Malaguti Dune X 125 Manuals

Manuals and User Guides for Malaguti Dune X 125. We have 2 Malaguti Dune X 125 manuals available for free PDF download: Service Station Manual, User Manual

Malaguti Dune X 125 Service Station Manual

Malaguti Dune X 125 Service Station Manual (273 pages)

Brand: Malaguti | Category: Motorcycle | Size: 13.5 MB

Table of Contents

Vehicle View
4
Table of Contents
5
Index of Topics
5
Safety Rules
7
Maintenance Rules
8
Disassembling Components
9
Reassembling Components
9
Electrical Connectors
9
Running-In
10
Vehicle Identification
11
Serial Number Location
11
Engine Number
11
Characteristics
11
- Dimensions and Mass
  11
- Engine Data
  12
- Transmission Data
  12
- Capacities Data
  12
- Electrical System Data
  12
- Wheels and Tyres Data
  13
- Warning Lights
  13
- Brakes Data
  13
- Frame and Suspensions Data
  13
- Fuel System
  14
- Supply
  14
- Tightening Torques
  14
- Front Wheel Exploded View
  15
- Fork Exploded View
  16
- Handlebar and Controls Exploded View
  17
- Lights Diagram
  18
- Plastic Covers View
  20
- Frame View
  21
- Canister Assembly View
  22
- Filter Box View
  22
- Electrical System View
  23
- Fuel Tank Exploded View
  24
- Lock Assy View
  25
- Exhaust System View
  25
- Rear Wheel View
  26
- Rear Fork View
  27
- Rear Brake Pedal View
  27
- CBS System View
  28
- Cylinder - Piston View
  29
- Engine Diagrams
  29
- Crankshaft View
  29
- Throttle Body View
  30
- Clutch Cover View
  30
- Head Cover View
  31
- Flywheel Cover View
  32
- Timing System View
  32
- Clutch View
  33
- Starter Motor View
  33
- Water Pump View
  34
- Oil Pump View
  34
- Gear Selector View
  35
- Engine Crankcase View
  36
- Head - Valves View
  37
- Ignition Unit View
  38
- Components of Gearbox View
  39
- Assembly Clearances
  40
- Linkage View
  40
- Cylinder - Piston Assy
  40
- Rod Small End - Pin - Piston
  41
- Special Tools
  42
Special Tools
43
- Maintenance
  47
- Scheduled Maintenance Table
  48
Maintenance
49
- Recommended Products
  50
- Spark Plug
  50
- Engine Oil Check
  51
- Spark Plug Data
  51
- Engine Oil Replacement
  52
- Air Filter
  54
- Engine Oil Filter
  54
- Braking System
  55
- Top-Up of Braking System
  56
- Adjusting the Levers
  57
- Clutch System
  57
- Electrical System
  59
- Electrical System Components Arrangement
  60
Electrical System
61
- Electrical System Installation
  62
- Instrument Panel
  62
- A-Oil Pressure Sensor
  63
- Turn Indicators
  63
- Cable Routing on RH Side
  63
- A1-Oil Pressure Sensor
  64
- A2-Oil Pressure Sensor
  64
- Horn
  65
- Voltage Regulator
  65
- Main Wiring Harness
  66
- Ecu
  67
- Flywheel
  67
- Starter Motor
  67
- Flasher
  68
- Fuses
  68
- Main Wiring Harness on Rear Chassis
  68
- Relay
  69
- General Wiring Diagram
  70
- Checks and Inspections
  71
- Checking Connectors
  71
- Checking Electrical Continuity
  72
- Checking Ground Connection
  72
- Checking Voltage
  72
- Dashboard Facilities
  73
- Instrument Function Button
  74
- Resetting the Scheduled Maintenance Icon
  74
- Ignition Circuit
  75
- Battery Recharge Circuit
  75
- Recharging System
  75
- Measurement of Resistance (with Engine Off)
  76
- Empty Voltage
  78
- Voltage Regulator Check
  79
- Start-Up System Check
  79
- Cold Short Circuit Current
