Cfmoto Papio 125 (2019+) - Workshop Repair Manual - Maintenance

CFMOTO PAPIO 125 (2019+) - SERVICE MANUAL - REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Cfmoto Papio 125 from 2019.
- Edition Item: CF125-3A(6FIA-WX-01-2)SM-20190311


CONTENTS:

01 GENERAL INFORMATION
- 1.1 Safety Information
- 1.2 Disassembly and Assembly Notifications
- 1.3 Locations of VIN and EIN
- 1.4 Wire, Pipe, Cable, and Sensor Locations
- 1.5 Fuel and EVAP System Diagram

02 MAINTENANCE INFORMATION
- 2.1 Maintenance Before Operation
- 2.2 Break-In Maintenance Schedule
- 2.3 Periodic Maintenance Schedule

03 TECHNICAL INFORMATION
- 3.1 General Vehicle Specifications
- 3.2 Engine Specifications Chart
- 3.3 Maintenance Specifications Chart
- 3.4 Service Specifications
- 3.5 Tightening Torque Values
- 3.6 Assembly and Consumable Materials

04 SEAT

05 FUEL TANK ASSEMBLY
- 5.1 Seat
- 5.2 Left and Right Hand Panels
- 5.3 Fuel Tank Guard
- 5.4 Fuel Tank

06 LIGHTS, DASHBOARD AND SWITCHES
- 6.1 Maintenance Information
- 6.2 Troubleshooting
- 6.3 Dashboard and Headlight Assemblies
- 6.4 Turn Indicators
- 6.5 Rear Fender Bracket and Rear License Light
- 6.6 Tail Light/Brake Light
- 6.7 Ignition Switch
- 6.8 Front Brake Switch
- 6.9 Rear Brake Switch
- 6.10 Left Handlebar Switch
- 6.11 RH Handlebar Switch
- 6.12 Horn
- 6.13 Fuel Level Sensor
- 6.14 Auxiliary Starter Relay and Fuel Pump Relay
- 6.15 Battery

07 AIR FILTER ASSEMBLY
- 7.1 Air Filter

08 ELECTRICAL SYSTEM
- 8.1 EFI Servicing Precautions
- 8.2 EFI Malfunction Test
- 8.2.1 Outline
- 8.2.2 EFI Malfunction Parameters
- 8.3 Charging System
- 8.3.1 Charging Diagram
- 8.3.2 Magneto Coil Resistance
- 8.3.3 Magneto Non-Loaded Performance
- 8.3.4 Voltage Regulator
- 8.4 EFI
- 8.4.1 EFI Structure
- 8.4.2 EFI Subsystems
- 8.4.2.1 Sensors
- 8.4.2.2 ECU
- 8.4.2.3 Actuators
- 8.4.3 EFI System Maintenance Notes
- 8.4.4 Service Tool
- 8.4.5 Structure and Performance of EFI Parts
- 8.4.5.1 ECU
- 8.4.5.2 Throttle Body
- 8.4.5.3 T-MAP
- 8.4.5.4 Idle Air Control Valve
- 8.4.5.5 Cylinder Head Temperature Sensor
- 8.4.5.6 Oxygen Sensor
- 8.4.5.7 Trigger (CKP)
- 8.4.5.8 Fuel Injector
- 8.4.5.9 Ignition Coil
- 8.4.5.10 Output Speed Sensor
- 8.4.5.11 Rollover Sensor
- 8.4.5.12 Fuel Pump
- 8.4.5.13 Gear Position Sensor
- 8.5 Self-Diagnosis
- 8.5.1 Engine Operation
- 8.5.2 Trouble Diagnosis In Accordance With Engine Error
- 8.5.3 Fault Codes

