Malaguti Dune X 125, Dune 125 Service Manual

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Page 1

SERVICE STATION MANUAL

ZP682837

Dune 125 - Dune X 125 - Euro 4

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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

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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

Page 4

Dune 125

Dune X 125

Page 5

INDEX OF TOPICS

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

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

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

CHAR

S-TOOLS

MAIN

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

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

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

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

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

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

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

ELE SYS

ENG VE

ENG

P SUPP

SUSP

CHAS

BRAK SYS

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

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

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

PRE-

COOL SYS

BODYW

PRE DE

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INDEX OF TOPICS

HARACTERISTICS

CHAR

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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.

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 ENGINE 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 APPEALING TO ANIMALS. NEVER LEAVE COOLANT IN OPEN CONTAINERS WHERE IT MAY BE REACHED AND DRUNK BY AN ANIMAL.

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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 VEHICLE. 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

Dune 125 - Dune X 125 - Euro 4

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 ADEQUATE 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.

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Dune 125 - Dune X 125 - Euro 4

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.

Characteristics



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.

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Characteristics



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

Dune 125 - Dune X 125 - Euro 4

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 FUNDAMENTAL 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 MANOEUVRABILITY, 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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Dune 125 - Dune X 125 - Euro 4

version;

Characteristics

Vehicle identification

SERIAL NUMBER LOCATION

These numbers are necessary for vehicle registration.

NOTE

ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PARTICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.

This number consists of numbers and letters, as

in the example shown below.

VB4ET500XXXXXXXXX

KEY:

VB4: WMI (World Manufacturer Identifier) code;

ET5: model;

00: (Dune 125) version; 01: (Dune X 125)

X: digit free;

X: year of manufacture;

X: production plant;

XXXXXX: serial number (6 digits);

CHASSIS NUMBER

The chassis number is stamped on the RH side of

the headstock.

ENGINE NUMBER (in countries where applica-

ble)

The engine number is stamped on the top of the

right hand side of the crankcase, near the rear

shock absorber.

The engine number is visible from right hand side

of the vehicle, looking from the rear.

Engine No.:.................................

Dimensions and mass

WEIGHT AND DIMENSIONS

Specification Desc./Quantity

Maximum length (Dune 125) 2130 mm Maximum length (Dune X 125) 2180 mm

Maximum width (Dune 125) 790 mm

Maximum width (Dune X 125) 795 mm

Maximum height to top fairing (Dune 125) 1245 mm

Maximum height to top fairing (Dune X 125) 1445 mm

Wheel base(Dune 125) 1425 mm

Wheel base(Dune X 125) 1435 mm

Kerb weight (Dune 125) 205 kg

Kerb weight (Dune x 125 ) 211 kg

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Characteristics

Type

EFI

Engine

Cooling

liquid

mechanism.

Type

Dune 125 - Dune X 125 - Euro 4

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

Start-up electric

Idle speed 1700 +/- 100 rpm

Clutch multi plate wet clutch operated from hand lever on left hand

side of handlebar.

GEARBOX

Specification Desc./Quantity

6 speed mechanical gearbox with pedal shifter on the left hand

side of engine, which operates the fork and drum selector

Transmission

Capacities

DRIVE RATIOS

Specification Desc./Quantity

Drive ratio, 1st gear 11 / 33 = 1: 3.000 Drive ratio, 2nd gear 15 / 30 = 1: 2.000 Drive ratio, 3rd gear 18 / 27 = 1: 1.500

Drive ratio, 4th gear 20 / 24 = 1: 1.200

Drive ratio, 5th gear 25 / 27 = 1: 1.080

Drive ratio, 6th gear 23 / 22 = 1: 0.956

Final drive ratio 13 / 62 = 1: 4.769

CAPACITY

Specification Desc./Quantity

Fuel tank 11.2+/- 3% L Fuel tank reserve 1.5 L

Engine oil 1000 cm³

Seats 2

Coolant 0.8 L

Maximum weight limit 300 kg (rider + passenger + luggage)

Electrical system

IGNITION

Specification Desc./Quantity

SPARK PLUG

Specification Desc./Quantity

Spark plug NGK CR9EKB or NGK CR9EB / NGK CR8EB

Electrode gap 0.6-0.7 mm (0.024-0.027 in)

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Dune 125 - Dune X 125 - Euro 4

Instrument

cluster

indicator

lamps

LED

Frame

type

Steel

outer

frame

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 12V - 5W

Turn indicator light LED

tail light /stop lights LED

Licence plate light 12V - 5W

WARNING LIGHTS

Specification Desc./Quantity

Frame and suspensions

Characteristics

Specification Desc./Quantity

fork travel

Rear shock absorber travel

Rear shock absorber travel（DuneX125

Brakes

Specification Desc./Quantity

Front brake disc

Rear brake disc

Wheels and tyres

Specification Desc./Quantity

Front (Dune 125) 2.15"x 18"

Front (Dune X 125) 1.85"x 21"

Rear (Dune 125) 3.00"x 17"

Rear (Dune X 125) 3.00"x 17"

CHASSIS

SUSPENSIONS

Front Upright hydraulic telescopic fork Front

Dune125

（

Dune X 125

Rear hydraulic single shock-absorber

）

Dune125

（

）

160 mm (6.30 in)

182 mm（7.165 in

42.5 mm (1.673 in)

47.5 mm（1.87 in

）

BRAKES

WHEELS

Type with spokes with alloy rims, for tyres with inner tubes

TYRES

Specification Desc./Quantity

Front (Dune 125) 100/90-18" 56P

Front (Dune X 125) 90/90-21" 54P

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Characteristics

Fuel

Unleaded

petrol

max

E10

(95

RON)

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" 65P

Rear tyre pressure, rider only 2.1 BAR (210 kPa) (30.46 PSI) Rear tyre pressure, rider + passenger 2.2 BAR (210 kPa) (31.91 PSI)

Dune 125 - Dune X 125 - Euro 4

Supply

FUEL SYSTEM

Specification Desc./Quantity

Tightening Torques

If the following tables do not expressly indicate the tightening torque values, refer to the table with the

generic torque values indicated below.

ENERAL TIGHTENING TORQUES

M4 M5 M6 M8 M10 M12

Metric tightening torque: TE - TEFL - SHC - TBEI

- TCC - TS

ENERAL TIGHTENING TORQUES FOR SELF TAPPING SCREWS FOR PLASTIC

Tightening torque 2 Nm (1.48 lb ft) 2 Nm (1.48 lb ft) 3 Nm (2.21 lb ft) 3 Nm (2.21 lb ft)

CAUTION

3 Nm (2.21

lb ft)

6 Nm (4.43

lb ft)

2.9 mm 3.9 mm 4.2 mm 5 mm

10 Nm

(7.38 lb ft)

25 Nm

(18.44 lb ft)

50 Nm

(36.88 lb ft)

80 Nm

(59.00 lb ft)

THE SCREWS WITH THREAD-LOCK SEALANT (PRE-IMPREGNATED) MUST BE REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LOOSENED. BEFORE FITTING THE NEW SCREWS, CLEAN THE THREADED HOLES CAREFULLY, MAKING SURE THAT ALL TRACES OF THE OLD THREAD-LOCK SEALANT HAVE BEEN ELIMINATED.

