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5. ENGINE REMOVAL/INSTALLATION

5-5

VENOX250/250i

Remove the gear shift pedal attaching bolt
and the gear shift pedal.
Remove the three left rear crankcase cover
attaching bolts and the cover.

Remove the drive gear attaching bolt.
Remove the drive gear and drive chain.

Remove the three front engine bracket lock
bolts and the left/right engine bracket.
Remove the two lock nuts attaching the
engine rear end.
Forward tilt the engine to remove the upper
bolt.

Torgue:

2.4~3.0kg-m

Remove the engine upper bracket nut and bolt.

Torgue:

3.5~4.5kg-m

Left Rear

Crankcase Cover

Drive Chain

Drive Gear

Bolts

Front Engine
Bracket Bolts

Upper Bracket

Gear Shift Pedal

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Summary of Contents for Venox 250

Page 1: ......

Page 2: ...SERVICE MANUAL Overseas Sales Division Overseas Service Department...

Page 3: ...50 250i By KWANG YANG Motor Co Ltd First Edition Dec 2006 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T10...

Page 4: ...ation 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 disasse...

Page 5: ...AD 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 SU...

Page 6: ...___________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION _____________________...

Page 7: ...1 GENERAL INFORMATION 1 1 VENOX250 250i ENGINE SERIAL NUMBER IDENTIFICATION Location of Frame Serial Number Vehicle Identification Serial Number Location of Engine Serial Number...

Page 8: ...2 5L Cooling Type Air water cooling Air cleaner type Paper element type Fuel capacity 14liter Type CVK Main Jet NO Front 110 Rear 108 Venturi dia mm I 30 equivalent Carburetor Throttle type Butterfly...

Page 9: ...ightening 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 sur...

Page 10: ...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 connect...

Page 11: ...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 con...

Page 12: ...r 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...

Page 13: ...make sure that it is not interfering with any moving or sliding parts When fixing the wire harnesses do not make it contact the parts which will generate high heat Route wire harnesses to avoid sharp...

Page 14: ...contact a sharp edge or corner When rubber protecting cover is used to protect the wire harnesses it shall be installed securely Do not break the sheath of wire If a wire or harness is with a broken s...

Page 15: ...positions When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions Be careful not to drop any parts When rust is foun...

Page 16: ...g symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use the designated engine oil for lubrication Engine Oil Apply grease fo...

Page 17: ...p second No1 0 10 0 25 No2 0 2 0 35 0 5 Connecting rod small end I D 16 013 16 028 16 09 Cylinder bore 58 0 58 015 58 20 Connecting rod big end side clearance 0 09 0 29 Connecting rod big end radial c...

Page 18: ...ke drum I D Rear 160 161 Brake lining thickness Front Rear 5 0 5 0 2 0 2 0 Rear shock absorber spring free length ELECTRICAL EQUIPMENT Venox 250 Capacity 12V8AH Voltage 13 0 13 2V Battery Charging cur...

Page 19: ...pump nut 8 1 8 2 3 Oil sump 6x25 0 8 1 2 Motor assy starter 6x25 0 8 1 2 Holder head FR RR 8x151 3 0 3 4 8x131 8x48 8x65 1 9 2 3 Tension guide pivot 1 8 2 2 Liter assy tension FR RR 6x22 1 0 1 4 Liter...

Page 20: ...0 Rear fork pivot nut 14x1 5 6 0 8 0 Up ENG hanger 10x1 25 3 5 4 5 Front ENG hanger 10x1 25 3 5 4 5 8x1 25 2 4 3 0 Rear ENG hanger 10x1 25 3 5 4 5 Handle nut 12x1 25 5 0 6 0 EXH Muffler bolt 8x1 25 3...

Page 21: ...2 11 12 12 Flywheel holder E021 8 3 8 4 Flywheel puller E042 8 4 Valve wrench E036 2 13 Vacuum CO adjuster E043 2 14 Vacuum gauge E045 2 14 Valve spring compressor E040 6 8 6 9 Piston installer E041 7...

Page 22: ...rts SAE 5W 50 SF 2 Cylinder movable parts SAE 5W 50 SF 3 Drive chain SAE 80 90 4 Kick lever movable parts Grease 5 Front suspension SAE 10W 400cc piece 6 Rear suspension SAE 5W 99cc piece FRAME Apply...

Page 23: ...1 GENERAL INFORMATION 1 17 VENOX250 250i CABLE HARNESS ROUTING Clutch Cable Throttle Cable Front Brake Speedometer Cable Wire Harness...

Page 24: ...1 GENERAL INFORMATION 1 18 VENOX250 250i Throttle Cable Radiator Ignition Coil...

Page 25: ...1 GENERAL INFORMATION 1 19 VENOX250 250i Choke Rod Battery Negative Terminal Battery Positive Terminal A C G Cord Clutch Cable Air Cleaner Starter Relay Spark Plug Rear Stop Switch Regulator Rectifier...

Page 26: ...1 GENERAL INFORMATION 1 20 VENOX250 250i Fuse Battery Starter Relay Horn...

Page 27: ...nder and piston rings Leaking cylinder head gasket Faulty choke control system Leaking intake manifold Incorrect ignition timing Incorrectly adjusted pilot screw Flooded carburetor Throttle valve exce...

Page 28: ...d Mixture too rich turn screw out Mixture too lean turn screw in Symptom Fuel does not reach carburetor Check ignition timing Check carburetor pilot screw adjustment Plug fouled or discolored Check if...

Page 29: ...ENOX250 250i Carburetor not securely tightened Faulty intake manifold gasket Deformed or broken carburetor O ring Inspection Adjustment Symptom No air leak Air leaks Check carburetor insulator rubber...

Page 30: ...ming too advanced Excessive carbon build up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too advanced Inspection Adjustment Symptom Engine speed increases C...

Page 31: ...generator Faulty ignition coil Broken or shorted high tension wire Faulty ignition switch Faulty A C generator Damaged vacuum tube Clogged air vent hole Remove spark plug and install it into spark plu...