  79
- Checking the Starter Motor Relay
  80
- Checking the Starter Motor
  80
- Starter Command
  81
- Horn Control
  82
- Lights List
  82
- Main Fuses Distribution
  84
- Headlamp
  84
- Taillight
  84
- Battery
  85
- Engine Rpm Sensor
  87
- Engine Temperature Sensor
  88
- Lambda Sensor
  90
- Injector
  92
- Fuel Pump
  93
- Coil
  95
- Engine Oil Pressure Sensor
  96
- Neutral Sensor
  97
- Clutch Lever Sensor
  98
- Electric Fan Circuit
  100
- RUN/STOP Switch
  101
- Connectors
  102
- Dashboard
  108
- Engine from Vehicle
  109
- Vehicle Preparation
  110
- Removing the Engine from the Vehicle
  110
Engine from Vehicle
111
- Installing the Engine to the Vehicle
  115
- Engine
  116
- Gearbox
  117
Engine
117
- Oil Filter
  118
- Gearbox Shafts
  119
- Disassembling the Gearbox
  119
- Removing the Secondary Shaft
  120
- Removing the Primary Shaft
  120
- Desmodromic Demounting
  124
- Checking the Desmodromic Drum
  124
- Checking the Forks
  124
- Starter Motor
  125
- Removing the Starter Motor
  126
- Generator Side
  126
- Removing the Flywheel Cover
  127
- Rotor Removal
  128
- Removing the Stator
  129
- Freewheel Removal
  130
- Clutch Side
  131
- Removing the Clutch Cover
  132
- Disassembling the Clutch
  133
- Checking the Clutch Plates
  134
- Checking the Clutch Housing
  135
- Checking the Clutch Hub
  135
- Checking the Springs
  136
- Assembling the Clutch
  136
- Crankcase
  138
- Balancing Countershaft Removal
  139
- Balancing Countershaft Fitting
  140
- Crankcase Opening
  140
- Bearing Removal
  143
- Crankcase Check
  144
- Bushing Selection
  145
- Bearing Fitting
  145
- Crankcase Closing
  146
- Head and Timing
  149
- Removing the Head Cover
  151
- Removing the Timing Control
  152
- Cylinder Head
  153
- Removing the Overhead Camshaft
  154
- Removing the Valves
  155
- Checking the Overhead Camshaft
  156
- Valve Check
  157
- Inspecting the Valve Sealings
  159
- Inspecting the Valve Housings
  160
- Inspecting the Springs and Half-Cones
  160
- Checking the Cylinder Head
  160
- Installing the Valves
  161
- Timing
  161
- Checking the Chain Tensioner
  161
- Removing the Cylinder
  162
- Checking the Chain
  162
- Cylinder-Piston Assembly
  162
- Disassembling the Piston
  163
- Checking the Piston
  164
- Inspecting the Wrist Pin
  166
- Inspecting the Piston Rings
  166
- Checking the Connecting Rod Small End
  166
- Fitting the Piston
  167
- Selecting the Base Gasket
  168
- Installing the Cylinder Head
  168
- Lubrication
  171
- Oil Pump Removal
  171
- Oil Pump Inspection
  172
- Oil Pump Installation
  173
- Power Supply
  174
- Injection
  175
- Circuit Diagram
  175
Power Supply
175
- Removing the Throttle Body
  176
- Suspensions
  178
- Front Suspension
  179
- Handlebar and Controls View
  179
Suspensions
179
- Front Fork Exploded View
  180
- Removing the Fork Legs
  181
- Removing the Left-Hand Fork
  182
- Draining Oil
  183
- Disassembling the Fork
  184
- Checking the Fork Components
  185
- Filling Oil
  186
- Reassembling the Fork
  186
- Installing the Fork Legs
  187
- Rear Suspension
  188
- Rear Suspension Removal
  189
- Chassis
  191
- Chassis Exploded View
  192
- Front Wheel View
  193
- Fork Diagram
  194
- Front Wheel Removal
  195
- Wheel Axle Check
  196