Chassis

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Dune 125 - Dune X 125 - Euro 4

Characteristics

RONT WHEEL

pos. Description Type Quantity Torque Notes

Wheel fastening pin M14

SHC front brake disc fastening

screws

M6x20

70/80 Nm (51.63/59 lb ft)

10/12 Nm (7.38/8.85 lb ft)

Loct. 243

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Characteristics

pos. Description Type Quantity Torque Notes

Dune 125 - Dune X 125 - Euro 4

ORK

SHC wheel axle clamp fastening

Hex head handlebar U-bolt flanged

SHC steering yoke fastening screws

Caps

screws

fastening screws

NUT

M8×25

M8×35

M25×1 M8×35 M8×35

15/25 Nm (11.06/18.44 lb ft)

15/18 Nm (11.06/13.27 lb ft)

20/24 Nm (14.75/17.70 lb ft)

50/60 Nm (36.87/44.12 lb ft)

20/24 Nm (14.75/17.70 lb ft)

ORK

pos. Description Type Quantity Torque Notes

SHC wheel axle clamp fastening

Hex head handlebar U-bolt flanged

SHC steering yoke fastening screws

Caps

screws

fastening screws

NUT

M6×25 3

M8×30

M24×1 M8×35 M8×35

15/25 Nm (11.06/18.44 lb ft)

4/6 Nm (2.95/4.42 lb ft)

20/25 Nm (14.75/18.44 lb ft)

50/60 Nm (36.87/44.12 lb ft)

20/24 Nm (14.75/17.70 lb ft)

CHAR - 16

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Dune 125 - Dune X 125 - Euro 4

Characteristics

ANDLEBAR AND CONTROLS

pos. Description Type Quantity Torque Notes

Balance hammer bolt

2 SHC brake master cylinder

fastening screws 3 4

5 6 7 8 9

Clutch control fastening screws

Front brake upper pump brake hose

bolt

PUMP ,FR DISC BRAKE

Throttle cable bolt

Brake oil line clamp bolt

Brake oil line clamp screw

Front brake upper pump brake hose

bolt

M6×25

M6×25 M10×1 M8×30

M5×8

M6×16

ST5,1×14

M10×1.25

2 1 1 1

7/10 Nm (5.16/7.38 lb ft) -

6/8 Nm (4.43/5.90 lb ft) -

28/33 Nm (20.66/24.35 lb ft) -

17/19 Nm (12.54/14.01 lb ft) Loct. 243

5/6 Nm (3.69/4.43 lb ft) -

7/10 Nm (5.16/7.38 lb ft) -

Nm (2.21 lb ft)

28/33 Nm (20.66/24.35 lb ft) -

CHAR - 17

Page 18

Characteristics

Dune 125 - Dune X 125 - Euro 4

IGHTS

pos. Description Type Quantity Torque Notes

1 Turninglight bolt 2 Windshield bolt

Instrument cover self-tapping

screws

bolt 5 Headlight cover bolt 6 Front shroud bolt 7 Headlight bolt

M6×20

St2.8×13

M5×16

M6×20

8 Rearlight bolt M5×35 9 License plate light bolt

M5×16

4 3

2 4 2 2 1

2/3 Nm (1.48/2.21 lb ft) -

0.6 Nm (0.44 lb ft) -

2/3 Nm (1.48/2.21 lb ft) -

2/3 Nm (1.48/2.21 lb ft) Loct. 243

2/3 Nm (1.48/2.21 lb ft) -

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Dune 125 - Dune X 125 - Euro 4

Characteristics

IGHTS

pos. Description Type Quantity Torque Notes

1 Turninglight bolt 2 Windshield bolt

Instrument cover self-tapping

screws

bolt 5 Headlight cover bolt 6 Front shroud bolt 7 Headlight bolt

M6×20

M6×30

St2.8×13

M5×16

M6×20

8 Rearlight bolt M5×35 9 License plate light bolt

M5×16

4 3

2 4 2 2 1

2/3 Nm (1.48/2.21 lb ft) -

0.6 Nm (0.44 lb ft) -

2/3 Nm (1.48/2.21 lb ft) -

2/3 Nm (1.48/2.21 lb ft) Loct. 243

2/3 Nm (1.48/2.21 lb ft) -

CHAR - 19

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Characteristics

Dune 125 - Dune X 125 - Euro 4

LASTIC COVERS

pos. Description Type Quantity Torque Notes

1 Fuel tank shell bolt 2 Fuel tank shroud bolt

Fuel tank shroud connecting

plate bolt 4 Radiator shroud bolt 5 Side cover bolt

6 Front fender bolt

7 Rear armrest bolt 8 Rear tail bolt 9 Rear tail bolt

10 License bracket bolt 11 Rear fender bolt

M6×25

M5×9

M6×16

（

Dune125

M6×25

（

X125

M8×30

M5×16

M6×16

）

Dune

）

12 Rear fender bolt M5×16 13 Rear fender bolt

M5×9

14 Back reflector nut M4 2

15 Small sprocket cover bolt M5×14 2

2 4

2 6 2 2 4 2

8/10 Nm (5.90/7.38 lb ft) -

2/3 Nm (1.48/2.21 lb ft) -

8/10 Nm (5.90/7.38 lb ft) -

17/19 Nm (12.54/14.01 lb ft) Loct. 243

2/3 Nm (1.48/2.21 lb ft) -

8/10 Nm (5.90/7.38 lb ft) -

5-6 Nm (3.69-4.43 lb ft) -

2/3 Nm (1.48/2.21 lb ft) -

2/3 Nm (1.48/2.21 lb ft)

5-6 Nm (3.69-4.43 lb ft) Loct. 243

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Dune 125 - Dune X 125 - Euro 4

Characteristics

RAME

pos. Description Type Quantity Torque Notes

1 Headlight bracket bolt 2 Headlight bracket bolt 3 Engine bracket bolt 4 Engine shroud bolt 5 Front Pedal bolt 6 Front fender bolt 7 Engine bracket bolt 8 Side bracket bolt

M6×16

M6×30

M10×100

M5×16

M8×40

M6×25

M10×25

2 2 4 3 2 1 2 1

5/7 Nm (3.69/5.16 lb ft) -

8/10 Nm (5.90/7.38 lb ft) -

37/39 Nm (27.29/28.76 lb ft) -

2/3 Nm (1.48/2.21 lb ft) -

17/19 Nm (12.54/14.01 lb ft) -

8/10 Nm (5.90/7.38 lb ft) -

37/39 Nm (27.29/28.76 lb ft) -

17/19 Nm (12.54/14.01 lb ft) -

CHAR - 21

Page 22

Characteristics

ANISTER ASSEMBLY

Dune 125 - Dune X 125 - Euro 4

pos. Description Type Quantity Torque Notes

1 Canister bracket bolt

M6×10

5/7 Nm (3.69/5.16 lb ft) -

ILTER BOX

pos. Description Type Quantity Torque Notes

1 2

Air filter box fastening screw M5×12

Air filter box

bolt

M6×16

3.5 Nm (2.58 lb ft)

5/7 Nm (3.69/5.16 lb ft) -

CHAR - 22

Page 23

Dune 125 - Dune X 125 - Euro 4

Characteristics

LECTRICAL SYSTEM

pos. Description Type Quantity Torque Notes

1 Ignition coil Assy bracket bolt 2 Ignition coil Assy bolt

3 ECU cable bracket bolt 4 Instrument

screw

5 Battery box bolt 6 Relay bolt 7 Horn bolt 8 Rectifier bolt

M6×16

M3×25

M5×15

ST3.6

M6×16

M8×20

2 4

3 3 1 1

5/7 Nm (3.69/5.16 lb ft) -

4/6 Nm (2.95/4.43 lb ft) -

2.7/3.3 Nm (1.99/2.43 lb ft)

0.6 Nm (0.44 lb ft) -

5/7 Nm (3.69/5.16 lb ft) -

17/19 Nm (12.54/14.01 lb ft) -

8/10 Nm (5.90/7.38 lb ft) -

CHAR - 23

Page 24

Characteristics

Dune 125 - Dune X 125 - Euro 4

UEL TANK

pos. Description Type Quantity Torque Notes

1 2

4 5 6

Coolant tank bolt

Fuel tank bolt M6×30

Fuel tank lock bolt M5×12

Fuel tank lock bolt M5×30

Radiator bolt M6×25

Oil pump bolt M5×16

×16

2 1

8/10 Nm (5.90/7.38 lb ft) -

2.7/3.3 Nm (1.99/2.43 lb ft)

8/10 Nm (5.90/7.38 lb ft) -

4.5/5.5 Nm (3.32/4.06 lb ft)

CHAR - 24

Page 25

Dune 125 - Dune X 125 - Euro 4

ft)

Characteristics

OCK ASSY

pos. Description Type Quantity Torque Notes

2 3

Electric Lock bolt

Electric Lock bolt M8×20

Electric Lock cover bolt M5×9

Seat lock bolt M6×10

2 2

18/20 Nm (13.28/14.75

lb ft)

2/3 Nm (1.48/2.21 lb ft) -

8/10 Nm (5.90/7.38 lb ft) -

CHAR - 25

Page 26

Characteristics

ft)