Page 32: ...or filter Clean and unclog Cam timing gear aligning marks not aligned Faulty spring Inspection Adjustment Symptom Check carburetor for clogged jets Check fuel tank for fuel supply Correct Incorrect Ch...

Page 33: ...r stuck Signals dim remain on or don t operate Stoplight does not come on Probable Cause Stopped Probable Cause Inspection Adjustment Symptom Not stopped Turn ignition switch OFF Signals operate prope...

Page 34: ...ar tire pressures are normal Steering stem nut too tight Broken steering steel balls Excessive wheel bearing play Bent rim Loose axle nut Misaligned front and rear wheels Bent front fork Steering is h...

Page 35: ...orn brake linings Worn brake cam contacting area on brake shoes Worn brake cam Worn brake drum Worn brake linings Foreign matter on brake linings Rough brake drum contacting area Sluggish or elongated...

Page 36: ...ate Pointer moves Pointer moves Faulty Probable Cause Signals operate properly Pointer does not move Good Pointer does not move Remove fuel unit and check operation of pointer by moving float up and d...

Page 37: ...voltage with ignition switch ON Normal Voltage does not increase Battery has no voltage with ignition switch ON Resistance too high Normal voltage No voltage Start engine and test limit voltage betwe...

Page 38: ...ion coil Inspection Adjustment Symptom Normal Abnormal Normal Abnormal Normal Abnormal Abnormal Weak or no spark Not loose Good spark Loose Normal Abnormal Replace with a new spark plug and inspect ag...

Page 39: ...____________________________________________________ _________________________________________________________________________________________________ INSPECTION ADJUSTMENT ___________________________...

Page 40: ...e play 2 6mm Front brake lever free play 10 20mm Spark plug gap 0 6 0 7mm Rear brake pedal free play 20 30mm Spark plug specification CR8E Brake fluid DOT 4 Valve clearance IN 0 1mm EX 0 1mm Cylinder...

Page 41: ...I Whichever Engine oil strainer R C R C R C R C R Cooling water Clean at every 10000km or once a year I Valve clearance A A A A Carburetor I I I Air Cleaner Replace R at every 20000km Spark plug Clean...

Page 42: ...rake pedal free plays Free Play Rear 20 30mm If the free plays do not fall within the limits adjust by turning the adjusting nuts If the pedal height is unsuitable turning the adjusting nut Measure th...

Page 43: ...row on the brake arm aligns with the reference mark on full application of the rear brake WHEELS TIRES Check the tires for cuts imbedded objects or other damages Check the tire pressure TIRE PRESSURE...

Page 44: ...compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage Recommended Oil SAE 10W Oil Capacity 400cc piece REAR Check the action of the rear shock abso...

Page 45: ...the steering head bearing Torgue Steering stem nut 6 0 8 0kg m CLUTCH Measure the clutch lever free play Free Play 10 20mm When major adjustment is required adjust by turning the adjusting nut on the...

Page 46: ...ar axle nut ELECTRICAL EQUIPMENT SPARK PLUG Remove the spark plug cap and spark plug Check the spark plug for wear fouling and carbon deposits Remove the fouling and carbon deposits with a spark plug...

Page 47: ...TLE OPERATION Check for smooth throttle grip movement in all steering positions Measure the throttle grip free play Free Play 2 6mm When major adjustment is required adjust by turning the adjusting nu...

Page 48: ...oke rod valve for wear fouling and carbon deposits Remove the fouling and carbon deposits LUBRICATION SYSTEM Oil Filter Cleaning Oil Level Check After the engine is stopped for 10 minutes check if the...

Page 49: ...Full capacity 2 5 liter At change with oil filter 2 2 liter At change without oil filter 2 0 liter Oil Filter Screen Replacement Remove the oil filter screen cap Remove the oil filter screen and spri...

Page 50: ...nical seal coolant leakage If the mechanical seal is leaking replace the water pump assy Remove the reserve tank cap and fill to the upper level line with distilled water Press down the reserve tank c...

Page 51: ...e valve fully and crank the engine with the starter motor or kick lever for 7 8 seconds to test the compression Compression 17 2kg cm If the compression is low check for the following Leaky valves Val...

Page 52: ...the engine up to 60 2 Remove the engine protector cover 3 Insert both of vacuum gauges on the both of vacuum holes 4 Check the vacuum value of twin cylinder separately 5 Adjust the differential vacuum...

Page 53: ...o the specified range by turning the throttle stop screw and pilot screw Idle Speed 1300r 100rpm CO density 3 0r 0 5 OTHERS LIGHTS Headlight Adjust the headlight beam by loosening the headlight adjust...

Page 54: ...3 LUBRICATION SYSTEM 3 0 VENOX250 250i 3 LUBRICATION SYSTEM...

Page 55: ..._________________________________________________________________ 3 __________________________________________________________________________________ _________________________________________________...

Page 56: ...rication SPECIFICATIONS Item Standard mm Service Limit mm Inner rotor to outer rotor clearance 0 20 Oil pump Outer rotor to pump body clearance 0 20 Rotor end to pump body clearance 0 015 0 10 0 15 Oi...

Page 57: ...ation and replace if necessary Install the oil filter screen spring and filter screen cap Torque 2 0 3 0kg m Oil Capacity At disassembly 2 5 liter At change without oil filter 2 2 liter At change with...

Page 58: ...olts Remove the clutch lifter and four tension springs Remove the clutch filter rotor lock nut and then remove the washer and clutch filter rotor Remove the clutch center clutch friction disks and pla...

Page 59: ...eler Gauge Feeler Gauge Remove the three oil pump mounting bolts and the oil pump body INSPECTION Measure the pump body to outer rotor clearance Service Limit 0 20mm Measure the inner rotor to outer r...

Page 60: ...rotor into the pump body Insert the pump shaft Pump Cover Install the pump cover Tighten the bolts After installation make sure that the pump shaft rotates freely INSTALLATION The installation sequenc...

Page 61: ...4 FUEL SYSTEM 4 0 VENOX250 250i VENOX 250 CARB 4...

Page 62: ...______________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM _______...