09 MUFFLER ASSEMBLY
- 9.1 Muffler

10 WHEELS AND BRAKE SYSTEM
- 10.1 Front Brake Assembly
- 10.2 Front Brake Assembly Inspection 
- 10.2.1 Brake Hose, Hose Damage, and Installation Inspection
- 10.2.2 Brake Performance Inspection
- 10.2.3 Front Brake Fluid Level Inspection
- 10.2.4 Brake Fluid Replacement
- 10.2.5 Front Brake Lever Free Play
- 10.2.6 Front Brake Pad Inspection
- 10.3 Front Wheel and Brake Rotor Removal
- 10.4 Rear Wheel Removal and Disassembly
- 10.5 Front/Rear Wheel Inspection
- 10.5.1 Tire Pressure Inspection
- 10.5.2 Tire Inspection
- 10.5.3 Wheel Bearing Inspection
- 10.5.4 Brake Pad Inspection
- 10.6 Rear Brake Assembly Removal
- 10.7 Rear Brake Assembly Inspection
- 10.7.1 Rear Brake Fluid Level Inspection
- 10.7.2 Rear Brake Fluid Replacement
- 10.7.3 Rear Brake Pedal Free Play
- 10.7.4 Rear Brake Pad Inspection

11 SHOCKS AND REAR SWING ARM 
- 11.1 LH Footrest Bracket
- 11.2 Side Stand
- 11.3 Rear Shock Absorber
- 11.4 Rear Swing Arm
- 11.5 Drive Chain
- 11.6 Front Shock Absorber

12 ENGINE ASSEMBLY
- 12.1 Special Tools for Engine Repair
- 12.2 Engine Removal
- 12.2.1 LH/RH Lower Engine Guard Removal
- 12.2.2 Engine Removal
- 12.3 Engine Disassembly
- 12.3.1 Draining Engine Oil
- 12.3.2 Rear LH Cover Removal
- 12.3.3 Gear Shifter Lever Removal
- 12.3.4 Timing Adjustment
- 12.3.5 Starter Motor Removal
- 12.3.6 Starter Dual Gear Removal
- 12.3.7 Magneto Rotor Removal
- 12.3.8 Magneto Stator Removal
- 12.3.9 Gear Sensor Removal
- 12.3.10 Drive Sprocket Removal
- 12.3.11 Oil Filter Removal
- 12.3.12 Clutch Removal
- 12.2.13 Oil Pump Removal
- 12.3.14 Drive Gear and Primary Drive Gear Removal
- 12.3.15 Balance Shaft Nut Removal
- 12.3.16 Timing Chain Tensioner Removal
- 12.3.17 Spark Plug Removal
- 12.3.18 Cylinder Head Cover Removal
- 12.3.19 Cylinder Head Removal
- 12.3.20 Timing Chain Removal
- 12.3.21 Cylinder Body Removal
- 12.3.22 Piston Removal
- 12.3.23 Gearshift Assembly Removal
- 12.3.24 Crankcase Disassembly
- 12.3.25 Transmission Case Removal
- 12.4 Engine Inspection
- 12.4.1 Valve Clearance Adjustment
- 12.4.2 Cylinder Head Cover Assembly Disassembly
- 12.4.3 Cylinder Head Parts Inspection
- 12.4.3.1 Cylinder Head Inspection
- 12.4.3.2 Rocker Arm Shaft Inspection
- 12.4.3.3 Rocker Arm Inspection
- 12.4.4 Cylinder Head Cover Assembly
- 12.4.5 Camshaft Disassembly
- 12.4.6 Camshaft Inspection
- 12.4.6.1 Camshaft Lobe Wear
- 12.4.6.2 Camshaft Journal Bearing Wear
- 12.4.6.3 Camshaft Bearing Wear
- 12.4.7 Camshaft Assembly
- 12.4.8 Cylinder Head Disassembly
- 12.4.9 Cylinder Head Inspection
- 12.4.10 Cylinder Head Assembly
- 12.4.11 Cylinder Body Inspection
- 12.4.11.1 Cylinder Body Deformation
- 12.4.11.2 Cylinder Body Bore Inspection
- 12.4.12 Piston Skirt Inspection
- 12.4.12.1 Piston Skirt Diameter
- 12.4.12.2 Piston Ring Groove Clearance
- 12.4.12.3 Piston Ring Free/Working Gaps
- 12.4.13 Piston Pin Hole and Pin
- 12.4.14 Piston Connecting Rod Assembly Inspection
- 12.4.14.1 Small End Inner Diameter
- 12.4.14.2 Large End Side Clearance
- 12.4.14.3 Crankshaft Runout
