Malaguti Dune X 125 Mode d’emploi

SERVICE STATION MANUAL

ZP682837

Dune 125 - Dune X 125 - Euro 4

SERVICE STATION

MANUAL

Dune 125 - Dune X 125 - Euro 4

THE VALUE OF SERVICE

Due to continuous updates and technical training programmes specific to the products, only Malaguti

Official Network mechanics know this vehicle fully and have the specific tools necessary to carry out

maintenance and repair operations correctly.

The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding

it, performing maintenance correctly and using only original Malaguti spare parts are essential

factors for the reliability of your vehicle!

For information on the nearest Official Dealer and/or Service Centre consult our website:

www.ksr-group.com

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.

The descriptions and images in this publication are given for illustrative purposes only.

While the basic features as described and illustrated in this manual remain unchanged, KSR Solution

GmbH reserves the right, at any time and without being required to update this publication beforehand,

to make any changes to components, parts or accessory supplies which it deems necessary to improve

the product, or which are required for manufacturing or commercial reasons.

Not all versions/models shown in this publication are available in all countries. The availability of individual

versions/models should be confirmed with the official Malaguti sales network.

The Malaguti trademark is the property of KSR Solution GmbH.

or in part is prohibited.

KSR Solution GmbH Im Wirtschaftspark 15, 3494 Gedersdorf, Austria

www.ksr-group.com

SERVICE STATION MANUAL

Dune 125 - Dune X 125 - Euro 4

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. Without this knowledge,

repairing or checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check

procedures are not described in detail, be extremely cautious so as not to damage components or

injure individuals. In order to optimise customer satisfaction when using our vehicles, KSR Solution

GmbH commits itself to continually improve its products and the relative documentation. The main

technical modifications 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 case of need or further queries on repair and check procedures, consult

Malaguti CUSTOMER DEPARTMENT, which will be prepared to provide any information on the

subject and any further communications on updates and technical changes related to the vehicle.

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee

Dune 125

Dune X 125

INDEX OF TOPICS

HARACTERISTICS..................P7-41

CHAR

PECIAL TOOLS.......................P43-46

S-TOOLS

AINTENANCE.........................P48-58

MAIN

LECTRICAL SYSTEM.............P59-109

ELE SYS

NGINE FROM VEHICLE.........P110-115

ENG VE

NGINE.....................................P117-173

ENG

OWER SUPPLY.....................P175-177

P SUPP

USPENSIONS........................P179-190

SUSP

HASSIS..................................P192-221

CHAS

RAKING SYSTEM..................P223-236

BRAK SYS

OOLING SYSTEM..................P238-244

COOL SYS

ODYWORK.............................P246-264

BODYW

DELIVERY.......................P266-268

PRE DE

INDEX OF TOPICS

CHARACTERISTICS CHAR

Dune 125 - Dune X 125 - Euro 4 Characteristics

CHAR - 7

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.

CAUTION

EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE

LOSS OF CONSCIOUSNESS AND EVEN DEATH.

Fuel

CAUTION

FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY INFLAMMABLE AND CAN BECOME

EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY

OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE EN-

GINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR. AVOID

ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES 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 remain in this condition for a certain

time interval after the engine has been switched off. Before handling these components, make sure that

you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.

Coolant

The coolant contains ethylene glycol which, under certain conditions, can become flammable.

When it burns, ethylene glycol produces an invisible flame which however can cause burns.

CAUTION

TAKE PARTICULAR CARE NOT TO SPILL COOLANT ONTO HOT PARTS OR THE ENGINE AND

EXHAUST SYSTEM; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN

CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES.

WHILE POISONOUS, COOLANT HAS A SWEET TASTE WHICH MAKES IT EXTREMELY AP-

PEALING TO ANIMALS. NEVER LEAVE COOLANT IN OPEN CONTAINERS WHERE IT MAY BE

REACHED AND DRUNK BY AN ANIMAL.

Dune 125 - Dune X 125 - Euro 4

Characteristics

CHAR - 8

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.

HANDLING ENGINE OIL FOR PROLONGED PERIODS AND ON A REGULAR BASIS CAN CAUSE

SERIOUS SKIN DAMAGE.

WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.

HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING

COMPANY OR THE SUPPLIER.

DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

KEEP OUT OF THE REACH OF CHILDREN.

Brake fluid

THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING

THE BRAKING SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS

WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKING SYSTEM. THE BRAKE FLUID

IS EXTREMELY DANGEROUS TO THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH

THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF COLD, CLEAN WATER AND SEEK

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 CONTACT WITH THE SKIN. WHEN HANDLING BATTERY

ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT

OF SKIN CONTACT 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 CONTACT WITH

YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE

SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY

FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-

QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.

KEEP OUT OF THE REACH OF CHILDREN.

BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN

PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY

BEING ACTIVATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

When repairs, disassembly and reassembly of the vehicle is carried out, follow the following recom-

mendations strictly.

Dune 125 - Dune X 125 - Euro 4 Characteristics

CHAR - 9

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

Do not loosen and/or tighten the screws and nuts using pliers or other tools, but always use

the specific wrench.

Mark the positions on all the connection joints (hoses, cables, etc.) before separating them

and identify them with different distinctive marks.

Each piece should be clearly marked in order to be identified during the installation phase.

Carefully clean and wash the disassembled components with detergents with a low flam-

mability grade.

Keep the coupled parts together because they have "adapted" to one another following

normal wear.

Some components must be used together or replaced entirely.

Keep away from heat sources.

REASSEMBLING COMPONENTS

CAUTION

BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY

NEED TO BE REPLACED.

Only 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 components with the largest diameter

or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-

cessive steps before applying the tightening torque.

Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins

and screws with new parts if the thread is damaged.

When assembling the bearings, make sure to lubricate them well.

Check that each component is assembled correctly.

After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on

private grounds or in an area with low traffic.

Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of

lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand

or batch number facing outward (visible side).

ELECTRICAL CONNECTORS

Electric connectors must be disconnected as described below; failure to comply with this procedure

causes irreparable damage to both the connector and the wiring harness:

Press the relative safety clips, if applicable.

Dune 125 - Dune X 125 - Euro 4

Characteristics

CHAR - 10

Grip the two connectors and disconnect them by pulling them in opposite directions.

If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully

with a jet of compressed air.

Ensure that the cables are correctly fastened to the internal connector terminals.

Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you

will hear them "click" into place).

CAUTION

DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

NOTE

THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM

THE RIGHT WAY ROUND.

TIGHTENING TORQUE

CAUTION

REMEMBER THAT THE TIGHTENING TORQUE FOR ALL THE FIXING ELEMENTS LOCATED ON

WHEELS, BRAKES, WHEEL AXLES AND OTHER SUSPENSION COMPONENTS PLAY A FUN-

DAMENTAL ROLE IN GUARANTEEING THE SAFETY OF THE VEHICLE AND MUST BE KEPT AT

THE PRESCRIBED VALUES. REGULARLY CHECK THE TIGHTENING TORQUE OF THE FIXING

ELEMENTS AND ALWAYS USE A TORQUE WRENCH WHEN REFITTING. IF THESE WARNINGS

ARE NOT OBSERVED, ONE OF THESE 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

Running the engine in correctly is essential for ensuring engine longevity and functionality. Twisty roads

and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding

speed during the running in period. This ensures that components operate in "loaded" conditions and

then "unloaded" conditions, allowing the engine components to cool.

CAUTION

THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT

THE END OF THE RUNNING IN PERIOD.

Follow these guidelines:

Do not fully open the throttle grip abruptly at low engine speeds, either during or after the

running in period.

During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged

braking. 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.

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