Page 63: ...be removed first to avoid damage Then clean with compressed air x When the motorcycle is not used for over one month drain the residual gasoline from the float chamber to avoid erratic idling and clog...

Page 64: ...Intake air leak Engine idles roughly stalls or runs poorly x Clogged fuel tank cap breather hole x Excessively used choke x Kinked or restricted fuel line x Ignition malfunction x Faulty carburetor R...

Page 65: ...he throttle cable from the carburetor Loosen the carburetor intake manifold band screws and then remove the carburetor Loosen the drain screw to drain the gasoline from the float chamber Remove the ei...

Page 66: ...e needle holder and jet needle INSPECTION Inspect the needle for stepped wear Inspect the vacuum piston for wear or damage Inspect the diaphragm for deterioration and tears Be careful not to damage th...

Page 67: ...clogging FLOAT CHAMBER DISASSEMBLY Remove the four float chamber screws and the float chamber Loosen the float pin screw Remove the float pin float and float valve x Be careful not to damage the diap...

Page 68: ...slow jet needle jet needle jet holder main jet and pilot screw Standard Opening 2r turns x Be careful not to damage the fuel jets and pilot screw x Before removing turn the pilot screw in and careful...

Page 69: ...Check if fuel flows out The valve is operating normally if fuel flows out of the fuel tube when the vacuum is applied The fuel shall stop flowing out when the vacuum pump is disconnected If the fuel...

Page 70: ...rder of removal AIR CLEANER Loosen the air cleaner connecting tube band screw Disconnect the transmission case breather tube from the air cleaner Remove the bolt and air cleaner case The installation...

Page 71: ...5 ENGINE REMOVAL INSTALLATION 5 0 VENOX250 250i 5 3 5 4 5kg m 0 8 1 2kg m 3 5 4 5kg m 2 4 3 0kg m...

Page 72: ...___________________________________________________________________________ __________________________________________________________________________________ _________________________________________...

Page 73: ...he engine installed in the frame Cylinder head valves Section 6 Cylinder piston Section 7 Starter motor generator left crankcase cover starter clutch camshaft Section 8 Clutch gear shift mechanism Sec...

Page 74: ...the hardness wire Disconnect the A C generator and starter motor wire coupler Loosen the air cleaner connecting tube band bolt Remove the carburetor Remove the spark plug cap Remove the two exhaust m...

Page 75: ...50 250i Remove the exhaust muffler brace lock bolt Torgue 3 0 3 6kg m Remove the exhaust muffler hanger lock bolt Remove the exhaust muffler Torgue 3 0 3 6kg m Disconnect the clutch cable Remove the c...

Page 76: ...lt Remove the drive gear and drive chain Remove the three front engine bracket lock bolts and the left right engine bracket Remove the two lock nuts attaching the engine rear end Forward tilt the engi...

Page 77: ...th a jack or other adjustable support Lower Bracket Nut x When installing the engine do not damage the bolt threads and route the wires and cables properly x Install the gear shift pedal by aligning t...

Page 78: ...6 CYLINDER HEAD VALVES 6 0 VENOX250 250i 6 VENOX 250 1 0 1 4kg m 1 0 1 4kg m...

Page 79: ...6 CYLINDER HEAD VALVES 6 1 VENOX250 250i VENOX 250 i...

Page 80: ...________ __________________________________________________________________________________ __________________________________________________________________________________ 6 CYLINDER HEAD VALVES __...

Page 81: ...ead and holder need to be replaced if anyone broken SPECIFICATIONS Standard mm Service Limit mm Item VENOX250 VENOX250 IN 0 1mm Valve clearance cold EX 0 1mm Compression pressure kg cm 17 2 Cylinder h...

Page 82: ...guide x Damaged valve stem seal Compression too low x Incorrect valve clearance too small x Burned or bend valves Abnormal noise x Incorrect valve timing x Incorrect valve clearance too large x Broke...

Page 83: ...E TABLE 1 2 3 4 5 6 7 8 9 10 11 12 13 BF 8 131 BF 8 71 BF 8 151 washer BF 8 131 BF 8 48 1st Tightening 1 8 1 8 1 8 1 8 1 2 1 2 1 2 1 2 1 2 2nd Tightening 3 4 3 4 3 4 3 4 2 3 2 3 2 3 2 3 2 3 3rd Tighte...

Page 84: ...emove the cam chain tensioner cap screw and the O ring Turn the cam chain tensioner screw clockwise to tighten it Torgue 0 35 0 5kg m Remove the twelve camshaft holder bolts Bolts Tensioner Screw FR R...

Page 85: ...e Limits Front IN 34 40mm replace if below EX 34 40mm replace if below Rear IN 34 40mm replace if below EX 34 40mm replace if below Check each camshaft for wear or damage Measure the camshaft height S...

Page 86: ...S DISASSEMBLY Remove the rocker arm shafts Remove the rocker arm Check the rocker arm shafts washer and O ring for damage or deformation and replace with a new one if necessary Measure the I D of each...

Page 87: ...pring Compressor Inspect the top of the cylinder head for plane surface Service Limits 0 1mm repair or replace if over VALVE SPRING FREE LENGTH Measure the free length of the inner and outer valve spr...

Page 88: ...il and insert the valves into the valve guides Apply engine oil to the valve stem seals and install them into the valve guides Install the valve spring seats washers inner and outer springs and retain...

Page 89: ...3 times to firmly seat the cotters ROCKER ARMS INSTALLATION Install the rocker arm shafts bolt and the rocker arm Lock the rocker arm shafts bolt CYLINDER HEAD INSTALLATION Install the cylinder head i...

Page 90: ...7 CRANKSHAFT PISTON CYLINDER 7 0 VENOX250 250i 7 2 4kg m 2 4kg m...

Page 91: ..._ __________________________________________________________________________________ __________________________________________________________________________________ CRANKSHAFT PISTON CYLINDER _____...

Page 92: ...iston piston ring Piston pin hole I D 16 0 16 006 16 012 Piston pin O D 15 994 15 997 15 90 Piston to piston pin clearance 0 001 0 007 0 01 Connecting rod small end I D 16 013 16 028 16 032 Connecting...