XHAUST SYSTEM

pos. Description Type Quantity Torque Notes

1 2

Muffer bent pipe cover bolt

Muffer cover bolt M5

Muffler fixing clamp M6

Muffer bolt M8×20

Muffer bent pipe bolt M8

Oxygen Sensor bolt

M12

Dune 125 - Dune X 125 - Euro 4

2 4

5/6 Nm (3.69-4.43 lb ft) -

8/10 Nm (5.90-7.38 lb

ft)

18/22 Nm (13.28-16.23

lb ft)

17/20 Nm (12.54-14.75

lb ft)

EAR WHEEL

pos. Description Type Quantity Torque Notes

1 2 3

Rear axle

Rear brake disc bolt M8×24.2

Rear sprocket bolt M8×30

M14

70/80 Nm (51.63/59 lb

15/18 Nm (11.06-13.27 lb ft) Loct. 243

17/19 Nm (12.54/14.01

lb ft)

Loct. 243

CHAR - 26

Page 27

Dune 125 - Dune X 125 - Euro 4

ft)

Characteristics

EAR FORK

pos. Description Type Quantity Torque Notes

M12

2 2 2

2 3

4 5 6 7

Rear shock absorber bolt

Rear shock absorber bolt M12×50

Flat fork shaft M12

Chain guard bolt M6×12

Chain adjuster bolt M6

Chain slider bolt M4.8×19

Chain guide bolt

55/65 Nm (10.56/47.94

lb ft)

70/75 Nm (51.62/55.56 lb ft) -

5/7 Nm (3.69/5.16 lb ft) -

3 Nm (2.21 lb ft)

5/7 Nm (3.69/5.16 lb ft) Loct. 243

CHAR - 27

Page 28

Characteristics

head

screws

ft)

ear Brake Pedal

pos. Description Type Quantity Torque Notes

Rear brake disc fastening torx button

Speed sensor fastening screws M6×35 1

M8 1

Dune 125 - Dune X 125 - Euro 4

17/19 Nm (14.75/16.23

8/10 Nm (5.90/7.38 lb ft)

SYSTEM

CBS

pos. Description Type Quantity Torque Notes

M10

Special brake pipe fastening screws

Special brake pipe fastening screws M10×32 2 28/33 Nm (20.66/24.35 lb ft)

SHC front brake caliper fastening

CBS control unit fastening screws M6×20 2 8/10 Nm (5.90/7.38 lb ft)

SHC front brake caliper fastening

screws

22 4 28/33 Nm (20.66/24.35 lb ft)

M8 2

12 2

22/24 Nm (16.23/17.70

lb ft)

25/30 Nm (18.45/22.14

lb ft)

CHAR - 28

Loct. 243

Page 29

Dune 125 - Dune X 125 - Euro 4

Engine

Characteristics

RANKSHAFT

pos. Description Type Quantity Torque Notes

1 Gear fixing screw M10 1 40 Nm (29.50 lb ft) -

YLINDER

pos. Description Type Quantity Torque Notes

- P

ISTON

1 Chain tensioner fastener screw M6×16 2 12 Nm (8.85 lb ft) -

CHAR - 29

Page 30

Characteristics

Dune 125 - Dune X 125 - Euro 4

HROTTLE BODY

pos. Description Type Quantity Torque Notes

1 Sleeve fixing screw M6×20 3 12 Nm (8.85 lb ft) -

2 Sleeve fixing clamp - 1 0.8 Nm (0.59 lb ft) -

3 Injector mounting fixing screw M6

20 1 10 Nm (7.38 lb ft) -

4 Cable stay on throttle body M4 1 4 Nm (2.95 lb ft) -

CHAR - 30

Page 31

Dune 125 - Dune X 125 - Euro 4

LUTCH COVER

pos. Description Type Quantity Torque Notes

Characteristics

1 Clutch cover fixing screw M6×35 10 12 Nm (8.85 lb ft) -

2 Oil filter cover M56

1.5 1 25 Nm (18.44 lb ft) -

3 Oil pressure sensor M10 1 13 Nm (9.59 lb ft) -

EAD COVER

pos. Description Type Quantity Torque Notes

1 Spark plug M10 1 13 Nm (9.59 lb ft) 2

Head cover fastener screw M6 4 11 Nm (8.11 lb ft) -

CHAR - 31

Page 32

Characteristics

Chain

tensioner

pad

fastener

screw

Timing

system

gear

fastener

Dune 125 - Dune X 125 - Euro 4

LYWHEEL COVER

pos. Description Type Quantity Torque Notes

Flywheel cover fastener screw M6 10 12 Nm (8.85 lb ft) -

1 2 3

Timing control cap M18 2 4 Nm (2.95 lb ft)

Oil dipstick M12

1.5 1 5 Nm (3.69 lb ft)

IMING SYSTEM

pos. Description Type Quantity Torque Notes

screw

M6×16 1 10 Nm (7.38 lb ft) Loctite 243

40 2 27 Nm (19.91 lb ft) Loctite 243

CHAR - 32

Page 33

Dune 125 - Dune X 125 - Euro 4

Characteristics

LUTCH

pos. Description Type Quantity Torque Notes

1 2 3

Clutch spring screw

Crankshaft primary gear fastener nut

Clutch nut

M12

- 1

4 Nm (2.95 lb ft)

79 Nm (58.27 lb ft)

40 Nm (29.50 lbf ft)

TARTERMOTOR

pos. Description Type Quantity Torque Notes

Starter motor fastener screw M6x25

12 Nm (8.85 lb ft)

CHAR - 33

Page 34

Characteristics

Dune 125 - Dune X 125 - Euro 4

ATER PUMP

pos. Description Type Quantity Torque Notes

1 2

Water pump fastener screw M5

Water pump rotor fastener screw

- 1

3.5 Nm (2.58 lb ft)

5 Nm (3.69 lb ft)

CHAR - 34

Page 35

Dune 125 - Dune X 125 - Euro 4

243

UMP

OILP

pos. Description Type Quantity Torque Notes

Oil pump fastener screw M5x35

Oil cap retainer

- 1

4 Nm (2.95 lb ft)

25 Nm (18.44 lb ft)

Characteristics

Loctite

EAR SELECTOR

pos. Description Type Quantity Torque Notes

Selector sprocket fastener screw M5

2 3 4

Lever fastener screw M6

Clutch lever fastener screw

Gear shift selector pin fixing

- 1

4 Nm (2.95 lb ft)

9 Nm (6.64 lb ft)

CHAR - 35

Page 36

Characteristics

Dune 125 - Dune X 125 - Euro 4

NGINECRANKCASE

pos. Description Type Quantity Torque Notes

1 2

Crankcase retainer screw

M6x60

M6x75

12 Nm (8.85 lb ft)

CHAR - 36

Page 37

Dune 125 - Dune X 125 - Euro 4

Characteristics

EAD

pos. Description Type Quantity Torque Notes

1 2 3

5 6 7

Head fastener screw M6x130

Drainage side stud bolt retainer M8x40

Camshaft cover fastener screw M6x40

Head fastener screw M8x166

Thermostat cover fastener screw M6x20

Head dowels retainer M8x10

Thermostat retainer

ALVES

- V

- 1

12 Nm (8.85 lb ft)

11 Nm (8.11 lb ft)

27 Nm + 90° (19.91 lb ft

+ 90°)

11 Nm (8.11 lb ft)

6.5 Nm (4.79 lb ft)

9 Nm (6.64 lb ft)

CHAR - 37

Page 38

Characteristics

Dune 125 - Dune X 125 - Euro 4

GNITION UNIT

pos. Description Type Quantity Torque Notes

1 2 3 4

Flywheel rotor fixing nut M14x1.5

Rotor fastener screw

Stator clamping screws

Pick-Up clamping screw

- 6

- 2

- 3

86 Nm (63.43 lb ft)

12 Nm (8.85 lb ft)

6 Nm (4.43 lb ft)

3.5 Nm (2.58 lb ft)

CHAR - 38

Page 39

Dune 125 - Dune X 125 - Euro 4

Characteristics

OMPONENTS OF GEARBOX

pos. Description Type Quantity Torque Notes

Gear sensor retainer

- 1

3 Nm (2.21 lb ft)

CHAR - 39

Page 40

Characteristics

270

Dune 125 - Dune X 125 - Euro 4

INKAGE

pos. Description Type Quantity Torque Notes

Pinion fastening screws M5

Pinion cover fastening screws M5

Gearbox lever fixing screws M6

4-5 Nm (2.95-3.69 lb ft)

2.5-3.5 Nm (1.84-2.58 lb ft)

9-11 Nm (6.64-8.11 lb

ft)

Overhaul data

Assembly clearances

Cylinder - piston assy.

