KYMCO Venox 250 Bedienungsanleitung

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, an

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. GENERAL INFORMATION

1-1

VENOX 250

ENGINE SERIAL NUMBER/IDENTIFICATION

Location of Engine Serial Numbe

Vehicle Identification Serial Numbe

Location of Fra

e Serial Numbe

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

timin

Exhaust

(1mm) Close 0°

Intake 0.1mm

Valve clearanc

(Cold engine) Exhaust 0.1mm

Idle speed (rpm) 1300±100

Lubrication type Forced

ressure &

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 2.0Tire pressure

²)(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 absorbe

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.

Confir

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.

Sna

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