ft)
Page 132 Dune 125 - Dune X 125 - Euro 4 Engine LUTCH pos. Description Type Quantity Torque Notes Clutch spring screw 4 Nm (2.95 lb ft) Crankshaft primary gear fastener nut 79 Nm (58.27 lb ft) Clutch nut 40 Nm (29.50 lbf ft) Removing the clutch cover ...
Page 133 Dune 125 - Dune X 125 - Euro 4 Engine Disassembling the clutch  Unscrew and remove the six screws by loosening them 1/4 of a turn at a time; operate in stages and diagonally, and retrieve the washers and the clutch springs.
Page 134: Checking The Clutch Plates
Dune 125 - Dune X 125 - Euro 4 Engine  Remove 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 Driven plates thickness 1.46 - 1.53 mm (0.057 - 0.06 in)
Page 135 Dune 125 - Dune X 125 - Euro 4 Engine Checking the clutch housing Check the primary driven gear for damage and wear and, if necessary, replace the primary driven gear and the clutch bell all together. Make sure there is not excessive noise duringop- eration;...
Page 136 Dune 125 - Dune X 125 - Euro 4 Engine Checking the springs  Check the springs for damage and, if necessary, replace the them all togeth-  Measure the clutch spring length when unloaded; if necessary, replace the springs all together.
Page 137 Dune 125 - Dune X 125 - Euro 4 Engine  Insert the clutch hub.  Screw in the retainer nut locking the rotation of the clutch housing with the specific tool. Specific tooling 00H05300041 Clutch lock  Lift one side of the lock tab.
Page 138 Dune 125 - Dune X 125 - Euro 4 Engine Crankcase NGINE RANKCASE pos. Description Type Quantity Torque Notes Crankcase retainer screw M6x60 12 Nm (8.85 lb ft) Crankcase retainer screw M6x75 12 Nm (8.85 lb ft) ENG - 138...
Page 139 Dune 125 - Dune X 125 - Euro 4 Engine RANKSHAFT Pos. Description Type Quantity Torque Notes Gear fixing screw 40 Nm (29.50 lb ft) Balancing countershaft removal  Before taking out the balancing coun- tershaft the clutch cover and flywheel cover must be removed.
Page 140 Dune 125 - Dune X 125 - Euro 4 Engine Balancing countershaft fitting  Insert the countershaft from the alter- nator side.  Insert the gear aligning its reference to the primary gear.  Using the specific tool, tighten the nut remember first to place the washer.
Page 141 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the primary gear unscrewing and removing the nut.  Collect the washer.  Remove the countershaft gear.  Remove the primary remaining gears.  Remove the head and cylinder.
Page 142 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the base gear of the main shaft.  Remove the cotter.  Remove the oil pump unscrewing the three fixing screws.  Collect the gasket.  Remove the gear spider screw, un- screwing and removing the fixing screw.
Page 143 Dune 125 - Dune X 125 - Euro 4 Engine  Moving from the left side of the engine, remove the flywheel and all of its com- ponents beforehand.  Unscrew and remove the six screws on the outside of the crankcase (1).
Page 144 Dune 125 - Dune X 125 - Euro 4 Engine List of extractors to be used with sleeve 020376Y: RIGHT CRANKCASE  Insertion of main shaft bearing: 020439Y+020359Y Removal of the main shaft bearing: 020358Y  Insertion of desmo bearing: 020439Y+020357Y Removal of desmo bearing: 020891Y ...
Page 145 Dune 125 - Dune X 125 - Euro 4 Engine Bushing selection USHING SEAT DIAMETER ON CRANKCASE Specification Desc./Quantity Class 1 MIN 36.500 mm (1.4370 in) MAX 36.508 mm (1.4373 in) Class 2 MIN 36.508 mm (1.4373 in) MAX 36.516 mm (1.4376 in)
Page 146 Dune 125 - Dune X 125 - Euro 4 Engine  Insertion of secondary shaft roller bearing cage: 020363Y Removal of the secondary shaft roller bearing cage: use universal extractor  Insertion of countershaft roller bearing cage: 020483Y Removal of countershaft roller bear-...
