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Table Of Contents - Malaguti Dune X 125 Service Station Manual

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User manual (112 pages)

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Table of Contents

Index Of Topics5

Table Of Contents5

Maintenance Rules8

Disassembling Components9

Reassembling Components9

Electrical Connectors9

Vehicle Identification11

Dimensions And Mass11

Serial Number Location11

Engine Number11

Characteristics11

Transmission Data12

Capacities Data12

Electrical System Data12

Frame And Suspensions Data13

Wheels And Tyres Data13

Warning Lights13

Tightening Torques14

Front Wheel Exploded View15

Fork Exploded View16

Handlebar And Controls Exploded View17

Lights Diagram18

Plastic Covers View20

Canister Assembly View22

Filter Box View22

Electrical System View23

Fuel Tank Exploded View24

Lock Assy View25

Exhaust System View25

Rear Wheel View26

Rear Fork View27

Rear Brake Pedal View27

Cbs System View28

Engine Diagrams29

Crankshaft View29

Cylinder - Piston View29

Throttle Body View30

Clutch Cover View30

Head Cover View31

Flywheel Cover View32

Timing System View32

Starter Motor View33

Water Pump View34

Oil Pump View34

Gear Selector View35

Engine Crankcase View36

Head - Valves View37

Ignition Unit View38

Components Of Gearbox View39

Assembly Clearances40

Cylinder - Piston Assy40

Rod Small End - Pin - Piston41

Special Tools42

Scheduled Maintenance Table48

Recommended Products50

Engine Oil Check51

Spark Plug Data51

Engine Oil Replacement52

Engine Oil Filter54

Braking System55

Top-Up Of Braking System56

Adjusting The Levers57

Clutch System57

Electrical System59

Electrical System Components Arrangement60

Electrical System Installation62

Instrument Panel62

Turn Indicators63

Cable Routing On Rh Side63

A-Oil Pressure Sensor63

A1-Oil Pressure Sensor64

A2-Oil Pressure Sensor64

Voltage Regulator65

Main Wiring Harness66

Starter Motor67

Main Wiring Harness On Rear Chassis68

General Wiring Diagram70

Checks And Inspections71

Checking Connectors71

Checking Electrical Continuity72

Checking Ground Connection72

Checking Voltage72

Dashboard Facilities73

Instrument Function Button74

Resetting The Scheduled Maintenance Icon74

Ignition Circuit75

Battery Recharge Circuit75

Recharging System75

Measurement Of Resistance (With Engine Off)76

Empty Voltage78

Voltage Regulator Check79

Start-Up System Check79

Cold Short Circuit Current79

Checking The Starter Motor80

Checking The Starter Motor Relay80

Starter Command81

Main Fuses Distribution84

Engine Rpm Sensor87

Engine Temperature Sensor88

Lambda Sensor90

Engine Oil Pressure Sensor96

Neutral Sensor97

Clutch Lever Sensor98

Electric Fan Circuit100

Run/Stop Switch101

Engine From Vehicle109

Vehicle Preparation110

Removing The Engine From The Vehicle110

Installing The Engine To The Vehicle115

Gearbox Shafts119

Disassembling The Gearbox119

Removing The Primary Shaft120

Removing The Secondary Shaft120

Desmodromic Demounting124

Checking The Desmodromic Drum124

Checking The Forks124

Removing The Starter Motor126

Generator Side126

Removing The Flywheel Cover127

Rotor Removal128

Removing The Stator129

Freewheel Removal130

Removing The Clutch Cover132

Disassembling The Clutch133

Checking The Clutch Plates134

Checking The Clutch Housing135

Checking The Clutch Hub135

Checking The Springs136

Assembling The Clutch136

Balancing Countershaft Removal139

Balancing Countershaft Fitting140

Crankcase Opening140

Bearing Removal143

Crankcase Check144

Bushing Selection145

Bearing Fitting145

Crankcase Closing146

Head And Timing149