- Radial and Axial Play Check
  196
- Front Wheel Bearings Check
  196
- Front Wheel Check
  197
- Front Wheel Installation
  197
- Rear Wheel
  198
- Rear Wheel Removal
  199
- Removing the Crown
  202
- Checking of Rear Wheel Components
  202
- Rear Wheel Bearings Check
  203
- Wheel Rim Check
  203
- Rear Wheel Installation
  204
- Swinging Arm
  205
- Swinging Arm Removal
  206
- Swinging Arm Check
  207
- Swingarm Pin Check
  208
- Swinging Arm Installation
  208
- Pinion
  208
- Pinion Removal
  209
- Pinion Inspection
  210
- Pinion Installation
  210
- Drive Chain Removal
  210
- Drive Chain Inspection
  211
- Drive Chain Installation
  213
- Drive Chain Adjustment
  213
- Footrest
  214
- Footrests Removal
  215
- Removing the Rear Brake Lever
  216
- Removing the Gear Shift Lever
  217
- Main Stand
  217
- Side Stand
  218
- Exhaust System
  219
- Removing the Tail Pipe
  220
- Removing the Exhaust Manifold
  220
- Removing the Lambda Sensor
  221
- Braking System Maintenance
  222
- Brake Pedal Position Adjustment
  223
- Brake Pedal Removal
  223
- Brake Pedal Installation
  224
- Front Caliper Removal
  224
- Front Caliper Assembly
  225
- Rear Caliper Assembly
  225
- Front Caliper Disassembly
  225
- Caliper Installation
  225
- Rear Caliper Disassembly
  225
- Rear Caliper Removal
  225
- Caliper Fluid Seal Damage
  226
- Caliper Dust Boot and Friction Boot Damage
  226
- Caliper Piston and Cylinder Damage
  226
- Caliper Holder Shaft Wear
  227
Braking System
227
- Front Brake Pad Installation
  228
- Front Brake Pad Removal
  228
- Brake Pads
  228
- Rear Brake Pad Installation
  229
- Rear Brake Pad Removal
  229
- Master Cylinder
  230
- Front Master Cylinder Installation
  230
- Rear Master Cylinder Removal
  231
- Rear Master Cylinder Installation
  231
- Front Master Cylinder Disassembly
  231
- Rear Master Cylinder Disassembly
  231
- Master Cylinder Inspection
  232
- Brake Disc Wear
  233
- Brake Disc Warp
  233
- Brake Disc Installation
  233
- Brake Disc Removal
  233
- Brake Fluid
  234
- Brake Line Bleeding
  234
- Brake Hose
  236
- Cooling System
  237
- Electric Fan
  238
- Coolant Replacement
  239
- Water Pump
  239
Cooling System
239
- Water Pump Removal
  240
- Water Pump Installation
  241
- Removing the Radiator
  242
- Removing the Expansion Tank
  244
- Bodywork
  245
- Side Fairings
  246
- Driving Mirrors
  246
Bodywork
246
- Instrument Panel Servicing
  247
- Headlight Assy
  248
- Horn Servicing
  248
- Turn Indicators Removal and Installation
  249
- Side Fairings Servicing
  250
- License Plate Holder
  252
- Rear Mudguard
  252
- Air Box
  253
- Lower Cowl
  255
- Fuel Tank
  256
- Removing the Fuel Pump
  257
- Rear Wheelhouse
  258
- Front Mudguard
  259
- Radiator Cover
  259
- Battery Servicing
  262
- Tail Guard
  263
Pre - Delivery
265
- Aesthetic Inspection
  266
- Tightening Torques Inspection
  266
- Electrical System Check
  266
- Levels Check
  267
- Road Test
  268
- Static Test
  268
- Functional Inspection
  268
- OBD List
  269

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Malaguti Dune X 125 User Manual

Malaguti Dune X 125 User Manual (112 pages)

Brand: Malaguti | Category: Motorcycle | Size: 5.5 MB

Table of Contents

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