YLINDER-PISTON COUPLING CLEARANCE

Coupling categories with cast-iron cylinder

NAME ABBREVIA

Cylinder/Piston

Cylinder/Piston O 58.024 58.031 57.977 57.984 0.040 0.054

Cylinder/Piston P 58.031 58.038 57.984 57.991 0.040 0.054

TION

M N

CYLINDER PISTON FITTING

min max min max min max

58.010 58.017 57.963 57.970 0.040 0.054

58.017 58.024 57.970 57.977 0.040 0.054

125CM³

CLEARANCE

Loctite

CHAR - 40

Page 41

Dune 125 - Dune X 125 - Euro 4

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)

Characteristics

CHAR - 41

Page 42

INDEX OF TOPICS

PECIAL TOOLS

S-TOOLS

Page 43

XSM 125 - XTM 125 - Euro 4

864868

Flywheel

extractor

Stores code Description

AP8140266 Dial gauge mount

865259 Flywheel retainer

866380 Water pump tool set

PECIAL TOOLS

Special tools

864567 Camshaft timing adjustment lock pins

864486 Countershaft lock tool

S-TOOLS - 43

Page 44

Special tools

XSM 125 - XTM 125 - Euro 4

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

Stores code Description

020359Y 42 x 47 mm Adaptor

020358Y 37 x 40 mm Adaptor

020357Y 32 x 35-mm Adaptor

Special tools

020439Y 17 mm punch for secondary shaft oil seal

020891Y 25 mm (0.98 in) adapter

020363Y 20 mm diam. punch for crankshaft oil seal

020412Y 15 mm diam. punch for clutch oil seal

S-TOOLS - 45

Page 46

Special tools

020483Y

30-mm

guide

XSM 125 - XTM 125 - Euro 4

Stores code Description

020375Y 28x30 mm punch

020364Y 25 mm adapter

S-TOOLS - 46

Page 47

INDEX OF TOPICS

AINTENANCE

MAIN

Page 48

Maintenance

Dune 125 - Dune X 125 - Euro 4

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. See the

"Warranty Booklet" for all other information concerning the applicability of the Warranty and on per-

forming "Scheduled Maintenance" correctly.

NOTE

CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE.

I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY

C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE

(1)

Grease every 500 km (310.69 mi) and before use in extreme conditions.

(2)

Replace every 4 years.

(3)

Check and clean and adjust or replace, if necessary, before every journey.

(4)

Check after every engine start (check brake function, check that handlebar turns freely, check clutch,

suspension, engine, lights, indicator lamps).

(5)

Replace at whichever of the following occurs first: 36,000 km (22,369.36 mi) or 4 years.

(6)

Check every 1,000 km (621.37 mi)

(7) Replace every 30,000 km (18,641.14 mi)

SCHEDULED MAINTENANCE TABLE

Km x 1,000 (mi x 1,000) 1

Rear shock absorber I I I I I I

Audible and visual warning devices I I I I I I I I I

Battery I I I I I I I I Spark plug I Timing chain (7) Steering bearings and steering clear-

ance Diagnosis by tool I I I I I I I I I I I

Air filter

Engine oil filter General vehicle operation (4) I I I I I I I I I I I Front light assembly A A A A A A A A Cooling system I I I I I I I I Safety switches (front brake, rear

brake, stand, clutch)

Clutch lever and cable

Brake lever and throttle grip I I I I I I I I I I

Brake fluid I I I

Coolant I I I Engine oil Brake pads I I I I I I I I I I I

Brake callipers and discs I I I I I I I I I I I

Tyres - pressure / wear (3) I I I I I I I I I I I

(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)

I I I I I I I I I I I

R R R R R R R R

R R R R R R R R R R R

I I I I I I I I I I I

L L L L

I I

R R R R R R R R R R R

R R

I I I I I I

EVERY

MONTH

EVERY

MONTH

I I

R R

MAIN - 48

Page 49

Dune 125 - Dune X 125 - Euro 4

Clutch

lever

and

cableLLLL

Brake

padsIIIIIIII

Maintenance

Km x 1,000 (mi x 1,000) 1

Valve clearance adjustment I I I I Screw tightness I I I I I I I I I Front suspension: oil (5) Indicator lamps I I I I I I I I I Final drive (1)(6) I I I I I I I I I I I Fuel and oil pipes + filters (2) I I Brake pipes I I I I I I I I Labour time (minutes) 60 140 80 170 80 250 170 140

(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)

I I

EVERY

MONTH

80 50

EVERY

MONTH

I I

SCHEDULED MAINTENANCE TABLE RESERVED TO THE USA-LATAM MARKET

I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY

C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE

(1)

Grease every 500 km (310.69 mi) and before use in extreme conditions.

(2)

Replace every 2 years or 18,000 Km (11,184.68 mi).

(3)

Replace every 4 years.

(4)

Check and clean and adjust or replace, if necessary, before every journey.

(5)

Check after every engine start (check brake function, check that handlebar turns freely, check clutch,

suspension, engine, lights, indicator lamps).

(6)

Replace at whichever of the following occurs first: 36,000 km (22,369.36 mi) or every 4 years.

(7)

Check every 1,000 km (621.37 mi)

(8) Replace every 30,000 km (18,641.14 mi)

SCHEDULED MAINTENANCE TABLE

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)

Rear shock absorber I I I I Audible and visual warning

devices Battery I I I I I I I I Spark plug I Timing chain (8) Steering bearings and

steering clearance Diagnosis by tool I I I I I I I I I Air filter Oil filter General vehicle operation

(5) Front light assembly A A A A A A A A Cooling system I I I I I I I I Safety switches (front brake, rear brake, stand, clutch)

Brake lever and throttle grip I I I I I I I I Brake fluid - level (2) I I I I-R I I I-R I I Coolant - level (2) I I I I-R I I I-R I I Engine oil

I I I I I I I I I

R R R R R R R R

R R R R R R R R R

I I I I I I I I I

R R R R R R R R R

Brake callipers and discs I I I I I I I I I Tyres - pressure / wear (4) I I I I I I I I I Valve clearance adjustment I I I I Screw tightness I I I I I I I I I Front suspension: oil (6) Indicator lamps I I I I I I I I I

MAIN - 49

Page 50

Maintenance

Brake

pipesIIIIIIII

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) I I I I I I I I I Fuel and oil pipes + filters

(3)

Labour time (minutes) 60 140 80 170 80 250 170 140 80

NOTE

I I

Dune 125 - Dune X 125 - Euro 4

I I

AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.

Recommended products

Brake fluid DOT 4 Synthetic brake fluid.

SAE J 1703; FMVSS 116; ISO 4925; CUNA NC 956 DOT4

Front braking system



Unscrew and remove the screws (1) on

the front braking circuit fluid tank (2).



Lift and remove the cover (3) and the

gasket.



Top up the tank (2) with the recom-

mended brake fluid until the sight glass

is completely covered.

CAUTION

ONLY FILL TO THE "MAX" LEVEL AFTER FITTING NEW BRAKE PADS. DO NOT FILL TO THE "MAX" LEVEL WITH WORN PADS, AS THIS WILL CAUSE FLUID TO ESCAPE WHEN REPLACING BRAKE PADS. CHECK BRAKING EFFICIENCY. IF THE DEAD ZONE OF THE BRAKE PEDAL OR BRAKE LEVER IS TOO LONG, OR IN CASE OF FLUID LOSS, IT MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN THE SYSTEM.

MAIN - 56

Page 57

Dune 125 - Dune X 125 - Euro 4

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).



Top up the tank (6) with the recom-

mended brake fluid until the sight glass

is completely covered.

CAUTION

Maintenance

Adjusting the levers

NOTE

NO ADJUSTMENT IS POSSIBLE FOR THE FRONT BRAKE LEVER. SEE THE CHAPTER "INSTALLING THE REAR BRAKE MASTER CYLINDER" FOR THE PROCEDURE FOR ADJUSTING THE REAR BRAKE LEVER.

Clutch system

MAIN - 57

Page 58

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.

Minor adjustments can be carried out through the

set screw (1):



Rest the vehicle on its stand.