Page 147 Dune 125 - Dune X 125 - Euro 4 Engine  Fit the selector star.  Fit and tighten 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.
Page 148 Dune 125 - Dune X 125 - Euro 4 Engine  Insert 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.
Page 149 Dune 125 - Dune X 125 - Euro 4 Engine  Fit the rest of the primary gears.  Tighten the fixing nut.  Remove the countershaft locking tool.  Fit the gear selector. Head and timing EAD COVER pos.
Page 150 Dune 125 - Dune X 125 - Euro 4 Engine ALVES pos. Description Type Quantity Torque Notes Head fastener screw M6x130 12 Nm (8.85 lb ft) Drainage side stud bolt retainer M8x40 12 Nm (8.85 lb ft) Camshaft cover fastener screw M6x40 11 Nm (8.11 lb ft)
Page 151 Dune 125 - Dune X 125 - Euro 4 Engine IMING SYSTEM pos. Description Type Quantity Torque Notes Chain tensioner pad fastener screw M6x16 10 Nm (7.38 lb ft) Loctite 243 Timing system gear fastener screw M8x40 27 Nm (19.91 lb ft)
Page 152 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the spark plug. Removing the timing control  Turn the crankshaft from the hole on the cover (1)  Take the piston to TDC.  The sign (2) must be aligned with the sign (3).
Page 153: Cylinder Head
Dune 125 - Dune X 125 - Euro 4 Engine  Remove the spring.  Unscrew and remove the two screws (6) and remove the entire tensioner control.  Lock the timing gear using the specific tool. Specific tooling 865260 Camshaft sprocket lock tool ...
Page 154 Dune 125 - Dune X 125 - Euro 4 Engine 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).
Page 155: Removing The Valves
Dune 125 - Dune X 125 - Euro 4 Engine  Remove the head (4). Removing the valves  Remove the head.  Place the head on supporting surface.  Number the valves and their bucket tappets in order to position them cor- rectly upon refitting.
Page 156 Dune 125 - Dune X 125 - Euro 4 Engine  Remove both cotter pins.  Release the valve springs.  Remove the cap and the valve spring. Checking the overhead camshaft  Check the camshaft bearings for signs of abnormal wear.
Page 157 Dune 125 - Dune X 125 - Euro 4 Engine Valve check  Measure the width of the sealing surface on the valve seats and on the valves themselves.  If the sealing surface on the valve is wider than the specified limit, damaged in one or more points or curved, replace the valve with a new one.
Page 158 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the chain tensioner.  Undo and remove the eight screws and remove the cam tower.  Remove the timing chain and the gears of the camshaft of the valves in ques- tion.
Page 159 Dune 125 - Dune X 125 - Euro 4 Engine  Fit the camshaft, the gears and the chain in their correct positions, using the references located on the flywheel side of the crankcase.  Fit the cam tower and tighten the eight screws to the prescribed torque.
Page 160: Checking The Cylinder Head
Dune 125 - Dune X 125 - Euro 4 Engine Inspecting the valve housings  Remove any carbon deposits from the valve guides.  Measure the inside diameter of each valve guide.  Measure according to the thrust direction at three different heights.
Page 161: Installing The Valves
Dune 125 - Dune X 125 - Euro 4 Engine  Check that the camshaft bushings are not worn.  Check that the head cover surface, the intake manifold and the exhaust manifold are not worn. Installing the valves ...
Page 162 Dune 125 - Dune X 125 - Euro 4 Engine Checking the chain  Check that the guide slider 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.
Page 163 Dune 125 - Dune X 125 - Euro 4 Engine  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.
Page 164 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the pin (3).  Remove the piston (4). Checking the piston  Measure the pin seat diameter on the piston.  Calculate the pin - piston coupling clearance.