Page 93: ...ht crankcase cover clutch x Clutch gear shift mechanism Remove the six attaching bolts on the upper crankcase Remove the eleven attaching bolts on the lower crankcase Separate the upper and lower cran...

Page 94: ...250i CRANKSHAFT REMOVAL Remove the four attaching nut on the connecting rod cap Remove the connecting rod cap Torgue 2 4kg m Remove the crankshaft INSPECTION Measure the crankshaft runout Service Lim...

Page 95: ...n piston pin and piston rings Remove the piston rings Remove carbon deposits from the piston ring grooves Install the piston rings onto the piston and measure the piston ring to groove clearance Servi...

Page 96: ...ce Limit 0 01mm replace if over PISTON INSTALLATION Piston Ring Installation First install the third ring side rail onto the piston and then install the oil ring side rail second ring and the top ring...

Page 97: ...repair or replace if over The true roundness is the difference between the values measured in X and Y directions The cylindricity difference between the values measured at the three levels in X or Y d...

Page 98: ...g end is installed Apply engine oil to the plate bearing on the connecting rod Install the piston and connecting rod into the cylinder with a piston installer Piston installer Crank Pin Mark Press the...

Page 99: ...installing the upper and lower crankcase Apply engine oil to the plate bearing on the crankcase Measure the axle clearance between the crank and crankcase Standard 0 30mm replace if over Put the pisto...

Page 100: ...7 CRANKSHAFT PISTON CYLINDER 7 10 VENOX250 250i INSTALLATION Install other removed parts in the reverse of order of removal Piston...

Page 101: ...8 GENERATOR LEFT CRANK CASE COVER 8 0 VENOX250 250i 8 VENOX 250 0 8 1 2kg 7 5 8 5kg VENOX 250i...

Page 102: ...____________________________________________________ __________________________________________________________________________________ ________________________________________________________________...

Page 103: ...ve in the flywheel with the key on the crankshaft TORQUE VALUE Flywheel nut 7 5 8 5kg m SPECIAL TOOLS Flywheel holder Flywheel puller TROUBLESHOOTING Hard starting Poor performance at high speed x Imp...

Page 104: ...the A C generator and starter motor wire coupler Remove the seven left crankcase cover bolts Remove the left crankcase cover and two dowel pins Clean off all gasket material from the left crankcase co...

Page 105: ...heel holder and tighten the flywheel lock bolt Torque 7 5 8 5kg m Flywheel Holder Flywheel Puller LEFT CRANKCASE COVER INSTALLATION Install the left crankcase cover and tighten the seven bolts Torque...

Page 106: ...9 CLUTCH GEAR SHIFT MECHANISM 9 0 VENOX250 250i 9 0 8 1 2kg 5 5 6 5kg 7 5 8 5kg 1 8 2 5kg...

Page 107: ..._______________________________________________ __________________________________________________________________________________9 ____________________________________________________________________...

Page 108: ...ree length 32 30 31 0 Clutch friction disk thickness 3 7 3 8 3 4 Clutch plate bending 0 0 05 0 1 Clutch outer I D 46 2 46 3 46 5 Flange starter clutch O D 27 95 27 97 27 80 O D 28 970 28 990 28 80 Oil...

Page 109: ...ure on clutch lever x Excessive free play x Kinked twisted or damaged clutch cable x Bent clutch plate x Damaged clutch lifter Improper shifting Clutch does not operate smoothly x Excessive clutch lev...

Page 110: ...taching bolts and right crankcase cover Remove the right crankcase cover ONE WAY CLUTCH REMOVAL Remove the one way clutch mounting bolt and one way clutch Torque 7 5 8 5kg m INSPECTION Measure the fla...

Page 111: ...vice Limit O D 42 0mm replace if over I D 32 20mm replace if below Remove the one way clutch rollers plungers and springs Check the one way clutch bearing for smooth turning Replace a new needle beari...

Page 112: ...ank mark CLUTCH REMOVAL Remove the four clutch lifter bolts Remove the clutch lifter and four tension springs Torque 0 8 1 2kg m Remove the one way clutch mounting bolt and the clutch Torque 5 5 6 5kg...

Page 113: ...he washer clutch outer INSPECTION CLUTCH TENSION SPRING Measure each clutch tension spring free length Service Limit 31 0mm replace if below CLUTCH FRICTION DISK Measure each clutch friction disk thic...

Page 114: ...friction disks Measure the clutch outer I D Service Limit 46 5mm replace if OVER OIL PUMP DRIVE SPROCKET BUSH Measure the oil pump drive bush I D and O D Service Limits I D 22 20mm replace if over O...

Page 115: ...10 TRANSMISSION SYSTEM 10 0 VENOX250 250i 10...

Page 116: ..._________________________________________________________ __________________________________________________________________________________ ___________________________________________________________...

Page 117: ...5 0 Transmission fork Shaft hole I D 12 12 013 12 053 Transmission fork shaft O D 11 96 11 98 11 92 Left 11 966 11 984 11 926 Transmission drum O D Right 24 95 24 97 24 90 Main shaft 4th gear 25 020...

Page 118: ...ring x Worn transmission bearings Transmission gear tripping x Worn gear teeth x Bent transmission fork x Bent transmission fork shaft x Damaged gear shift cam stopper Hard shifting x Improperly adjus...

Page 119: ...emove the gear shift pedal Remove the two water pump attaching bolts and remove the water pump Remove the three gear shift mechanism cover attaching bolts Remove the gear shift mechanism cover Remove...

Page 120: ...r change shape Check the change cover bearing for damage slack or change shape INSTALLATION The installation sequence is the reverse of removal CRANKCASE REMOVAL The following parts must be removed be...

Page 121: ...upper and lower crankcase halves Slightly tap the crankcase to separate the crankcase halves using a plastic hammer Remove the main counter shaft ball bearing clip TRANSMISSION SYSTEM REMOVAL Remove...