Remove the protection casing (2).



Loosen the lock nut (3).



Turn the set screw (1) until the empty

travel at the clutch lever end is approx-

Dune 125 - Dune X 125 - Euro 4

imately 10 - 15 mm (0.39 - 0.59 in) (see

figure).



After adjusting, tighten the check nut

(3) to lock the adjuster screw (1).



Check the empty travel at the clutch

lever end.



Refit he protection casing (2).

NOTE

CHECK THE CONDITION OF THE CLUTCH CABLE: THERE MUST BE NO SIGNS OF CRUSHING OR WEAR ALONG THE ENTIRE LENGTH OF THE CABLE SHEATH.



Lubricate the clutch cable periodically with suitable lubricant to prevent premature wear and

corrosion.

MAIN - 58

Page 59

Dune 125 - Dune X 125 - Euro 4

INDEX OF TOPICS

LECTRICAL SYSTEM

Electrical system

ELE SYS

ELE SYS - 59

Page 60

Electrical system

Components arrangement

Dune 125 - Dune X 125 - Euro 4

ELE SYS - 60

Page 61

Dune 125 - Dune X 125 - Euro 4

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. Electric fan

12. Oxygen sensor

Electrical system

13. Flasher unit

14. Oil pressure sensor

15. Coil

16. Fuel pump

17. Injection relay

18. Secondary fuses

19. Instrument

20. MIU G3 control unit

21. Regulator

22. Spark plug boot

23. Temperature sensor

24. Starter motor

25. Neutral sensor

ELE SYS - 61

Page 62

Electrical system

Dune 125 - Dune X 125 - Euro 4

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.

Consumables such as cable clamps, cable fasteners or cable glands are indicated in the figures.

Special checks for the correct connection and routing of cables

It is extremely important that any security-locks for the following connectors are properly connected and

correctly tightened to ensure proper engine, and therefore proper vehicle, operation.

The installation is shown with the vehicle ideally

divided into three parts:

Front section

Central section

Rear section

Front side

INSTRUMENT PANEL



Make sure the instrument panel con-

nector (1) is correctly connected to the

ELE SYS - 62

instrument panel.

Page 63

Dune 125 - Dune X 125 - Euro 4

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

side of the motorcycle as indicated and

Electrical system

pass them through the metal cable gland

(1) on the chassis.

Central part

A-OIL PRESSURE SENSOR



Using a clamp (1), placed near the red

taping, secure the oil pressure sensor

wiring harness (2).

ELE SYS - 63

Page 64

Electrical system

A1-OIL PRESSURE SENSOR



The oil pressure sensor wiring harness (2)

mustpass throughthe metal cablegland ofthe

frame (3).

Dune 125 - Dune X 125 - Euro 4

A2-OIL PRESSURE SENSOR



The oil pressure sensor wiring harness (2)

mustpass underthe water pipe (4).

ELE SYS - 64

Page 65

Dune 125 - Dune X 125 - Euro 4

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.

Electrical system

VOLTAGE REGULATOR



After securing the voltage regulator (1),con

nected the wiring harness (2) .

ELE SYS - 65

Page 66

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.

MAIN WIRING HARNESS



Place the main wiring harness (1) on

the metal flange which must be cov-

ered with a piece of PVC pipe.

Dune 125 - Dune X 125 - Euro 4

MAIN WIRING HARNESS



Place the main wiring harness (1) on

the metal flanges and tighten them to

stop the wiring harness from moving.

ELE SYS - 66

Page 67

Dune 125 - Dune X 125 - Euro 4

ECU



Secure the ECU connector using the

special metal plate.

FLYWHEEL



The flywheel wiring harness must be

fastened to the other wiring

harnesses by a clamp.

Electrical system

STARTER MOTOR



Make sure that the starter motor

earth cable is fastened correctly.

ELE SYS - 67

Page 68

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

Dune 125 - Dune X 125 - Euro 4

Back side

MAIN WIRING HARNESS ON REAR CHASSIS



Secure the main wiring harness using

two clamps (2) near the red taping.

FLASHER



Make sure the flasher(1) is

connected to the right side of the

tailgate.

ELE SYS - 68

Page 69

Dune 125 - Dune X 125 - Euro 4

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

turn indicators cable(1) are

connected to the rear side of the

Electrical system

tailgate.

ELE SYS - 69

Page 70

Electrical system

Dune 125 - Dune X 125 - Euro 4

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. FROM THE SIDE ON WHICH THE CABLES LEADING

FROM THE MAIN WIRING HARNESS ENTER THE CONNECTOR/COMPONENT.

CAUTION

BEFORE STARTING ANY TROUBLESHOOTING PROCEDURES ON THE VEHICLE, CHECK THAT THE BATTERY VOLTAGE IS ABOVE 12V.

PROCEDURE FOR CHECKING CONNECTOR

This procedure consists of the following checks and inspections:

1. Visually inspect connector and check that it is fitted correctly onto the component or onto the relative

connection point, and where applicable, check that the connector retainer or clip is correctly fastened.

2. Visually inspect the terminals on the connector: there must be no signs of corrosion or dirt. It isalso

important to check that the terminals are positioned correctly on the connector (terminals must all be

straight and of the same length) and to check the condition of the terminals themselves (terminals must

not be loose, bent etc.).

CAUTION

ELE SYS - 71

Page 72

Electrical system

IN THE CASE OF SPORADIC FAULTS, MOVE OR WIGGLE THE RELATIVE WIRING HARNESS SLIGHTLY WHILE PERFORMING EACH OF THE CHECKS INDICATED FOR TROUBLESHOOTING.

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.

Checking electrical CONTINUITY

Purpose of check: the purpose of this check is ensure that there are no interruptions or excess re-

sistance (due to corroded terminals, for example) in the circuit under inspection.

Tester: set the tester selector to the "continuity" symbol and place the probes of the tested at the two

ends of the circuit. Normally, the tester will sound an audible signal to confirm continuity in the section

of circuit tested. Continuity may also be tested by setting the tester selector to the "Ohm" symbol and

checking that the resistance in the circuit is zero or of a few tenths of an Ohm.

IMPORTANT: THE CIRCUIT MUST BE UNPOWERED DURING THIS TEST. IF THE CIRCUIT IS

POWERED, THE RESULTS OF THIS TEST ARE MEANINGLESS.

Dune 125 - Dune X 125 - Euro 4

Checking GROUND CONNECTION

Purpose of check: the purpose of this check is to verify that a cable or circuit is correctly connected

to the ground (-) of the vehicle.

Tester: set the tester selector to the "continuity" symbol and place one of the tester probes on the vehicle

ground point (or on the battery negative pole) and the other probe on the cable under inspection. Nor-

mally, the tester will sound an audible signal to confirm continuity in the section of circuit tested.

Continuity may also be tested by setting the tester selector to the "Ohm" symbol and checking that the

resistance in the circuit is zero or of a few tenths of an Ohm.

IMPORTANT: WHERE GROUND IS PROVIDED BY THE ECU, CHECK THAT THE ECU IS EFFEC-

TIVELY PROVIDING THE GROUND CONNECTION FOR THE CIRCUIT DURING THE TEST.

Checking VOLTAGE

Purpose of check: the purpose of this check is to determine if a cable is carrying voltage, in other

terms, to verify whether it powered by the battery or ECU.

Tester: set the tester selector to the "DC voltage" symbol and place the red tester probe on the cable

under inspection and the black tester probe on the vehicle ground point (or on the battery negative

pole).

CAUTION

IN THE CASE OF SPORADIC FAULTS, MOVE OR WIGGLE THE RELATIVE WIRING HARNESS SLIGHTLY WHILE PERFORMING EACH OF THE CHECKS INDICATED FOR TROUBLESHOOTING.

Dashboard

ELE SYS - 72

Page 73

Dune 125 - Dune X 125 - Euro 4

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.

Fuel reserve



In the event of a broken circuit, the MI

engine alarm warning lamp does not

Electrical system

light, no icons illuminate and none of

the fuel gauge indicator bars are dis-

played. In this case, the fuel reserve

warning lamp will not illuminate even

when the tank is empty.

Water temperature



The red water temperature warning

lamp (3) illuminates in the event of ex-

cessive coolant temperature (T>116°

C).

