Malaguti Dune X 125, Dune 125 Service Manual
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.
© Copyright 2018 - KSR Solution GmbH All rights reserved. Reproduction of this publication in whole
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
C
PECIAL TOOLS.......................P43-46
S
AINTENANCE.........................P48-58
M
CHAR
S-TOOLS
MAIN
E
LECTRICAL SYSTEM.............P59-109
NGINE FROM VEHICLE.........P110-115
E
NGINE.....................................P117-173
E
OWER SUPPLY.....................P175-177
P
S
USPENSIONS........................P179-190
HASSIS..................................P192-221
C
B
RAKING SYSTEM..................P223-236
ELE SYS
ENG VE
ENG
P SUPP
SUSP
CHAS
BRAK SYS
OOLING SYSTEM..................P238-244
C
ODYWORK.............................P246-264
B
DELIVERY.......................P266-268
PRE-
COOL SYS
BODYW
PRE DE
INDEX OF TOPICS
HARACTERISTICS
C
CHAR
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.
CHAR - 7
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.
CHAR - 8
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.
CHAR - 9
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.
CHAR - 10
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
CHAR - 11
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)
CHAR - 12
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
Specification Desc./Quantity
fork travel
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
CHAR - 13
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
G
M4 M5 M6 M8 M10 M12
Metric tightening torque: TE - TEFL - SHC - TBEI
- TCC - TS
ENERAL TIGHTENING TORQUES FOR SELF TAPPING SCREWS FOR PLASTIC
G
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
CHAR - 14
Dune 125 - Dune X 125 - Euro 4
Characteristics
RONT WHEEL
F
pos. Description Type Quantity Torque Notes
1
2
Wheel fastening pin M14
SHC front brake disc fastening
screws
M6x20
1
6
70/80 Nm (51.63/59 lb ft)
10/12 Nm (7.38/8.85 lb ft)
-
Loct. 243
CHAR - 15
Characteristics
F
pos. Description Type Quantity Torque Notes
Dune 125 - Dune X 125 - Euro 4
ORK
1
SHC wheel axle clamp fastening
2
Hex head handlebar U-bolt flanged
3
4
SHC steering yoke fastening screws
5
SHC steering yoke fastening screws
6
Caps
screws
fastening screws
NUT
-
M8×25
M8×35
M25×1
M8×35
M8×35
2
1
4
1
2
2
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)
20/24 Nm (14.75/17.70 lb ft)
-
-
-
-
-
-
ORK
F
pos. Description Type Quantity Torque Notes
1
SHC wheel axle clamp fastening
2
Hex head handlebar U-bolt flanged
3
4
SHC steering yoke fastening screws
5
SHC steering yoke fastening screws
6
Caps
screws
fastening screws
NUT
-
M6×25 3
M8×30
M24×1
M8×35
M8×35
2
6
1
2
2
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)
20/24 Nm (14.75/17.70 lb ft)
CHAR - 16
-
-
-
-
-
-
Dune 125 - Dune X 125 - Euro 4
Characteristics
ANDLEBAR AND CONTROLS
H
pos. Description Type Quantity Torque Notes
1
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
M6×25
M10×1
M8×30
M5×8
M6×16
ST5,1×14
M10×1.25
2
2
2
1
2
1
1
1
1
7/10 Nm (5.16/7.38 lb ft) -
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) -
3
Nm (2.21 lb ft)
28/33 Nm (20.66/24.35 lb ft) -
-
CHAR - 17
Characteristics
Dune 125 - Dune X 125 - Euro 4
IGHTS
L
pos. Description Type Quantity Torque Notes
1 Turninglight bolt
2 Windshield bolt
Instrument cover self-tapping
3
Instrument cover self-tapping
4
screws
bolt
5 Headlight cover bolt
6 Front shroud bolt
7 Headlight bolt
M6×20
M6×20
St2.8×13
M5×16
M5×16
M5×16
M6×20
8 Rearlight bolt M5×35
9 License plate light bolt
M5×16
4
3
4
2
2
4
2
2
1
2/3 Nm (1.48/2.21 lb ft) -
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) -
2/3 Nm (1.48/2.21 lb ft) -
2/3 Nm (1.48/2.21 lb ft) -
2/3 Nm (1.48/2.21 lb ft) -
CHAR - 18
Dune 125 - Dune X 125 - Euro 4
Characteristics
IGHTS
L
pos. Description Type Quantity Torque Notes
1 Turninglight bolt
2 Windshield bolt
Instrument cover self-tapping
3
Instrument cover self-tapping
4
screws
bolt
5 Headlight cover bolt
6 Front shroud bolt
7 Headlight bolt
M6×20
M6×30
St2.8×13
M5×16
M5×16
M5×16
M6×20
8 Rearlight bolt M5×35
9 License plate light bolt
M5×16
4
3
4
2
2
4
2
2
1
