Kymco Venox 250 Workshop Service Repair Manual

KYMCO SERVICE MANUAL VENOX 250 KYMCO Overseas Sales Division Overseas Service Department

PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO VENOX 250. In this manual, many illustrations and drawings are used to help servicemen have better understanding. Section 2 contains the service precautions for all operations and troubleshooting stated in this manual. Read them carefully before starting any operation. Section 3 describes the inspection/adjustment procedures, safety rules and service information for each part, starting from periodic maintenance. Sections 4 through 18 give instructions for disassembly, assembly and inspection of engine, chassis frame and electrical equipment. Most sections start with an assembly or system illustration and troubleshooting for the section. The subsequent pages give detailed procedures for the section. KWANG YANG MOTOR CO., LTD. OVERSEAS SALES DIVISION OVERSEAS SERVICE DEPARTMENT MAR 2002 The information, specifications, and illustrations included in this manual may be different from the motorcycle in case specifications are changed. ＊

TABLE OF CONTENTS GENERAL INFORMATION......................................................................... 1 INSPECTION/ADJUSTMENT...................................................................... 2 LUBRICATION SYSTEM ............................................................................. 3 FUEL SYSTEM ............................................................................................... 4 ENGINE REMOVAL/INSTALLATION...................................................... 5 CYLINDER HEAD/VALVES ........................................................................ 6 CRANKSHAFT/PISTON/CYLINDER......................................................... 7 GENERATOR/LEFT CRANK CASE COVER ........................................... 8 CLUTCH/GEAR SHIFT MECHANISM...................................................... 9 TRANSMISSION SYSTEM ...........................................................................10 COOLING SYSTEM ......................................................................................11 FRONT WHEEL/SUSPENSION/STEERING .............................................12 REAR WHEEL/BRAKE/SUSPENSION ......................................................13 HYDRAULIC BRAKE ...................................................................................14 IGNITION SYSTEM ......................................................................................15 CHARGING SYSTEM ...................................................................................16 STARTING SYSTEM .....................................................................................17 LIGHTS/INSTRUMENT/SWITCHES/HORN ............................................18

1. GENERAL INFORMATION 1-0 VENOX 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER/IDENTIFICATION............................. 1- 1 SPECIFICATIONS .............................................................................. 1- 2 SERVICE PRECAUTIONS ................................................................. 1- 3 SERVICE INFORMATION ................................................................ 1-10 TORQUE VALUES ............................................................................. 1-12 SPECIAL TOOLS ................................................................................ 1-14 LUBRICATION POINTS .................................................................... 1-16 WIRING DIAGRAM ........................................................................... 1-17 CABLE & HARNESS ROUTING....................................................... 1-18 TROUBLESHOOTING ....................................................................... 1-22 1

1. GENERAL INFORMATION 1-1 VENOX 250 ENGINE SERIAL NUMBER/IDENTIFICATION Location of Engine Serial Number Vehicle Identification Serial Number Location of Frame Serial Number

1. GENERAL INFORMATION 1-2 VENOX 250 SPECIFICATIONS Motorcycle name & Model No. VENOX 250 Chassis name & Model No. RA50AA Overall length (mm) 2325 Overall width (mm) 840 Overall height (mm) 1080 Wheel base (mm) 1600 Engine type 4 ∞ Displacement (cc) 249.4 Fuel type Nonleaded gasoline Front 80 Rear 95 Dry weight (kg) Total 175 Front 90 Rear 100 Gross weight (kg) Total 190 Front 120/80-17 Tires Rear 150/80-15 Ground clearance (mm) 150 Braking distance (m) <6.9(40km/h) Perform- ance Min. turning radius (m) 2.750 Starting system Self motor Type DOHC8V Cylinder arrangement Twin cylinder Combustion chamber type Dome head Valve arrangement DOHC Bore x stroke (mm) 58.0 x 47.2 Compression ratio 11±0.2 Compression pressure (kg/cm²− rpm) 17±2 Max. output (ps/rpm) 27.5/10500 Max. torque (kg-m/rpm) 2/8500 Open 4° Intake (1mm) Close 35° Engine Open 31° Port timing Exhaust (1mm) Close 0° Intake 0.1mm Valve clearance (Cold engine) Exhaust 0.1mm Idle speed (rpm) 1300±100 Lubrication type Forced pressure & wet sump Oil pump type Inner/outer rotor Oil filter type Wire gauze filter Lubrication System Oil capacity 2.5 liter Cooling Type Air＋water cooling Air cleaner type Paper element Fuel capacity 14 liter Type CVK Main Jet NO Front:112 Rear:108 Venturi dia.(mm) φ30 equivalent Fuel System Carburetor Throttle type Butterfly type Type Fully Transistor Ignition timing B.T.D.C10°/1000rpm Breaker type ⎯ CR8E Spark plug Ignition System Spark plug gap 0.6～0.7mm Electrical Equipment Battery Capacity 12V8AH Clutch Type Wet multi-disc clutch Type 5-speed transmission Operating method Foot operated Type International type 1st gear 2.733 2nd gear 1.8 3rd gear 1.375 4th gear 1.111 Power Drive System Transmission Gear Reduction ratio 5th gear 0.965 Front Caster angle 35° Axle Front 2.0 Tire pressure (kg/cm²)(2 riders) Rear 2.25 Left 40° Turning angle Right 40° Front Disk brake Moving Device Brake system type Rear Drum brake Front Telescopic fork Suspension Rear Telescopic fork Front Oil damper spring Damping Device Shock absorber Rear Oil damper spring

1. GENERAL INFORMATION 1-3 VENOX 250 SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally. Use genuine parts and lubricants. When servicing the motorcycle, be sure to use special tools for removal and installation. After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly.

1. GENERAL INFORMATION 1-4 VENOX 250 Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation. When using a spanner or other tools, make sure not to damage the motorcycle surface. After operation, check all connecting points, fasteners, and lines for proper connection and installation. When connecting the battery, the positive (+) terminal must be connected first. After connection, apply grease to the battery terminals. Terminal caps shall be installed securely.

1. GENERAL INFORMATION 1-5 VENOX 250 If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation. Hold the connector body when connecting or disconnecting it. Do not pull the connector wire. Check if any connector terminal is bending, protruding or loose. Confirm Capacity

1. GENERAL INFORMATION 1-6 VENOX 250 The connector shall be inserted completely. If the double connector has a lock, lock it at the correct position. Check if there is any loose wire. Check the double connector cover for proper coverage and installation. Before connecting a terminal, check for damaged terminal cover or loose negative terminal. Insert the terminal completely. Check the terminal cover for proper coverage. Do not make the terminal cover opening face up. Secure wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wire harnesses. Snapping!

Kymco Venox 250 Workshop Service Repair Manual

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