Engine alarm warning MI



The amber engine alarm warning lamp

MI (4) lights continuously in the event

of a fault identified by the engine con-

trol unit. Check for errors with the di-

agnostic tool.

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Page 74

Electrical system

Instrument function button



Function switch button II(5).



Function switch button I(6).

Instrument function button operation instructions

Dune 125 - Dune X 125 - Euro 4

RESETTING THE SCHEDULED

MAINTENANCE ICON



Elimination warning

battery and ignition switch is off ,long

press the function button I over

5S,and switch on the ignition switch

at the same time to remove warning.

ELE SYS - 74

：

only connect

Page 75

Dune 125 - Dune X 125 - Euro 4

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

Electrical system

Key:

Multiple connectors

Battery

Main fuses

Voltage regulator

Alternator

RECHARGING SYSTEM



Disconnect the six-way connector (1)

(black colour) located behind the left

side cover.

NOTE

THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER "A"

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Page 76

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

turning fan on) by using a tester, using

alternatively 3 of the 5 connector pins

(no. 2, 4, 6): stage "1" (pin 2-4), stage

"2" (pin 2-6), stage "3" (pin 4-6).

Dune 125 - Dune X 125 - Euro 4



Example:



Take the measurement; The correct value is determined by the value measured for each

stage in which from time to time the resistance of the tester wires is subtracted, obtained by

touching the two lugs.

Resistance of stage 1 read on the display = 0.67 Ohm

Resistance of the wires read on the display = 0.47 Ohm

ELE SYS - 76

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Dune 125 - Dune X 125 - Euro 4



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.

ESISTANCE MEASUREMENT

Winding stage Ambient temperature (ohm) Afterwards heat stabilisation (ohm)

Stage 1 0.15 - 0.30 0.20 - 0.35

Stage 2 0.15 - 0.30 0.20 - 0.35

Stage 3 0.15 - 0.30 0.20 - 0.35

Electrical system

Empty voltage



Disconnect the six-way connector (1).



Make a special cable harness using

two connectors that can be coupled

with those on the alternator side and

the chassis side of the motorcycle. The

outgoing wires from pins 1 and 5 must

maintain the continuity of the positive

and negative of the pick-up, otherwise

the engine will not start; while the out-

going cables from pins 2, 4, 6 (alterna-

tor side) must have the ends free in

order to perform the appropriate ac-

tion.

CAUTION

KEEP THE THREE ENDS OF THE FREE CABLES WELL SEPARATED TO AVOID DANGEROUS SHORT CIRCUITS.



For a correct detection of the alternator voltage, the measurements must be carried out using

alternatively the 3 ends of the free cables: stage "1" (outgoing cables from pins 2 and 4),

stage "2" (outgoing cables from pins 2 and 6), stage "3" (outgoing cables from pins 4 and

6).



Start the engine and carry out the measurement.

ELE SYS - 77

Page 78

Electrical system



If there is a significant difference between one stage and another (other than 15 V), this

Dune 125 - Dune X 125 - Euro 4

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.

MPTY VOLTAGE

rpm 2000 6000 8000

Vm linked voltage Reference values (V rms) 20 - 30 75 - 85 95 - 105

Short circuit current



For correct detection of short circuit

current it is necessary to make a spe-

cial cable harness using two connec-

tors that can be coupled with those on

the alternator side and the chassis side

of the motorcycle. The outgoing wires

from pins 1 and 5 must maintain the

continuity of the positive and negative

of the pick-up, otherwise the engine will

not start; while the ends of the outgoing

cables from pins 2, 4, 6 (alternator

side) must be short circuited with each

other in order to be able to perform the

appropriate action.



Start the engine and with an ammeter

clamp measure each single cable.



If there is a significant difference be-

tween the measurement taken of the

single cables (other than 10 A), this

means that the alternator is defective

and must be replaced.

CAUTION

WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 2-3 A LESS THAN THOSE DETECTED WITH THE ENGINE COLD.

WARNING

NEVER KEEP THE ENGINE RUNNING FOR MORE THAN ONE MINUTE; FAILURE TO DO SO COULD CAUSE SERIOUS OVERHEATING DAMAGES TO THE MOTORCYCLE CIRCUITS.

ELE SYS - 78

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Dune 125 - Dune X 125 - Euro 4

OLD SHORT CIRCUIT CURRENT

RPM 2000 4000 6000 8000

RMS DC current (Arms) (average of the 3 stage

currents)

12 - 18 12 - 18 12 - 18 12 - 18

Electrical system

Voltage on battery poles with engine speed always between 3000 - 5000 RPM



Start the engine, after about one minute of operating bring the speed to 3000-5000 RPM,

then measure with a tester the voltage at the battery poles that must always be between

13V and 15V. Otherwise, if the correct operation of the alternator has already been checked,

replace the regulator.

CAUTION

PERFORM THE CHECK DESCRIBED ABOVE WITH A BATTERY IN GOOD CONDITION (START VOLTAGE ABOUT 13V) MAKING SURE THAT THERE ARE NO ELEMENTS IN THE SHORT CIRCUIT.

Voltage regulator check



Output voltage 13.5 V - 15 V



Output current higher than 10 A (with

load)

Start-up system check

ELE SYS - 79

Page 80

Electrical system

Key:

Multiple connectors

MIU G3 control unit

Gear in neutral switch

Clutch switch

Right light switch

Ignition switch

Starter motor relay

Starter motor

Battery

10.Secondary fuses

11.Main fuses

12.Regulator

Dune 125 - Dune X 125 - Euro 4

13.Alternator

14.Pick-up

CHECKING THE STARTER MOTOR



To carry out the check, power up the

motor with a 12 V 9 AH battery.



Win an AC ammeter clamp measure

the steady running absorbed current

(after 5 seconds).

Correct value 50 - 60 A.

CHECKING THE STARTER MOTOR RELAY



To check that the relay is operating

correctly:



Power the two male terminals (85 - 86)

with a 12 V voltage.



Using a tester (in ohmmeter mode)

check the continuity between the other

two terminals (87 - 30).

Correct value with relay energised: 0 Ohm

Correct value with relay not energised: infinite

ohm



If the values do not correspond to those

indicated, replace the relay.

ELE SYS - 80

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Dune 125 - Dune X 125 - Euro 4

are

STARTER COMMAND

Function

Commands engine starting through the

injection control unit.

Operation / Operating principle

Electrical system

The starter button, brake switches, No.

starter relay and the injection control unit

involved, via PINs 5 and 10.

Level in electrical circuit diagram Start

enable signals, Starting Position

Starter button: on right hand switch set

Connector: ...

Electrical specifications



Button released: open circuit



Button pressed: closed circuit

Diagnostic tool



Diagnostics tool

Starter button P0512 - signal not valid

Error cause

- Parameters and statuses

Starting request - (Absent, Present,

Closed Loop, Closed)

- Logic errors



Fault in the switch (lock) of the engine start-up or short circuit to ground

Troubleshooting



Check if the button remains in start position; if not OK, restore, if OK check that there is no

short circuit to ground of the grey/red cable; if it is not, restore. If it is OK, replace

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Page 82

Electrical system

Horn control

Testing voltage: 13 V (nominal 12 V)

Input: < 3.5 A

Lights list

Dune 125 - Dune X 125 - Euro 4

ELE SYS - 82

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Dune 125 - Dune X 125 - Euro 4

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

Electrical system

9.Rear right turn indicator

10.Licence plate light

11.Rear left turn indicator

12.Taillight

13.Starter motorrelay

14.Starter motor

15.Battery

16.Main fuses

17.Secondary fuses

18.MIU G3 control unit

19.Front left turn indicator

20.Light relay

21.Front daylight running light

22.Headlamp

23.High beam/low beam light

24.Front right turn indicator

ELE SYS - 83

Page 84

Electrical system

Dune 125 - Dune X 125 - Euro 4

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:

LED



License plate light (where applicable):

12 V - 5W

Fuses

MAIN FUSES DISTRIBUTION

Specification Desc./Quantity

30A fuse Main fuse：Vehicle circuit fuse

10A fuse Secondary fuse：EFI System and front / back position lamp

The fuses are located in the central part of the motorcycle, under the saddle on the left hand side.