Page 165 Dune 125 - Dune X 125 - Euro 4 Engine Characteristic Piston / cylinder Piston pin hole - standard: 15.003 - 15.008 mm (0.5907 - 0.5908 in) Maximum piston / cylinder coupling clearance after use - top ring: 0.075 mm (0.0029 in) - middle ring: 0.065 mm (0.0025 in)
Page 166 Dune 125 - Dune X 125 - Euro 4 Engine Inspecting the wrist pin  Check the pin outside diameter. Characteristic Minimum diameter: 14.995 mm (0.590 in) Standard diameter: 15.0000 +0/-0.0030 mm (0.00012 in) Inspecting the piston rings ANELLI DI TENUTA Specification Desc./Quantity...
Page 167 Dune 125 - Dune X 125 - Euro 4 Engine Fitting the piston  Install the piston and the piston pin on the connecting rod, orienting the piston with the arrow facing towards the ex- haust side.  Fit the retainer circlip.
Page 168: Installing The Cylinder Head
Dune 125 - Dune X 125 - Euro 4 Engine Installing the cylinder  Fit a new cylinder base gasket of the chosen thickness.  Refit the cylinder as indicated in the figure using the specific clamp tighten- er tool.
Page 169 Dune 125 - Dune X 125 - Euro 4 Engine  Screw but do not tighten both central long screws (3) and position thewash- ers.  Screw but do not tighten both central long screws (2) and position the wash- ers.
Page 170 Dune 125 - Dune X 125 - Euro 4 Engine  Position the cam tower cap.  Screw but do not and tighten the eight screws.  Place the pins in their positions on the overhead camshafts. Specific tooling 864567 Camshaft timing adjustment lock pins ...
Page 171: Oil Pump
Dune 125 - Dune X 125 - Euro 4 Engine  Check the valve clearance and adjust it if required.  Refit the tappet cover. Lubrication pos. Description Type Quantity Torque Notes Oil pump fastener screw M5x35 4 Nm (2.95 lb ft)
Page 172 Dune 125 - Dune X 125 - Euro 4 Engine  Remove the pump gear.  Remove the pump gear.  Separate the components to inspect them. Inspection  Measure distance between rotors with a feeler gauge at the positions shown in the picture.
Page 173 Dune 125 - Dune X 125 - Euro 4 Engine Radial clearance (2) between points of the rotor: 0.08 mm (0.003 in) Radial 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)
Page 174 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 175: Circuit Diagram
Dune 125 - Dune X - Euro 4 Power supply Circuit diagram Key: 1. Fuel tank 2. Fuel pump Fuel pump Injection Diagram 1. ECU control unit position 2. Ignition switch 3. Fuel pump 4. Instrument panel 5. Air temperature sensor 6.
Page 176 Dune125 - Dune X - Euro 4 Power supply 9. Lambda probe position 10.Engine speed sensor 11.Electric fan Removing the throttle body  Remove the filter box  Loosen the nut (1)  Remove the gas control cable from the points indicated in the figure ...
Page 177 Dune 125 - Dune X - Euro 4 Power supply  Remove the throttle body from the sleeve indicated in the figure  Unscrew the screw (3) and remove the bracket (4)  Disconnect the connector (5)  Removing the throttle body (6) P SUPP - 177...
Page 178 INDEX OF TOPICS SUSP USPENSIONS...
Page 179 Dune 125 - Dune X 125 - Euro 4 Suspensions Front Handlebar ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes M6×25 Balance hammer bolt 7/10 Nm (5.16/7.38 lb ft) SHC brake master cylinder M6×25 7/10 Nm (5.16/7.38 lb ft) fastening screws M6×25...
Page 180: Front Fork
Dune 125 - Dune X 125 - Euro 4 Suspensions Front fork pos. Description Type Quantity Torque Notes Caps 15/25 Nm (11.06/18.44 lb ft) SHC wheel axle clamp fastening M8×25 15/18 Nm (11.06/13.27 lb ft) screws Hex head handlebar U-bolt flanged M8×35...