- 12.4.14.4 Crankshaft Journal Clearance
- 12.4.15 Balance Shaft Assembly
- 12.4.15.1 Disassembly 
- 12.4.15.2 Inspection
- 12.4.15.3 Assembly
- 12.4.16 Magneto Rotor Inspection
- 12.4.17 Magneto Overriding Clutch
- 12.4.17.1 Magneto Overriding Clutch Disassembly
- 12.4.17.2 Starter Driven Gear Inspection
- 12.4.17.3 Overriding Clutch Inspection
- 12.4.17.4 Overriding Clutch Assembly
- 12.4.18 Dual Gear and Dual Gear Shaft
- 12.4.19 Clutch Parts Inspection
- 12.4.19.1 Primary Driven Gear 
- 12.4.19.2 Primary Drive Gear
- 12.4.19.3 Clutch Friction Discs
- 12.4.19.4 Clutch Driven Discs
- 12.4.19.5 Clutch Springs
- 12.4.19.6 Thrust Bearing and Clutch Bracket
- 12.4.20 Gearshift Assembly
- 12.4.21 Main Shaft Assembly
- 12.4.22 Gearshift Rod Inspection
- 12.4.22.1 Gearshift Position Spring
- 12.4.22.2 Gearshift Cam Position Assembly
- 12.4.23 Crankcase Parts Inspection
- 12.4.24 Tensioner Inspection
- 12.4.25 Speed Sensor Inspection
- 12.4.26 Magneto Stator Inspection
- 12.5 Engine Assembly
- 12.5.1 Transmission Case Installation
- 12.5.2 Crankshaft and Balance Shaft Installation
- 12.5.3 Crankcase Installation
- 12.5.4 Gearshift Assembly Installation
- 12.5.5 Piston Installation
- 12.5.6 Cylinder Body Installation
- 12.5.7 Magneto Rotor Installation
- 12.5.8 Dual Gear II Installation
- 12.5.9 Magneto Stator Installation
- 12.5.10 Starter Motor Installation
- 12.5.11 Cylinder Head Installation
- 12.5.12 Camshaft Installation
- 12.5.13 Timing Adjustment
- 12.5.14 Cylinder Head Cover Installation
- 12.5.15 Tensioner Installation
- 12.5.16 Clutch Assembly Installation
- 12.5.17 Primary Drive Gear Assembly and Oil Pump Installation
- 12.5.18 Balance Shaft Nut Installation
- 12.5.19 RH Side Cover Installation
- 12.5.20 Oil Filter Installation
- 12.5.21 Engine Drain Bolt Installation
- 12.5.22 Gear Sensor Installation
- 12.5.23 Drive Sprocket Installation
- 12.5.24 Rear LH Cover Installation
- 12.5.25 Gearshift Pedal Lever Installation
- 12.5.26 Screw Plug and Plug Bolt Cover
- 12.6 Engine Installation
- 12.6.1 Engine Installation
- 12.6.2 LH/RH Lower Engine Guard Installation
- 12.7 Air Intake System
- 12.7.1 Throttle Body Removal
- 12.7.2 Throttle Body Inspection
- 12.7.3 Fuel Injector
- 12.7.4 Air Intake Pipe
- 12.7.5 Throttle Body Installation
- 12.8 Lubrication System
- 12.8.1 Engine Oil Volume Inspection
- 12.8.2 Engine Oil Replacement
- 12.8.3 Oil Strainer

13 HANDLEBAR ASSEMBLY
- 13.1 Handlebar Levers
- 13.1.1 Rearview Mirror
- 13.1.2 Handlebar Lever Assemblies
- 13.1.3 Handlebar Clamp
- 13.2 Handlebar Inspection
- 13.2.1 Throttle Cable Free Play
- 13.2.2 Clutch Lever Inspection
- 13.2.3 Handlebar Interference Inspection 

14 TRIPLE CLAMPS
- 14.1 Special Tool
- 14.2 Triple Clamps
- 14.2.1 Upper Triple Clamp
- 14.2.2 Front Fork Pipe and Lower Triple Clamp Assembly

15 STARTING SYSTEM
- 15.1 Starter Relay
- 15.2 Engine Starting Notice

16 CLEANING AND MAINTENANCE
- 16.1 Motorcycle Cleaning
- 16.2 Inspection and Maintenance in Winter 

17 STORAGE
- 17.1 Storing
- 17.2 Motorcycle Use After Storage