2/3 Nm (1.48/2.21 lb ft) -
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) -
2/3 Nm (1.48/2.21 lb ft) -
2/3 Nm (1.48/2.21 lb ft) -
2/3 Nm (1.48/2.21 lb ft) -
CHAR - 19
Characteristics
Dune 125 - Dune X 125 - Euro 4
LASTIC COVERS
P
pos. Description Type Quantity Torque Notes
1 Fuel tank shell bolt
2 Fuel tank shroud bolt
Fuel tank shroud connecting
3
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
M5×9
M5×9
M5×9
M6×16
（
Dune125
M6×25
（
X125
M8×30
M5×16
M5×16
M6×16
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
5
2
4
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) -
2/3 Nm (1.48/2.21 lb ft) -
2/3 Nm (1.48/2.21 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) -
2/3 Nm (1.48/2.21 lb ft) -
8/10 Nm (5.90/7.38 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
-
CHAR - 20
Dune 125 - Dune X 125 - Euro 4
Characteristics
RAME
F
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
M8
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
Characteristics
ANISTER ASSEMBLY
C
Dune 125 - Dune X 125 - Euro 4
pos. Description Type Quantity Torque Notes
1 Canister bracket bolt
M6×10
1
5/7 Nm (3.69/5.16 lb ft) -
ILTER BOX
F
pos. Description Type Quantity Torque Notes
1
2
Air filter box fastening screw M5×12
Air filter box
bolt
M6×16
4
4
3.5 Nm (2.58 lb ft)
5/7 Nm (3.69/5.16 lb ft) -
CHAR - 22
-
Dune 125 - Dune X 125 - Euro 4
Characteristics
LECTRICAL SYSTEM
E
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
M6×16
M8×20
M6
×
×
25
18
2
4
1
3
3
1
1
2
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) -
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
Characteristics
Dune 125 - Dune X 125 - Euro 4
UEL TANK
F
pos. Description Type Quantity Torque Notes
M6
1
2
3
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
4
3
3
6
8/10 Nm (5.90/7.38 lb ft) -
8/10 Nm (5.90/7.38 lb ft) -
2.7/3.3 Nm (1.99/2.43 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
-
-
-
Dune 125 - Dune X 125 - Euro 4
lb
ft)
Characteristics
OCK ASSY
L
pos. Description Type Quantity Torque Notes
M8
20
1
2
3
4
Electric Lock bolt
Electric Lock bolt M8×20
Electric Lock cover bolt M5×9
Seat lock bolt M6×10
×
1
1
2
2
18/20 Nm (13.28/14.75
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
Characteristics
lb
ft)
ft)
E
XHAUST SYSTEM
pos. Description Type Quantity Torque Notes
1
2
3
4
5
6
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
M5
M12
Dune 125 - Dune X 125 - Euro 4
2
4
1
2
2
1
5/6 Nm (3.69-4.43 lb ft) -
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
18/22 Nm (13.28-16.23
lb ft)
17/20 Nm (12.54-14.75
lb ft)
-
-
-
-
EAR WHEEL
R
pos. Description Type Quantity Torque Notes
1
2
3
Rear axle
Rear brake disc bolt M8×24.2
Rear sprocket bolt M8×30
M14
1
3
6
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
Dune 125 - Dune X 125 - Euro 4
lb
ft)
Characteristics
EAR FORK
R
pos. Description Type Quantity Torque Notes
×
M12
M6
×
12
58
1
1
2
2
2
2
2
1
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
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) -
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
Characteristics
head
screws
lb
ft)
R
ear Brake Pedal
pos. Description Type Quantity Torque Notes
Rear brake disc fastening torx button
1
Speed sensor fastening screws M6×35 1
2
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
1
Special brake pipe fastening screws M10×32 2 28/33 Nm (20.66/24.35 lb ft)
2
SHC front brake caliper fastening
3
CBS control unit fastening screws M6×20 2 8/10 Nm (5.90/7.38 lb ft)
4
SHC front brake caliper fastening
5
screws
screws
22 4 28/33 Nm (20.66/24.35 lb ft)
M8 2
×
12 2
M8
22/24 Nm (16.23/17.70
lb ft)
25/30 Nm (18.45/22.14
lb ft)
CHAR - 28
-
-
Loct. 243
-
Dune 125 - Dune X 125 - Euro 4
Engine
Characteristics
RANKSHAFT
C
pos. Description Type Quantity Torque Notes
1 Gear fixing screw M10 1 40 Nm (29.50 lb ft) -
YLINDER
C
pos. Description Type Quantity Torque Notes
- P
ISTON
1 Chain tensioner fastener screw M6×16 2 12 Nm (8.85 lb ft) -
CHAR - 29
Characteristics
Dune 125 - Dune X 125 - Euro 4
HROTTLE BODY
T
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
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