Malaguti Dune 125 - Service Station Manual

Malaguti Dune 125

272 pages

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SERVICE STATION MANUAL

ZP682837

Dune 125 - Dune X 125 - Euro 4

Table of Contents

Vehicle View4
Table of Contents5
Index of Topics5
Safety Rules7
Maintenance Rules8
Disassembling Components9
Reassembling Components9
Electrical Connectors9
Running-In10
Vehicle Identification11
Serial Number Location11
Engine Number11
Characteristics11
- Dimensions and Mass11
- Engine Data12
- Transmission Data12
- Capacities Data12
- Electrical System Data12
- Wheels and Tyres Data13
- Warning Lights13
- Brakes Data13
- Frame and Suspensions Data13
- Fuel System14
- Supply14
- Tightening Torques14
- Front Wheel Exploded View15
- Fork Exploded View16
- Handlebar and Controls Exploded View17
- Lights Diagram18
- Plastic Covers View20
- Frame View21
- 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
- Cylinder - Piston View29
- Engine Diagrams29
- Crankshaft View29
- Throttle Body View30
- Clutch Cover View30
- Head Cover View31
- Flywheel Cover View32
- Timing System View32
- Clutch View33
- 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
- Linkage View40
- Cylinder - Piston Assy40
- Rod Small End - Pin - Piston41
- Special Tools42
Special Tools43
- Maintenance47
- Scheduled Maintenance Table48
Maintenance49
- Recommended Products50
- Spark Plug50
- Engine Oil Check51
- Spark Plug Data51
- Engine Oil Replacement52
- Air Filter54
- Engine Oil Filter54
- Braking System55
- Top-Up of Braking System56
- Adjusting the Levers57
- Clutch System57
- Electrical System59
- Electrical System Components Arrangement60
Electrical System61
- Electrical System Installation62
- Instrument Panel62
- A-Oil Pressure Sensor63
- Turn Indicators63
- Cable Routing on RH Side63
- A1-Oil Pressure Sensor64
- A2-Oil Pressure Sensor64
- Horn65
- Voltage Regulator65
- Main Wiring Harness66
- Ecu67
- Flywheel67
- Starter Motor67
- Flasher68
- Fuses68
- Main Wiring Harness on Rear Chassis68
- Relay69
- 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 Motor Relay80
- Checking the Starter Motor80
- Starter Command81
- Horn Control82
- Lights List82
- Main Fuses Distribution84
- Headlamp84
- Taillight84
- Battery85
- Engine Rpm Sensor87
- Engine Temperature Sensor88
- Lambda Sensor90
- Injector92
- Fuel Pump93
- Coil95
- Engine Oil Pressure Sensor96
- Neutral Sensor97
- Clutch Lever Sensor98
- Electric Fan Circuit100
- RUN/STOP Switch101
- Connectors102
- Dashboard108
- Engine from Vehicle109
- Vehicle Preparation110
- Removing the Engine from the Vehicle110
Engine from Vehicle111
- Installing the Engine to the Vehicle115
- Engine116
- Gearbox117
Engine117
- Oil Filter118
- Gearbox Shafts119
- Disassembling the Gearbox119
- Removing the Secondary Shaft120
- Removing the Primary Shaft120
- Desmodromic Demounting124
- Checking the Desmodromic Drum124
- Checking the Forks124
- Starter Motor125
- Removing the Starter Motor126
- Generator Side126
- Removing the Flywheel Cover127
- Rotor Removal128
- Removing the Stator129
- Freewheel Removal130
- Clutch Side131
- 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
- Crankcase138
- 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
- Valve Check157
- Inspecting the Valve Sealings159
- Inspecting the Valve Housings160
- Inspecting the Springs and Half-Cones160
- Checking the Cylinder Head160
- Installing the Valves161
- Timing161
- Checking the Chain Tensioner161
- Removing the Cylinder162
- Checking the Chain162
- Cylinder-Piston Assembly162
- 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
- Lubrication171
- Oil Pump Removal171
- Oil Pump Inspection172
- Oil Pump Installation173
- Power Supply174
- Injection175
- Circuit Diagram175
Power Supply175
- Removing the Throttle Body176
- Suspensions178
- Front Suspension179
- Handlebar and Controls View179
Suspensions179
- Front Fork Exploded View180
- Removing the Fork Legs181
- Removing the Left-Hand Fork182
- Draining Oil183
- Disassembling the Fork184
- Checking the Fork Components185
- Filling Oil186
- Reassembling the Fork186
- Installing the Fork Legs187
- Rear Suspension188
- Rear Suspension Removal189
- Chassis191
- Chassis Exploded View192
- Front Wheel View193
- Fork Diagram194
- Front Wheel Removal195
- Wheel Axle Check196
- Radial and Axial Play Check196
- Front Wheel Bearings Check196
- Front Wheel Check197
- Front Wheel Installation197
- Rear Wheel198
- 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
- Pinion208
- Pinion Removal209
- Pinion Inspection210
- Pinion Installation210
- Drive Chain Removal210
- Drive Chain Inspection211
- Drive Chain Installation213
- Drive Chain Adjustment213
- Footrest214
- Footrests Removal215
- Removing the Rear Brake Lever216
- Removing the Gear Shift Lever217
- Main Stand217
- Side Stand218
- 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
- Front Caliper Assembly225
- Rear Caliper Assembly225
- Front Caliper Disassembly225
- Caliper Installation225
- Rear Caliper Disassembly225
- Rear Caliper Removal225
- Caliper Fluid Seal Damage226
- Caliper Dust Boot and Friction Boot Damage226
- Caliper Piston and Cylinder Damage226
- Caliper Holder Shaft Wear227
Braking System227
- Front Brake Pad Installation228
- Front Brake Pad Removal228
- Brake Pads228
- Rear Brake Pad Installation229
- Rear Brake Pad Removal229
- 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 Wear233
- Brake Disc Warp233
- Brake Disc Installation233
- Brake Disc Removal233
- Brake Fluid234
- Brake Line Bleeding234
- Brake Hose236
- Cooling System237
- Electric Fan238
- Coolant Replacement239
- Water Pump239
Cooling System239
- Water Pump Removal240
- Water Pump Installation241
- Removing the Radiator242
- Removing the Expansion Tank244
- Bodywork245
- Side Fairings246
- Driving Mirrors246
Bodywork246
- Instrument Panel Servicing247
- Headlight Assy248
- Horn Servicing248
- Turn Indicators Removal and Installation249
- Side Fairings Servicing250
- License Plate Holder252
- Rear Mudguard252
- Air Box253
- Lower Cowl255
- Fuel Tank256
- Removing the Fuel Pump257
- Rear Wheelhouse258
- Front Mudguard259
- Radiator Cover259
- Battery Servicing262
- Tail Guard263
Pre - Delivery265
- Aesthetic Inspection266
- Tightening Torques Inspection266
- Electrical System Check266
- Levels Check267
- Road Test268
- Static Test268
- Functional Inspection268
- OBD List269

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