Removing The Head Cover151

Removing The Timing Control152

Cylinder Head153

Removing The Overhead Camshaft154

Removing The Valves155

Checking The Overhead Camshaft156

Inspecting The Valve Sealings159

Inspecting The Valve Housings160

Inspecting The Springs And Half-Cones160

Checking The Cylinder Head160

Installing The Valves161

Checking The Chain Tensioner161

Checking The Chain162

Cylinder-Piston Assembly162

Removing The Cylinder162

Disassembling The Piston163

Checking The Piston164

Inspecting The Wrist Pin166

Inspecting The Piston Rings166

Checking The Connecting Rod Small End166

Fitting The Piston167

Selecting The Base Gasket168

Installing The Cylinder Head168

Oil Pump Removal171

Oil Pump Inspection172

Oil Pump Installation173

Power Supply174

Circuit Diagram175

Removing The Throttle Body176

Front Suspension179

Handlebar And Controls View179

Front Fork Exploded View180

Removing The Fork Legs181

Removing The Left-Hand Fork182

Draining Oil183

Disassembling The Fork184

Checking The Fork Components185

Reassembling The Fork186

Installing The Fork Legs187

Rear Suspension188

Rear Suspension Removal189

Chassis Exploded View192

Front Wheel View193

Fork Diagram194

Front Wheel Removal195

Front Wheel Bearings Check196

Radial And Axial Play Check196

Wheel Axle Check196

Front Wheel Check197

Front Wheel Installation197

Rear Wheel Removal199

Removing The Crown202

Checking Of Rear Wheel Components202

Rear Wheel Bearings Check203

Wheel Rim Check203

Rear Wheel Installation204

Swinging Arm205

Swinging Arm Removal206

Swinging Arm Check207

Swingarm Pin Check208

Swinging Arm Installation208

Pinion Removal209

Pinion Inspection210

Pinion Installation210

Drive Chain Removal210

Drive Chain Inspection211

Drive Chain Installation213

Drive Chain Adjustment213

Footrests Removal215

Removing The Rear Brake Lever216

Removing The Gear Shift Lever217

Exhaust System219

Removing The Tail Pipe220

Removing The Exhaust Manifold220

Removing The Lambda Sensor221

Braking System Maintenance222

Brake Pedal Position Adjustment223

Brake Pedal Removal223

Brake Pedal Installation224

Front Caliper Removal224

Rear Caliper Removal225

Caliper Installation225

Front Caliper Disassembly225

Front Caliper Assembly225

Rear Caliper Disassembly225

Rear Caliper Assembly225

Caliper Fluid Seal Damage226

Caliper Dust Boot And Friction Boot Damage226

Caliper Piston And Cylinder Damage226

Caliper Holder Shaft Wear227

Front Brake Pad Removal228

Front Brake Pad Installation228

Rear Brake Pad Removal229

Rear Brake Pad Installation229

Master Cylinder230

Front Master Cylinder Installation230

Rear Master Cylinder Removal231

Rear Master Cylinder Installation231

Front Master Cylinder Disassembly231

Rear Master Cylinder Disassembly231

Master Cylinder Inspection232

Brake Disc Removal233

Brake Disc Installation233

Brake Disc Wear233

Brake Disc Warp233

Brake Line Bleeding234

Cooling System237

Electric Fan238

Coolant Replacement239

Water Pump Removal240

Water Pump Installation241

Removing The Radiator242

Removing The Expansion Tank244

Side Fairings246

Driving Mirrors246

Instrument Panel Servicing247

Headlight Assy248

Horn Servicing248

Turn Indicators Removal And Installation249

Side Fairings Servicing250

License Plate Holder252

Rear Mudguard252

Removing The Fuel Pump257

Rear Wheelhouse258

Front Mudguard259

Radiator Cover259

Battery Servicing262

Pre - Delivery265

Aesthetic Inspection266

Tightening Torques Inspection266

Electrical System Check266

Levels Check267

Functional Inspection268

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This manual is also suitable for:

Dune 125