Page 181: Removing The Fork Legs
Dune 125 - Dune X 125 - Euro 4 Suspensions pos. Description Type Quantity Torque Notes Caps 15/25 Nm (11.06/18.44 lb ft) SHC wheel axle clamp fastening M6×25 4/6 Nm (2.95/4.42 lb ft) screws Hex head handlebar U-bolt flanged M8×30 20/25 Nm (14.75/18.44 lb ft)
Page 182 Dune 125 - Dune X 125 - Euro 4 Suspensions REMOVING THE 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...
Page 183 Dune 125 - Dune X 125 - Euro 4 Suspensions Draining oil  Clamp the fork in a vice using the appropriate protection (1) to avoid damaging the sleeve.  Unscrew the cap (2). Specific tooling AP8140149 Guard for assembly operations CAUTION THE FOLLOWING OPERATIONS REFER TO A SINGLE STEM BUT APPLY TO BOTH.
Page 184 Dune 125 - Dune X 125 - Euro 4 Suspensions Disassembling the fork  Remove the dust guard(1)  Remove the retainer circlip (2).  Remove the oil seal (3).  Remove the spacer (4). SUSP - 184...
Page 185 Dune 125 - Dune X 125 - Euro 4 Suspensions Checking the components Bearing tube Check that the sliding surface is not scratched or scored. Any scoring can be removed by sanding with damp sandpaper (grain 1). If the scorings are deep, replace the bearing tube.
Page 186 Dune 125 - Dune X 125 - Euro 4 Suspensions Reassembling the fork Please install in sequence Filling oil Place the fork upright in a vice fitted with protection jaws it will go. Push the stem into the sleeve as far as Pour part of the fork oil into the stanchion.
Page 187: Installing The Fork Legs
Dune 125 - Dune X 125 - Euro 4 Suspensions Installing the fork legs  Insert the left-hand fork (1)  Tighten the screws (2)  Insert the left-hand fork (3)  Tighten the screws (4) SUSP - 187...
Page 188 Dune 125 - Dune X 125 - Euro 4 Suspensions  Tighten the top fairing support screws  Tighten the top fairing support screws  Mount the front wheel  Secure the front brake calliper (7) with support bracket by tightening the screw (8) ...
Page 189 Dune 125 - Dune X 125 - Euro 4 Suspensions Removing Lift the vehicle using a hoist and support it in the centre using a support.  Remove the nut (1)  Remove the washer (2)  emove the screws (3) ...
Page 190 Dune 125 - Dune X 125 - Euro 4 Suspensions  Remove the screw and washer (7)  Remove the shock absorber (8) SUSP - 190...
Page 191 INDEX OF TOPICS CHAS HASSIS...
Page 192 Dune 125 - Dune X 125 - Euro 4 Chassis Chassis HASSIS pos. Description Type Quantity Torque Notes Headlight bracket bolt M6 × 16 5/7 Nm (3.69/5.16 lb ft) Headlight bracket bolt 8/10 Nm (5.90/7.38 lb ft) M6 × 30 Engine bracket bolt M10 ×...
Page 193: Front Wheel
Dune 125 - Dune X 125 - Euro 4 Chassis Wheels Front wheel RONT WHEEL pos. Description Type Quantity Torque Notes Wheel fastening pin 70/80 Nm (51.63/59 lb ft) SHC front brake disc fastening M6x20 10/12 Nm (7.38/8.85 lb ft) Loct.
Page 194 Dune 125 - Dune X 125 - Euro 4 Chassis FORK pos. Description Type Quantity Torque Notes Caps 15/25 Nm (11.06/18.44 lb ft) SHC wheel axle clamp fastening M8×25 15/18 Nm (11.06/13.27 lb ft) screws Hex head handlebar U-bolt flanged M8×35...
Page 195 Dune 125 - Dune X 125 - Euro 4 Chassis Removal  Lift the front of the vehicle using a hoist, make it safe by using belts and support it in the centre using a support.  Remove the cap (1) ...
Page 196 Dune 125 - Dune X 125 - Euro 4 Chassis  Remove the front wheel (6) Checking FRONT WHEEL BEARINGS Check the bearings installed on the wheel. CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR.
Page 197 Dune 125 - Dune X 125 - Euro 4 Chassis WHEEL  Use a dial gauge to check that the ra- dial (A) and axial (B) eccentricity of the wheel do not exceed the specified lim- its. Excessive eccentricity is usually caused by worn or damaged bearings.
Page 198: Rear Wheel
Dune 125 - Dune X 125 - Euro 4 Chassis Rear wheel EAR WHEEL pos. Description Type Quantity Torque Notes 70/80 Nm (51.63/59 lb Rear axle Rear brake disc bolt M8 × 24.2 15/18 Nm (11.06-13.27 lb ft) Loct. 243 17/19 Nm (12.54/14.01...
Page 199 Dune 125 - Dune X 125 - Euro 4 Chassis Rimozione BEFORE CARRYING OUT THE FOLLOWING OPERATIONS, LEAVE THE ENGINE AND MUFFLER TO COOL TO AMBIENT TEMPERATURE TO PREVENT THE RISK OF BURNS. CAUTION DURING REMOVAL, TAKE CARE NOT TO DAMAGE THE PIPE, THE DISC AND THE BRAKE PADS.
Page 200 Dune 125 - Dune X 125 - Euro 4 Chassis  Unscrew the nut (3) and remove it  Retrieve the washer (4)  Remove the wheel axle (5) CHAS - 200...
Page 201 Dune 125 - Dune X 125 - Euro 4 Chassis  Remove the chain (6) from the crown  Retrieve the washer (7)  Remove the rear wheel (8) CHAS - 201...
Page 202 Dune 125 - Dune X 125 - Euro 4 Chassis REMOVING THE CROWN  Remove the rear wheel  Remove the spacer (1)  Block the nuts at the rear and unscrew and remove the screws (2) at the points indicated in the figure ...
Page 203 Dune 125 - Dune X 125 - Euro 4 Chassis REAR WHEEL BEARINGS Check the bearings installed on the wheel. CHECKING ROTATION  Manually rotate the inner race of each bearing. The race must turn smoothly without im- pediment or noise.
Page 204 Dune 125 - Dune X 125 - Euro 4 Chassis 0.6 mm (0.0236 in) Maximum lateral (B) eccentricity: 0.5 mm (0.0197 in) CROWN GEAR  Check the condition of the teeth of the crown gear (3). If excessively worn: ...
Page 205 Dune 125 - Dune X 125 - Euro 4 Chassis Swinging arm EAR FORK pos. Description Type Quantity Torque Notes 55/65 Nm (10.56/47.94 M12 × 58 Rear shock absorber bolt lb ft) 55/65 Nm (10.56/47.94 Rear shock absorber bolt M12 × 50...
Page 206 Dune 125 - Dune X 125 - Euro 4 Chassis 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 Dune 125 - Dune X 125 - Euro 4 Chassis  Remove the nut (5)  Extract the pin (6) and remove it.  Remove the swingarm (7) Checking CAUTION CHECK THAT NO COMPONENT IS NOTICEABLY DISTORTED, DAMAGED, CRACKED AND/OR DENTED.
Page 208 Dune 125 - Dune X 125 - Euro 4 Chassis SWINGARM PIN With a dial gauge check if the pin eccentricity ex- ceeds the limit value. Otherwise, replace the pin. Maximum pin eccentricity: 0.3 mm (0.01 in) Installing  To 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.
Page 209 Dune 125 - Dune X 125 - Euro 4 Chassis Removing REMOVING THE PINION GUARD  Unscrew and remove the two screws  Remove the pinion guard (2) REMOVING THE PINION  Remove the chain  Remove the pinion guard ...
Page 210: Drive Chain
Dune 125 - Dune X 125 - Euro 4 Chassis  Remove the pinion (3) Inspection  Check the state of the teeth of the front and rear sprockets. If excessively worn, replace: the rear sprocket, front sprocket and drive chain.
Page 211 Dune 125 - Dune X 125 - Euro 4 Chassis  Remove the outer plate (2).  Remove the inner plate (3) and the pins.  Remove the drive chain. inspection Also check the following parts and check that the chain, the front sprocket and the rear sprocket do not have: - Damaged rollers.
Page 212 Dune 125 - Dune X 125 - Euro 4 Chassis The vehicle has a chain with a 1/2" pitch closed using a link. With wear, the chain lengthens. Replace the chain if there is lengthening equal to or more than 2%.
Page 213 Dune 125 - Dune X 125 - Euro 4 Chassis Installing  After fitting the chain on the pinion and on the crown, connect the two ends of the chain by placing the inner plate (1) complete with pins on the chain.
Page 214 Dune 125 - Dune X 125 - Euro 4 Chassis  Move the vehicle forwards to check the vertical deflection of the chain in other positions; the chain deflection must be constant throughout the entire rotation of the wheel. CAUTION...
Page 215 Dune 125 - Dune X 125 - Euro 4 Chassis Rimozione REMOVING THE RIDER FOOTRESTS The following procedure is only shown from the left-hand side of the vehicle, but is valid for both footrests  Unscrew the nut (1) and remove it.
Page 216 Dune 125 - Dune X 125 - Euro 4 Chassis  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) ...
Page 217 Dune 125 - Dune X 125 - Euro 4 Chassis  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) ...
Page 218: Side Stand
Dune 125 - Dune X 125 - Euro 4 Chassis 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 Dune 125 - Dune X 125 - Euro 4 Chassis Exhaust XHAUST SYSTEM pos. Description Type Quantity Torque Notes Muffer bent pipe cover bolt 5/6 Nm (3.69-4.43 lb ft) 5/6 Nm (3.69-4.43 lb ft) Muffer cover bolt 8/10 Nm (5.90-7.38 lb Muffler fixing clamp 18/22 Nm (13.28-16.23...
Page 220 Dune 125 - Dune X 125 - Euro 4 Chassis Removing the tail 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) ...
Page 221 Dune 125 - Dune X 125 - Euro 4 Chassis  Remove the exhaust manifold (2) Removing the lambda sensor  Remove the horn  Disconnect the connector (1)  Undo and remove the probe (2) CHAS - 221...
Page 222 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 223: Brake Pedal
Dune 125 - Dune X 125 - Euro 4 Braking system Brake Pedal Brake Pedal Position Inspection Check that the brake pedal [A] is in the correct position. Footpeg [B] Brake Pedal Position Adjustment  Loosen the locknut [A] and turn the push rod with...
Page 224: Brake Pedal Installation
Dune 125 - Dune X 125 - Euro 4 Braking system 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.
Page 225: Rear Caliper Removal
Dune 125 - Dune X 125 - Euro 4 Braking system Rear Caliper Removal  Remove: Brake Hose Banjo Bolt [A] Brake Hose [B] Rear Caliper Mounting Bolts [C] Rear Caliper [D] CAUTION IMMEDIATELY WASH AWAY ANY BEAKE FLUID SPILLS.
Page 226 Dune 125 - Dune X 125 - Euro 4 Braking system Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear.
Page 227 Dune 125 - Dune X 125 - Euro 4 Braking system Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
Page 228: Brake Pads
Dune 125 - Dune X 125 - Euro 4 Braking system Brake Pads Front Brake Pad Removal  Loosen the brake pad pins [A].  Remove the front caliper with the brake hose installed (see Front Caliper Removal).  Remove the pad pins.
Page 229 Dune 125 - Dune X 125 - Euro 4 Braking system Rear Brake Pad Removal  Loosen the brake pad pins [A ]  Remove the rear caliper with the brake hose installed (see rear Caliper Removal).  Remove: Pad Pin Jaw Side Pad [A] Piston Side Pad [B ] Rear Brake Pad Installation ...
Page 230: Master Cylinder
Dune 125 - Dune X 125 - Euro 4 Braking system Master Cylinder Front Master Cylinder Removal  Disconnect the brake hose from the master cylinder (see brake Hose Replacement in the Periodic Maintenance chapter).  Disconnect the front brake light switch connectors [A].