ELE SYS - 84

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Dune 125 - Dune X 125 - Euro 4

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

lights logic, low beam lights and DRL lights logic,

brake lights logic, instrument cluster, horn, pre-

configuration for BlueDash, USB port, electric fan

Position:



on the vehicle: behind headstock



connector: on the battery

Electrical system

Electrical specifications:12 V / 4 Ah

Pin out:

Positive pole (red): approx. 12,6 V

negative pole (black): ground lead

DIAGNOSTIC TOOL:PARAMETERS

Battery voltage



Example value with key ON: 12.0 V



Example value with engine on: 14.2 V

This is one of the values set by the ECU in the

event of recovery mode

Battery voltage before prior to Recovery mode



Example value with key ON: 12.0 V



Example value with engine on: 14.2 V

ELE SYS - 85

Page 86

Electrical system

Value determined from signal read without taking

considering whether recovery mode is implemen-

ted

Dune 125 - Dune X 125 - Euro 4

Diagnostics tool

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.

Troubleshooting



If too high: check that the voltage regulator is working correctly.



If too low: check voltage regulator connectors, engine-vehicle wiring harness connector and

ECU connector (check in particular for oxidation): if not OK, repair. If OK, check that resist-

ance of the Red/White cable from the voltage regulator connector to the ECU connector is

a few tenths of an Ohm; if not OK, repair the wiring harness. If OK, check that the alternator

is working correctly: if not OK, repair. If OK, check that the voltage regulator is working

correctly

- Logic errors

ELE SYS - 86

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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-

erence position

Level in electrical circuit diagram

Engine speed sensor

Position



Sensor: LH side of motorcycle, near flywheel



Connector: ...

Electrical specifications

Winding resistance 105-124 Ω at 20°

Pin-out

Engine revolution sensor positive signal (X2)

Engine revolution sensor negative signal (X1)

Engine speed sensor anti-disturbance cable (blue)

Diagnostic tool



Diagnostic tool

Engine revolution sensor P0336 - inconsistent signal

Cause of error



Troubleshooting



- Parameters and statuses

Engine speed - (rpm)

Target engine revs - (rpm) (Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep the engine running at this revs, acting on the ignition advance)

- Electrical errors

Possible false contact in the electric circuit detected at PIN 20 and 29 of the engine control unit connector

Check the electric circuit is in good conditions and the flywheel teeth cleaning and correct positioning of the sensor in its own housing; if it is not, replace it. If it is OK, replace the sensor

ELE SYS - 87

Page 88

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).

Level in electrical circuit diagram

Temperature sensors

Position

Sensor: On the head, LH side

Connector: near the sensor

Dune 125 - Dune X 125 - Euro 4

Electrical specifications



Resistance (PIN B1 - B2) at 25°C (77° F): 2.05 kΩ +/- 100 Ω



Resistance (PIN B1 - B2) at 60°C (158° F): 575 Ω +/- 15 Ω



Resistance (PIN B1 - B2) at 90°C (194°



F): 230 Ω +/- 5 Ω



Resistance (PIN A1 - A2) at 25°C (77° F): 2.4 kΩ +/- 200 Ω



Resistance (PIN A1 - A2) at 60°C (158°



F): 557 Ω +/- 30 Ω



Resistance (PIN A1 - A2) at 90°C (194° F): 196 Ω +/- 8 Ω

Pin-out:

Control unit ground (B2)

Instrument panel power (A2)

Control unit power (B1)

Instrument panel ground (A1)

ELE SYS - 88

Page 89

Dune 125 - Dune X 125 - Euro 4

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.

Short circuit to negative: null voltage between PIN 13 and 15 of the control unit connector.

Troubleshooting

Open circuit:



Disconnect the connector of the control unit.



Measure the resistance value of the sensor at different temperatures between PIN 13 and

15.



Disconnect the sensor connector.



Verify continuity of the wiring harness between the sensor connector and the control unit

connector: Control unit PIN 13 - sensor PIN 3 and control unit PIN 15 - sensor PIN 1. If

Electrical system

necessary, restore the wiring harness.



If the wiring harness is intact but the sensor resistance value is incorrect, this means that

the sensor is faulty and must be replaced, otherwise proceed with the checks.

Short-circuit to positive:



With the sensor connector and the control unit disconnected, verify that the fault is shorted

with the battery positive of sensor connector PIN 3 (or control unit connector PIN 13) and

restore the cabling.

Short circuit to negative:



Disconnect the sensor connector.



Check the sensor connector PIN 3 ground insulation.



If there is no ground insulation restore the wiring harness.



If PIN 3 is insulated from the ground and the error persists, this means that there is a

probable fault in the control unit.

ELE SYS - 89

Page 90

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

fumes and the environment, this generates volt-

age which is read and interpreted by the injection

control unit. It does not require an external supply

source but, in order to work properly, it should

reach a high operating temperature: that is why

there is a heating circuit inside.

Level in electrical circuit diagram

Lambda probe, Injection utilities relay

Dune 125 - Dune X 125 - Euro 4

Position



Sensor: exhaust duct



Connector: underneath battery, behind

headstock, RH side

Electrical specifications



Heater circuit: 12 -14 Ω at 20 °C (68 °

Pin-out:

Heater power (A)

Heater ground (B)

Sensor signal + (C)

Sensor signal - (D)

Diagnostic tool

Check the air-fuel ratio / Lambda probe P0130 - short circuit to positive / open circuit, short circuit to

negative or mixture excessively lean / signal not plausible for abnormal title correction or probe signal

fault.

- Electrical errors

Cause of error

ELE SYS - 90

Page 91

Dune 125 - Dune X 125 - Euro 4

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.

Troubleshooting

Short-circuit to positive:



Disconnect the control unit connector and the sensor connector.



Verify that there is no short to battery positive on sensor connector PIN C (corresponding

to control unit connector PIN 11); if there is a short, restore the wiring harness.



Verify that there is no short to battery positive on sensor connector PIN D (corresponding

to control unit connector PIN 12); if there is a short, restore the wiring harness.

Open circuit:



Disconnect the control unit connector and the sensor connector.



Check the continuity of the wiring harness between the sensor connector and the control

Electrical system

unit connector: Control unit PIN 11 - sensor PIN C and control unit PIN 12 - sensor PIN D.

If necessary, restore the wiring harness.



If the wiring harness is intact and the error persists, proceed with the following checks.

Short circuit to negative:



Disconnect the sensor connector and the control unit connector.



Check the sensor connector PIN C ground insulation. If there is no insulation, restore the

wiring harness.



Check the sensor connector PIN D ground insulation. If there is no insulation, restore the

wiring harness.



If PIN C and PIN D are insulated from the ground and the error persists, this means that

there is a probable fault in the control unit.

Lambda probe heater P0135 - shorted to positive / shorted to negative / open circuit.

Cause of error

Short-circuit to positive: excessive voltage at PIN 31 of the control unit connector.

Short circuit to negative: lack of insulation from ground on the sensor connector PIN A.

Open circuit: circuit interruption.

Troubleshooting

Short-circuit to positive:



Disconnect the control unit connector and the sensor connector.



Verify that there is no short to battery positive on sensor connector PIN B (corresponding to

control unit connector PIN 31); if there is a short, restore the wiring harness.

Open circuit:



Disconnect the control unit connector and the sensor connector.

ELE SYS - 91

Page 92

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.



Verify continuity of the wiring harness between the sensor connector and the injection relay:

sensor PIN A - injection relay PIN 3. If necessary, restore the wiring harness.



If the wiring harness is intact and the error persists, proceed with the following checks.

Short circuit to negative:



Disconnect the sensor connector.



Check the sensor connector PIN B ground insulation. If there is no insulation, restore the

wiring harness.



If PIN B is insulated from ground and in the absence of other errors (fuel pump, injector,

coil), this means that the control unit is most likely faulty.

Injector

Dune 125 - Dune X 125 - Euro 4

Function

Provide the correct amount of fuel at the correct time.

Operation / Operating principle

Injector coil is excited for the petrol passage to open.

Level in electrical circuit diagram

Relay for injection utilities, Coils and injectors

Electrical specifications



14.8 Ώ +/- 5% (at 20 °C - 68°F)

Pin-out:

Control unit ground

Power via relay

Diagnostic tool



Diagnostic tool

Injector P0201 - short circuit to positive / short cir-

cuit to negative / open circuit.

- Activation

Injector control

- Electrical errors

Error cause

Short-circuit to positive: excessive voltage to PIN

34 of the control unit connector.