Page 122: ...Check the transmission fork shaft for bending or damage Measure the transmission fork shaft O D Service Limit 11 92mm replace if below Inspect the transmission drum for scratches or poor lubrication...

Page 123: ...each gear and gear teeth for wear damage or poor lubrication Measure each gear I D Service Limits Main shaft 4th gear25 081mm replace if over Main shaft 5th gear25 081mm replace if over Countershaft...

Page 124: ...27 927mm replace if below MAIN SHAFT COUNTERSHAFT INSPECTION Inspect the main shaft and countershaft for wear or damage Measure the main shaft and countershaft O D Service Limits MAIN SHAFT 4th gear...

Page 125: ...to the shaft using a bearing driver Bearing Remover MAIN SHAFT COUNTERSHAFT INSTALLATION Apply engine oil to the main shaft countershaft before installation Align the hole on the collar with the hole...

Page 126: ...10 TRANSMISSION SYSTEM 10 11 VENOX250 250i INSTALLATION The installation sequence is the reverse of removal...

Page 127: ...11 COOLING SYSTEM 11 0 VENOX250 250i SCHEMATIC DRAWING 0 8 1 2kg m...

Page 128: ...___________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM...

Page 129: ...g the system check for leaks with a cooling system tester TORQUE VALUES Water pump cover bolt 0 8 1 2 kg m Water bleeding bolt 0 8 1 2 kg m TROUBLESHOOTING Engine temperature too high Coolant leaks x...

Page 130: ...035 1 034 1 033 1 031 1 029 1 027 1 025 1 023 1 021 1 019 25 1 045 1 044 1 043 1 042 1 040 1 038 1 036 1 034 1 031 1 028 1 025 30 1 053 1 051 1 051 1 049 1 047 1 045 1 043 1 041 1 038 1 035 1 032 35 1...

Page 131: ...nts and seams for leaks Blow dirt out from between core fins with compressed air If insects etc are clogging the radiator wash them off Carefully straighten any bent fins RADIATOR REMOVAL Drain the co...

Page 132: ...iator Disconnect the thermostatic switch wire coupler Disconnect the fan motor wire coupler Remove the two bolts on the radiator RADIATOR DISASSEMBLY Remove the three bolts and then remove the fan shr...

Page 133: ...on sequence is the reverse of removal Connect the overflow tube and secure with the tube clamp Connect the air vent tube to the radiator filler Fill the radiator with coolant After installation check...

Page 134: ...the three bolts and the water pump cover gasket and two dowel pins WATER PUMP INSTALLATION Install the dowel pins and a new gasket and then install the water pump assembly into the lower crankcase Tig...

Page 135: ...ERMOSENSOR INSTALLATION Apply 3 BOND No 1212 sealant or equivalent to the thermosensor threads and install it into the thermostat housing Connect the thermosensor wire Fill the radiator with coolant T...

Page 136: ...burner and gradually raise the water temperature to check its operation Technical Data Begins to open 80r 2 Full open 90 Valve lift 3 5 4 5mm Bolts Thermostat Thermostat Thermostat Thermometer x Do no...

Page 137: ...10 VENOX250 250i THERMOSTAT INSTALLATION The installation sequence is the reverse of removal Fill the radiator system with the specified coolant Replace the O ring with a new one and apply sealant to...

Page 138: ...12 FRONT WHEEL SUSPENSION STEERING 12 0 VENOX250 250i 12 6 0 8 0kg m 2 4 3 0kg m 0 15 0 25kg m 1 7 2 1kg m 6 0 8 0kg m...

Page 139: ..._____________________________________________________ __________________________________________________________________________________ _______________________________________________________________...

Page 140: ...Item Standard mm Service Limit mm Front axle shaft runout 0 2 Axial 2 0 Front wheel rim runout Radial 2 0 Front fork spring free length 334 5 Front fork tube runout 0 2 Front fork oil capacity 400cc...

Page 141: ...rbers x Bent front fork x Bent front axle or uneven tire Front wheel wobbling x Improperly tightened axle nut x Bent rim x Worn front wheel bearing x Faulty tire Soft suspension x Weak fork springs x...

Page 142: ...le from the throttle grip and then remove the throttle pipe from the handlebar Remove the two master cylinder holder bolts and the master cylinder Remove the two left handlebar switch housing screws a...

Page 143: ...ndlebar First tighten the front bolts and then the rear bolts Torque 1 7 2 1kg m When installing the right and left handlebar switch housings Tighten the two switch housing screws When installing the...

Page 144: ...aligning the pin on the housing with the punch hole in the handlebar Then tighten the two screws FRONT WHEEL REMOVAL Place a jack or other adjustable support under the engine to raise the front wheel...

Page 145: ...its Axial 2 0mm replace if over Radial 2 0mm replace if over Check the wheel spoke wires for looseness If the wheel rim is made of aluminum alloy replace with a new one if necessary Check the wheel be...

Page 146: ...he brake disk Drive out the wheel bearings and distance collar Bearing remover ASSEMBLY Pack all bearing cavities with grease First drive in the right bearing and then install the distance collar Fina...

Page 147: ...eal and install it Install the speedometer gearbox by aligning the tabs with the grooves Apply grease to the speedometer gearbox and dust seal then install them to the wheel from the left side Install...

Page 148: ...0 8 0kg m Connect the speedometer cable and secure it with the screw Bolts Front Fender FRONT FORK REMOVAL Remove the front wheel Remove the four front fender bolts and the front fender Remove the fro...

Page 149: ...n remove the right and left front forks INSTALLATION The installation sequence is the reverse of removal STEERING STEM REMOVAL Remove the handlebar Remove the front fork tubes Remove the steering stem...

Page 150: ...ll the top cone race and the steering head nut Tighten the steering head nut until it seats against the top cone race then turn it back 1 4 turn Steering stem wrench Torque 0 15 0 25kg m Install the f...

Page 151: ...12 FRONT WHEEL SUSPENSION STEERING 12 13 VENOX250 250i...

Page 152: ...13 REAR WHEEL BRAKE SUSPENSION 13 0 VENOX250 250i 13 3 5 4 5kg m 2 4 3 0kg m 0 8 1 2kg m 3 5 4 5kg m 6 0 8 0kg m 3 0 4 0kg m 8 0 10 0kg m...

Page 153: ...___________________________________________ __________________________________________________________________________________ _________________________________________________________________________...

Page 154: ...e chain is adjusted make sure that the rear brake pedal free play is normal and adjust it if necessary SPECIFICATIONS Item Standard mm Service Limit mm Rear axle shaft runout 0 2 Axial 2 0 Rear rim ru...

Page 155: ...gs x Faulty tire x Worn brake cam x Improperly tightened axle nut x Worn brake drum x Loose rear fork pivot nut x Improperly installed brake linings x Worn brake shoes at cam contacting area Soft susp...

Page 156: ...oose both of the chain adjuster nut Push the rear wheel forward Disconnect the drive chain Remove the rear wheel INSPECTION Set the rear axle in V blocks and measure the runout with a dial gauge Servi...

Page 157: ...emove the side collar and dust seal from the left side of the rear wheel Remove the five drive chain gear lock nuts Remove the drive chain gear Check the damping bushings for damage Drive out the whee...

Page 158: ...side collar INSTALLATION Install the rear wheel in the reverse order of removal Drive Chain Slack 10 20mm Torque 8 0 10 0kg m REAR BRAKE REMOVAL Remove the rear wheel and rear brake panel INSPECTION...

Page 159: ...prings and brake shoes Remove the brake arm bolt to remove the brake arm Remove the dust seal Remove the brake cam ASSEMBLY Brake Springs Brake Cam Brake Arm x Keep grease off the linings because cont...

Page 160: ...e brake cam aligning the mark on the plate with the groove on the brake cam Install the brake arm onto the brake cam aligning the punch mark on the cam with the scribed line on the arm Install and tig...

Page 161: ...AR FORK REMOVAL Remove the rear wheel Remove the rear shock absorbers Remove the rear fork pivot nut to remove the pivot and rear fork Remove the drive chain slider and check for wear or damage INSTAL...

Page 162: ...ight rear stop light and taillight wires Remove the right and left side cover bolts and then remove the two upper lock bolts to remove the rear fender INSTALLATION Install the rear fender in the rever...

Page 163: ...14 HYDRAULIC BRAKE 14 0 VENOX250 250i 14 2 4 3 0kg 3 0 4 0kg 0 8 1 2kg...

Page 164: ...____________________ ________________ ________________________________________________ ________________ ________________________________________________ ________________ HYDRAULIC BRAKE ______________...

Page 165: ...riding x Brake fluid will damage painted coated surfaces and plastic parts When working with brake fluid use towel to cover and protect painted rubber and plastic parts Wipe off any splash of brake fl...

Page 166: ...e lever x Seized piston x Clogged hydraulic brake system x Smooth or worn brake pad Hard braking x Seized hydraulic brake system x Seized piston Poor brake performance x Contaminated brake pad surface...

Page 167: ...t until there is no air bubbles in the hose Then tighten the bleed valve nut Recommended Brake Fluid DOT 4 BRAKE SYSTEM BLEEDING Connect a transparent hose to the bleed valve and fully apply the brake...

Page 168: ...the brake pad pin bolt and then remove the pad pin bolt and brake pads Remove the brake pads and springs ASSEMBLY Assemble the brake pads in the reverse order of removal Tighten the pad pin bolt Tight...

Page 169: ...der holder bolts and remove the master cylinder DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder Remove the washer main piston and spring from the brake master c...

Page 170: ...D Service Limit 12 64mm replace if below ASSEMBLY Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup Install the main piston and snap ring Insta...

Page 171: ...id tube with the bolt and two sealing washers Then install the rearview mirror Fill the brake reservoir with recommended brake fluid to the upper level Bleed air from the hydraulic brake system Refer...

Page 172: ...wel under the caliper to avoid contamination caused by the removed pistons Push the piston oil seals inward to remove them Clean each oil seal groove with brake fluid INSPECTION Check each piston for...

Page 173: ...ssive brake fluid with a clean towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the brake caliper onto the right front fo...

Page 174: ...______________________________________________________________ __________________________________________________________________________________ ______________________________________________________...

Page 175: ...15 IGNITION SYSTEM 15 1 VENOX250 250i CDI Battery Ignition Switch Pulser Coil Ignition Coil...

Page 176: ...k each connector before operation x Check the spark plug heat range Use of spark plug with improper heat range is the main cause of poor engine performance or burned engine x Perform inspections accor...

Page 177: ...n or shorted wire Between pulser coil CDI unit and ignition coil Between exciter coil and CDI unit Between CDI unit and ignition coil Between CDI unit and ignition switch Between ignition coil and spa...

Page 178: ...sure the resistance between the ignition coil primary wire terminals Resistance 3 57 4 83 Measure the secondary coil resistance between the spark plug wire and the primary coil terminal Resistance 14...

Page 179: ...ied tester Use of an improper tester or measurements in an improper range may give false readings Picture A Picture B Item Terminal Standard Remark Continuity from ignition switch to CDI unit Black wh...

Page 180: ...SYSTEM 15 6 VENOX250 250i PULSER COIL INSPECTION Disconnect the pulser coil wire coupler and measure the resistance between the blue yellow and green white wire terminals Resistance 396 594 Picture C...

Page 181: ...________________________________________________ __________________________________________________________________________________ ____________________________________________________________________...

Page 182: ...16 CHARGING SYSTEM 16 1 VENOX250 250i REG REC Ignition Switch ACG...

Page 183: ...stem wires properly to avoid short current due to wires being twisted or kinked SPECIFICATIONS VENOX 250 Battery capacity 12V8AH Electrolyte specific gravity 1 32 Battery Charging current Less than 0...

Page 184: ...power x Weak battery x Loose battery connection terminal x Charging system failure x Faulty regulator rectifier Intermittent power x Loose battery cable connection x Loose charging system connection x...

Page 185: ...e Connect the charger negative cable to the battery negative cable CHARGING METHOD Standard Charging Less than 0 9A 5 10hr Do not quick charge the battery Quick charging should only be done in an emer...

Page 186: ...generator INSPECTION Disconnect the A C generator connector Check the continuity between the yellow wires There should be continuity between the yellow wires and no continuity between each yellow wire...

Page 187: ...ier wire coupler Check the continuity between the wire terminals Normal Direction Continuity Probe Probe I Yellow Green II Red White Yellow Reverse Direction No Continuity Probe Probe I Green Yellow I...

Page 188: ...____________________________________________________ __________________________________________________________________________________ ________________________________________________________________...

Page 189: ...17 STARTING SYSTEM 17 1 Engine Stop Switch Clutch Diode Neutral Switch Side Stand Switch Starter Motor...

Page 190: ...f power x Fuse burned out x Weak battery x Weak battery x Loose wire or connection x Faulty ignition switch x Foreign matter stuck in starter motor or gear x Faulty starter switch x Faulty starter rel...

Page 191: ...by slightly turning it left and right Tighten the two starter motor mounting bolts Install the starter motor cable screw After installation check the starter motor for proper operation Before removin...

Page 192: ...osition is up x Check if is neutral position If not directly apply the clutch lever and push the starter switch Connect a 12V battery across the starter relay yellow red and green red wire terminals C...

Page 193: ..._________________________________________________________________________________ __________________________________________________________________________________ LIGHTS INSTRUMENT SWITCHES HORN ___...

Page 194: ...r Heating Indicator Light Stoplight Taillight 12V 21 5W Oil Pressure Warning Indicator Light Turn signal light 12V 10W x 4 Fuel Indicator Light Turn signal indicator light 12V 3W Side Stand Switch Ind...

Page 195: ...eadlight bulb and bulb socket Check the bulb for damage and replace with a new one if necessary INSTALLATION Install the headlight in the reverse order of removal INSTRUMENT SPEEDOMETER REMOVAL Remove...

Page 196: ...quence is the reverse of removal STOP LIGHT TAIL LIGHT Remove the two taillight shell screws and the shell Remove the bulb and check the bulb for damage Replace with a new one if necessary Bulb Specif...

Page 197: ...TTON Disconnect the right switch wire coupler Check for continuity between the black white and yellow red wires Color Position Black White Yellow Red FREE PUSH HORN BUTTON Disconnect the left switch w...

Page 198: ...uel gauge and fuel unit wire couplers Connect the fuel gauge green wire with the yellow white wire Turn the ignition switch ON and the fuel gauge is normal if its indicator is light HANDLEBAR SWITCHES...

Page 199: ...e pedal released No continuity TURN SIGNAL SWITCH Disconnect the turn signal switch wire coupler Check for continuity between the turn signal switch wires Color Position Orange Gray Light Blue R L HEA...

Page 200: ...UN DIMMER SWITCH Disconnect the dimmer switch wire coupler Check for continuity between the dimmer switch wires Color Position White Blue Blue White Brown Blue HI LO PASSING FUEL UNIT REMOVAL Remove t...

Page 201: ...nit wire coupler to the wire harness and turn the ignition switch ON Check the fuel indicator for lighting If the fuel indicator isn t light the fuel indicator is faulty and replace it with a new one...

Page 202: ...eck for continuity with the tester probe connected to Yellow Black lead and the probe to Green lead Item Yellow Black probe Green probe OFF When the side stand is up No continuity ON When the side sta...

Page 203: ...does not start check for voltage between the fan motor coupler wire terminals blue green If there is no voltage check for the following x Blown or faulty fuse x Loose terminals or connectors x Shorte...

Page 204: ...__________________________ SYSTEM DIAGRAM 19 01 SERVICE INFORMATION 19 03 SYSTEM LOCATION 1 19 04 SYSTEM LOCATION 2 19 05 TROUBLESHOOTING 19 06 SELF DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL 19 07...

Page 205: ...19 AFI AUTOMATIC FUELINJECTION 19 1 VENOX250 250i VENOX 250i AFI...

Page 206: ...19 AFI AUTOMATIC FUELINJECTION 19 2 VENOX250 250i SYSTEM DIAGRAM...

Page 207: ...ation failure Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been removed Do not damage the throttle...

Page 208: ...19 AFI AUTOMATIC FUELINJECTION 19 4 VENOX250 250i SYSTEM LOCATION 1 TILT SWITCH I S C WATER TEMPERATURE SENSOR IGNTION DRIVER CRANK POSITION SENSOR THROTTLE BODY FUEL INJECTER TPS...

Page 209: ...19 AFI AUTOMATIC FUELINJECTION 19 5 VENOX250 250i SYSTEM LOCATION 2 ECU FUEL PUMP T MAP SENSOR O2 SENSOR MAP SENSOR CRANK POSITION SENSOR...

Page 210: ...Pinched or clogged fuel hose x Faulty fuel pump x Clogged fuel filter x Sticking fuel injector needle x Faulty fuel pump operating system Engine stall hard to start rough idling Poor performance drive...

Page 211: ...ws the codes in the order of lowest number to highest number For example if the indicator blinks once after code off 4 seconds and comes on 4 seconds then blink 2 times two failures have occurred Foll...

Page 212: ...19 AFI AUTOMATIC FUELINJECTION 19 8 VENOX250 250i CELP lamp show as a model Light Dark Light Light Dark THROTTLRE CLOSE Dark KEY ON...

Page 213: ...to confirm whether the error code disappears P0110 11 Air Temperature Sensor Circuit Malfunction 2 z Confirm whether the resistance of the sensor normal z Check whether the output pin position of the...

Page 214: ...sensor according to the part exchanging process to confirm whether the error code disappears P0135 38 O2 Heater Relay Malfunction 2 z Confirm the resistance of the sensor exists open or short circuit...

Page 215: ...n replace the fuel injector according to the part exchanging process to confirm whether the error code disappears P0252 62 Re Fuel Injector Circuit Malfunction 2 z Confirm whether the resistance of th...

Page 216: ...result of above steps is OK and the error code still exists then replace the coil according to the part exchanging process to confirm whether the error code disappears P0351 52 Re Ignition Driver Circ...

Page 217: ...to be full shut normally P0560 10 Battery Voltage Malfunction 1 z Confirm whether the battery voltage is too low or high z Confirm whether the ACG system is abnormal or open circuit occurs z Confirm...

Page 218: ...correct or open circuit occurs the ECU pin 108 z If the check result of above steps is OK and the error code still exists then replace the sensor according to the part exchanging process to confirm wh...

Page 219: ...use a PDA and download diagnostics program Dtool 5 0 or latest version of diagnostics program at KYMCO web site The diagnostic cable can be purchased from KYMCO SELF DIAGNOSTIC PROCEDURES 1 Connect P...

Page 220: ...INJECTION 19 16 VENOX250 250i 5 Turn PDA on and select the word START START PROGRAMS 6 Select the word PROGRAMS 7 Select Dtool 5 0 8 Select OK 9 Select Find ECU then system automatic select ECU Type F...

Page 221: ...NOX250 250i 10 Select SET then select Language Choice you want 10 Select to appear failure codes Picture than Select Load DTC If the problems have been corrected then select Clear DTC to clear failure...

Page 222: ...pressure 101 3 2kpa TPS voltage Idle 0 68 0 05 V Battery voltage 11 8 V Intake air pressure 101 3 2kpa Tilt switch output voltage 5 0 1 V stand Side stand switch ON stand Normal gear switch ON stand...

Page 223: ...00 100 rpm Coolant temperature 80 C check data Battery voltage 12 V Intake air pressure 72 80 5 kpa Coolant temperature ISC motor Duty 15 30 TPS voltage Idle 0 68 0 05 V Repair Adjust Engine Warm up a...

Page 224: ...19 AFI AUTOMATIC FUELINJECTION 19 20 VENOX250 250i PAGE 05 PAGE 04 PAGE 06 PAGE 03...

Page 225: ...19 AFI AUTOMATIC FUELINJECTION 19 21 VENOX250 250i PAGE 07 PAGE 08 PAGE 10 PAGE 09...

Page 226: ...parts check Page 1 Setting Front CO data Up Now data 0 01 Dn Now data 0 01 Q Up Now data 0 05 Q Dn Now data 0 05 Snowing Fr CO Data at now Setting Rear CO data Up Now data 0 01 Dn Now data 0 01 Q Up...

Page 227: ...250 250i Page 2 STEP 3 Adjust measure STEP 2 Start test Your choise STEP 1 Choise Signal data to adjust item 1 Idle Control Adaption 2 Engine Temp Coolant 3 Idle Speed Setpoint 4 Injection Duration Fr...

Page 228: ...CTION 19 24 VENOX250 250i Page 3 STEP 3 Adjust Test Test Open Close STEP 2 Start test Your choise item STEP 1 Choise Parts turning function item check 1 Oil Pump Relay 2 Cooling Fan Relay 3 Engine Che...

Page 229: ...he voltage between the terminals There should be battery voltage for a few seconds If there is battery voltage replace the fuel pump If there is no battery voltage inspect the following Fuse C 10 A Fu...

Page 230: ...eight screws then remove the fuel pump and O ring INSTALLATION Place a new O ring onto fuel tank Install the fuel being careful not to damage the fuel pump wire and make sure fuel connector rearward I...

Page 231: ...ect he 12 V battery to the following fuel cut off relay connector terminals Connection Blue Black Black There should be continuity only when the 12 V battery connected If there is no continuity when t...

Page 232: ...he ignition switch to ON Incline the tilt switch 65 10 degrees to the left or right with the ignition switch turned to ON If you repeat this test first turn the ignition switch to OFF then turn the ig...

Page 233: ...from the frame Installation is in the reverse order of the removal INSPECTION Disconnect and remove the ECU from the frame Do not disconnect or connect the ECU connector during the ignition switch ON...

Page 234: ...r Measure the resistance between 2 pins of the fuel injector connector Standard 11 7 0 6 at 20 C 68 REMOVAL Disconnect the fuel injector connector and from fuel injector Remove the bolt then pull fuel...

Page 235: ...ng Install the new O ring and WTS sensor Tighten the WTS sensor to specified torque Torque 1 2 kgf m 12 N m 8 6 lbf ft Connect the WTS sensor connector Fill the cooling system with the recommended coo...

Page 236: ...nect the O2 O2 HT sensor connector Measure the resistance between each White wire terminals of the O2 O2 HT sensor side connector Standard 7 7 1 2 at 20 C 68 F REMOVAL INSTALLATION Disconnect the O2 O...

Page 237: ...dy is factory pre set do not disassemble it in a way other than shown in this manual Do not loosen or tighten the painted bolts and screws of the throttle body Loosening or tightening them can cause t...

Page 238: ...N 19 34 VENOX250 250i ISC INSPECTION REMOVAL Disconnect the ISC connector Removal the clamp 2 screws then remove the I S C THROTTLE BODY REMOVAL Remove the3 connector Tank inside and tube disconnect t...

Page 239: ...IC FUELINJECTION 19 35 VENOX250 250i Remove the 5 screws inlet pipes clamp Remove STEP as Remove carb is same Remove air clean clamp Remove MAP sensor screw connect pipe Remove ISC sensor clamps conne...

Page 240: ...19 AFI AUTOMATIC FUELINJECTION 19 36 VENOX250 250i T MAP SENSOR REMOVE Remove T MAP sensor connector M4X2 Screws Remove T MAP sensor...

Page 241: ...the side stand up and engine stop switch is at RUN Turn the ignition switch to ON Measure the voltage between the following terminals of the diagnostic tool connector with Terminal Normal Black Green...

Page 242: ...WIRING DIAGRAM VENOX250 250I W R G L Y B White Red Green Blue Yellow Black Gr P Lg Sb O Br Gray Pink Light green Light blue Orange Brown VENOX 250...

Page 243: ...WIRING DIAGRAM VENOX250 250I VENOX 250i...

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