Page 231: Rear Master Cylinder Installation
Dune 125 - Dune X 125 - Euro 4 Braking system Rear Master Cylinder Removal  Remove: Cotter Pin [A] Joint Pin [B] Washer [C]  Unscrew the brake hose banjo bolt [A] on the master cylinder (see Brake Hose Replacement in the Periodic Maintenance chapter).
Page 232 Dune 125 - Dune X 125 - Euro 4 Braking system Master Cylinder Assembly Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Inspection  Remove master cylinders (see Front/Rear Master Cylinder Removal). ...
Page 233: Brake Disc Installation
Dune 125 - Dune X 125 - Euro 4 Braking system Brake Disc Removal  Remove the wheel(see Front/Rear Wheel Removal in the Wheels/Tires chapter).  Unscrew the mounting bolts [A], and take off the brake disc [B]. Brake Disc Installation ...
Page 234: Brake Fluid
Dune 125 - Dune X 125 - Euro 4 Braking system If runout exceeds the service limit, replace the disc. Disc Runout Standard: TIR 0.15 mm (0.0059 in.) or less Service Limit: TIR 0.3 mm (0.01 in.) Brake Fluid Brake Fluid Level Inspection Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter.
Page 235 Dune 125 - Dune X 125 - Euro 4 Braking system  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].
Page 236: Brake Hose
Dune 125 - Dune X 125 - Euro 4 Braking system Brake Hose Brake Hose Removal/Installation Refer to the Brake Hose Replacement in the Periodic Maintenance chapter. Brake Hose Inspection Refer to the Brake Hose Damage and Installation Condition Inspection in the Periodic Maintenance chapter.
Page 237 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 238 Dune 125 - Dune X 125 - Euro 4 Cooling system Electric fan  Remove the radiator  Unscrew and remove the screws (1)  Retrieve the grooved washers (2) and washers (3)  Remove the electric fan (4) COOL SYS - 238...
Page 239: Coolant Replacement
Dune 125 - Dune X 125 - Euro 4 Cooling system Coolant replacement  Remove the side fairings  Unscrew and remove the cap  Loosen the clamp shown in the figure and disconnect the pipe (2)  Collect the coolant that flows out in a...
Page 240 Dune 125 - Dune X 125 - Euro 4 Cooling system Removal  Remove the water pump and rotor cov-  Remove the rotor;  Remove the clutch cover;  Heat the clutch cover to facilitate extraction of the water pump spindle assembly;...
Page 241 Dune 125 - Dune X 125 - Euro 4 Cooling system  Support the group of the water pump shaft on a vice and after it is sufficiently heated up, separate it with a punch from the gear; Installing CAUTION ALWAYS REPLACE THE BEARINGS, THE OIL SEAL, AND THE SEALING RING, WHENEVER IT IS NECESSARY TO REMOVE THE WATER PUMP.
Page 242 Dune 125 - Dune X 125 - Euro 4 Cooling system  Place the oil seal as in figure and push it until it stops;  Place the gear paying attention that the operation is oriented to the cover; ...
Page 243 Dune 125 - Dune X 125 - Euro 4 Cooling system THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD BECAUSE THE BOIL- ING COOLANT OR VAPOURS MAY CAUSE SERIOUS BURNS. COLLECT THE COOLANT IN A SPECIAL CONTAINER. COOLANT IS HARMFUL, AVOID CONTACT WITH THE SKIN AND EYES.
Page 244 Dune 125 - Dune X 125 - Euro 4 Cooling system  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) ...
Page 245 INDEX OF TOPICS BODYW ODYWORK...
Page 246 Dune 125 - Dune X 125 - Euro 4 Bodywork Side fairings The following procedure is only shown from the RH side of the vehicle but is valid for both side bump-  Open the bottom plug(1)  Unscrew and remove the screws (2) ...
Page 247: Instrument Panel
Dune 125 - Dune X 125 - Euro 4 Bodywork Instrument panel  Unscrew and remove the screws(1)  Disconnect the connector (2)  Remove the top fairing/headlamp(3)  Disconnect the connector(4)  Remove the instrument panel. BODYW - 247...
Page 248 Dune 125 - Dune X 125 - Euro 4 Bodywork 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) ...
Page 249: Turn Indicators
Dune 125 - Dune X 125 - Euro 4 Bodywork  Disconnect 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) ...
Page 250 Dune 125 - Dune X 125 - Euro 4 Bodywork REMOVING THE REAR TURN INDICATORS  Remove the license plate holder brack-  move the screws (1) Unscrew and re  Remove the right-hand rear turn indi- cator (2) Remove the left-hand rear turn indicator (3) Side fairings ...
Page 251 Dune 125 - Dune X 125 - Euro 4 Bodywork  Undo and remove the screw (2)  Unscrew and remove the screw (3)  Remove the left side engine fairing (4) BODYW - 251...
Page 252 Dune 125 - Dune X 125 - Euro 4 Bodywork License plate holder  Remove the rear light cluster  Unscrew and remove the screws  Remove the license plate holder  Remove the rear turn indicators  Remove the licence plate light Rear mudguard ...
Page 253 Dune 125 - Dune X 125 - Euro 4 Bodywork Air box  Remove the side fairing panels  Remove the tail fairing  Remove the battery  Remove the exhaust system  Remove the rear mudguard  Remove the rear wheelhouse ...
Page 254 Dune 125 - Dune X 125 - Euro 4 Bodywork  To unload the filter box (7)  Remove the filter box (7) BODYW - 254...
Page 255 Dune 125 - Dune X 125 - Euro 4 Bodywork Lower cowl  Unscrew and remove the screws (1)  Undo and remove the screw (2)  Remove the engine fairing lug (3) BODYW - 255...
Page 256: Fuel Tank
Dune 125 - Dune X 125 - Euro 4 Bodywork Fuel tank  Undo and remove the screw (1)  Remove the battery.  Remove the battery box(3). BODYW - 256...
Page 257 Dune 125 - Dune X 125 - Euro 4 Bodywork  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 Dune 125 - Dune X 125 - Euro 4 Bodywork Rear wheelhouse  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 ...
Page 259: Front Mudguard
Dune 125 - Dune X 125 - Euro 4 Bodywork 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) ...
Page 260 Dune 125 - Dune X 125 - Euro 4 Bodywork  Undo and remove the screw (3)  Undo and remove the screw (4)  Undo and remove the screw (5)  Undo and remove the screw (6) BODYW - 260...
Page 261 Dune 125 - Dune X 125 - Euro 4 Bodywork  Unscrew and remove the screws (7)  Remove the radiator cover (8) BODYW - 261...
Page 262 Dune 125 - Dune X 125 - Euro 4 Bodywork Battery  Remove 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 ...
Page 263 Dune 125 - Dune X 125 - Euro 4 Bodywork 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.
Page 264 Dune 125 - Dune X 125 - Euro 4 Bodywork  Remove the tail guard(5) BODYW - 264...
Page 265 Dune 125 - Dune X 125 - Euro 4 Bodywork INDEX OF TOPICS PRE DE DELIVERY BODYW - 265...
Page 266 Dune 125 - Dune X 125 - Euro 4 Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection Paintwork Fitting of Plastic Parts Scratches Dirt Tightening torques inspection Safety fasteners: front and rear suspension unit...
Page 267 Dune 125 - Dune X 125 - Euro 4 Pre-delivery - Through the diagnostic tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about avail- able upgrades and details regarding the operation.
Page 268: Road Test
Dune 125 - Dune X 125 - Euro 4 Pre-delivery Road test Cold start Instrument panel operation Response to throttle control Stability when accelerating and braking Front and rear brake efficiency Front and rear suspension efficiency Abnormal noise Static test...
Page 269 Dune 125 - Dune X 125 - Euro 4 Pre-delivery OBD LIST The OBD list are the following: PRE DE - 269...
Page 270 Dune 125 - Dune X 125 - Euro 4 Pre-delivery PRE DE - 270...
Page 271 Dune 125 - Dune X 125 - Euro 4 Pre-delivery PRE DE - 271...

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