Short circuit to negative: zero voltage to the PIN 2

of the injector connector.

Open circuit: circuit interruption.

Troubleshooting

ELE SYS - 92

Page 93

Dune 125 - Dune X 125 - Euro 4

Short-circuit to positive:



Disconnect the injector connector, turn

the key to ON and activate thecompo-

nent through the diagnostic tool.



Verify the absence of voltage at the in-

jector connector PIN 1; if present re-

store the wiring harness, otherwise

proceed with the following checks.

Short circuit to negative:



Disconnect the injector connector, turn

the key to ON and activate thecompo-

nent through the diagnostic tool.



Verify the presence of voltage at the

Electrical system

ends of the injector connector; if there

is no voltage, restore the wiring har-

ness, otherwise proceed with the fol-

lowing checks.

Open circuit:



Carry out the check procedure of the

injector and control unit connectors.



Check continuity of cable between

ECU connector and injector connector

(ECU PIN 34 - injector PIN 1). In the

absence of continuity restore the wiring

harness.

Fuel pump

CAUTION

BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.

ELE SYS - 93

Page 94

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.

Shorted to negative: null voltage at PIN 2 of the

injection relay.

The circuit is open: interruption of the circuit.

Troubleshooting

Shorted to positive:



Disconnect the injection relay (No. 35

on the electrical circuit diagram), turn

the key to the ON position and activate

Dune 125 - Dune X 125 - Euro 4

the relay through the diagnostics in-

strument.



Verify the presence of voltage between

relay connector PIN 1 and 2 toward the

cabling.



If no voltage is read, disconnect the

control unit and verify insulation from

battery positive of the relay PIN 1 (or

control unit PIN 22). Restore the ca-

bling if necessary.

Shorted to negative:



Disconnect the injection relay (No. 35

on the electrical circuit diagram) and

the control unit.



Verify ground insulation of the relay

connector PIN 1 and 2 toward the ca-

bling: if there is no insulation, restore

the cabling.

The circuit is open:



Disconnect the injection relay (No. 35

on the electrical circuit diagram) and

the control unit.



Verify continuity of the cabling between

the relay and control unit: Relay PIN 1

ELE SYS - 94

Page 95

Dune 125 - Dune X 125 - Euro 4

CAUTION

- 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. The reading in ohms does

not need to be exact but, if the windings are intact,

their continuity must be detected with the resist-

ance values indicated above.

Primary: 550 +/- 50 mOhm

Electrical system

Secondary: 3.3 +/- 0.3 kOhm

Function

Allows generation of the electrical discharge on

the spark plug, with an increase of voltage.

Pin-out:

Relay powered (PIN 3 relay side)

Activation by control unit (control unit side

PIN 1)

BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.

ELECTRICAL ERRORS

H.V.

Coil P0351 - shorted to positive / open circuit or shorted to negative.

Error cause

Shorted to positive: excessive voltage at PIN 1 of the control unit connector.

Circuit open or shorted to negative: interruption of the circuit or null voltage at PIN 1 of the control unit

connector.

ELE SYS - 95

Page 96

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.

The circuit is open:



Carry out the check procedure of the coil and control unit connectors.



Verify continuity of the cabling between the coil and control unit: Coil PIN 2 - control unit PIN

In the absence of continuity restore the cabling.



Verify, with the key turned ON, the presence of voltage on the coil connector PIN 1. If no

voltage is read, verify the continuity of the cabling between coil and injection relay (No. 35

on the electrical circuit diagram): Coil PIN 1 - relay PIN 3.

Dune 125 - Dune X 125 - Euro 4



If the above tests provided a positive result, the coil should be replaced.

Shorted to negative:



Disconnect the control unit connector and the coil connector.



Verify the coil connector PIN 2 ground insulation (or control unit connector PIN 1). Restore

the cabling if necessary.

Engine oil pressure sensor

Function

Notifies the instrument panel that the oil pressure

in the engine is sufficient.

Operation / Operating principle

The switch is normally closed (connects ECU sig-

nal to ground). At pressures above ... bar, the

switch opens.

Level in electrical circuit diagram:

Low fuel and oil pressure

Position:



on the vehicle: RH side, near the water

pump



connector: on the sensor

Electrical specifications: -

Pin out:

Voltage: 5 V

ELE SYS - 96

Page 97

Dune 125 - Dune X 125 - Euro 4

NOTE

NO ERRORS

Electrical system

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

warning light

Level in electrical circuit diagram

Neutral sensor, Start enable signals.

Position



Sensor: rear / upper side of the gearbox



Connector: on the sensor

Electrical specifications



Gear in neutral: closed circuit (0 V on wire from control unit to sensor / switch in continuity).



Gearshift engaged: open circuit (12 V on the wire from control unit to sensor)

Pin-out:

Voltage 12V (green/black)

Diagnostic tool



Diagnosis

Warning light "N" always off

Error cause



Troubleshooting



- Parameters and statuses

Gear in neutral - (YES, NO)

Possible malfunction

Carry out the check procedure on the

green/black sensor/control unit cable.

Restore if damaged.



If OK, with the transmission in neutral,

check for continuity to ground of the

sensor connector.



If there is no continuity, replace the

sensor.



Restore if damaged.



If OK, check continuity.

ELE SYS - 97

Page 98

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



Possible malfunction

Troubleshooting



Disconnect the terminals from the sen-

sor and verify that, with the transmis-

sion in gear, there is continuity with the

ground.



If there is continuity, replace the sen-

Dune 125 - Dune X 125 - Euro 4

sor.



If there is no continuity this means that

there is a short to ground of the green

black cable which goes to PIN 3 of the

control unit, therefore restore the wir-

ing harness.



If there is no continuity, restore the wir-

ing harness.



If there is no continuity, replace the wir-

ing harness.

Clutch lever sensor

Function

Indicates the clutch lever position to the control

unit

Operation / Operating principle

In order to start the engine, pull the clutch also with

the gear in neutral

Level in electrical circuit diagram

Start enable switches

Position



Sensor: under clutch lever



Connector: ...

ELE SYS - 98

Page 99

Dune 125 - Dune X 125 - Euro 4

Electrical specifications



Clutch engaged: closed circuit (con-

tinuity)



Clutch released: open circuit (infinite

resistance)

Pin-out

12 V Voltage (brown/white)

Ground (blue/green)

Electrical system

Diagnostic tool



Diagnosis

Even with the clutch lever engaged, the vehicle does not start

Error cause



Troubleshooting



- Parameters and statuses

Clutch - (Pulled, Released)

Possible malfunction

Verify that, if a gear is engaged, the stand is up.

If it is up, check continuity of the brown/white cable and control unit PIN 18.

If there is no continuity, restore the wiring harness.

If there is continuity, disconnect the sensor and, with the clutch engaged, check for continuity

between the two sensor PINs.

If absent, replace the sensor.

If present, check for continuity of the blue/green cable between the sensor and control unit

PIN 15.

If absent, restore the wiring harness.

The vehicle starts even without pulling the clutch lever

Error cause



Possible malfunction

Troubleshooting



Disconnect the terminals from the sensor and check that, with the clutch released, there is

continuity between the two PINs.



If there is continuity, replace the sensor.



If there is no continuity, this means that the blue/green cable which goes from the sensor

PIN 2 to the control unit PIN 15 is shorted to ground.

ELE SYS - 99

Page 100

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.

Position:



sensor: relay installed in front frame re-

cess on left hand side



connector: on relay

Dune 125 - Dune X 125 - Euro 4

DIAGNOSTIC TOOL:STATUSES

Fan relay



on/off

DIAGNOSTIC TOOL:ACTIVATIONS

Fan



The fan relay is excited (No. 42 in elec-

trical circuit diagram - ALWAYS

CHECK colour of wires to identify relay

correctly) for 10 seconds. Electrical

continuity is required in the wiring for

the relay to activate correctly: no errors

are generated if the relay fails to acti-

vate

ELECTRICAL ERRORS

Fan relay P0480 - short circuit to positive / short circuit to negative / open circuit.

Error cause

Short-circuit to positive: excessive voltage to PIN 24 of the control unit connector.

Short circuit to negative: null voltage at PIN 24 of the control unit connector.

Open circuit: circuit interruption.

Troubleshooting

Short-circuit to positive:

ELE SYS - 100

Malaguti Dune X 125, Dune 125 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual