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Venox 250
KYMCO Venox 250 User Manual
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10
.
TRANSMISSION SYSTEM
10-4
VENOX250/250i
GEAR SHIFT MECHANISM REMOVE
Remove 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 the gear shift spindle.
Bolts
Wate
r P
ump
Bolts
Gear Shift Spindle
Cove
r
118
120
Table of Contents
Table of Contents
5
General Information
6
General Information
7
Specifications
8
Service Precautions
9
Service Information
17
Torque Values
19
Special Tools
21
Lubrication Points
22
Cable & Harness Routing
23
2. Inspection/Adjustment
39
Inspection/Adjustment
39
Inspection/Adjustment
40
Service Information
40
Rear Axle Nut
40
Maintenance Schedule
41
Brake System
42
Brake Shoe
43
Wheels/Tires
43
Suspension
44
Clutch
45
Steering Handlebar
45
Drive Chain
46
Spark Plug
46
Ignition Timing
47
Throttle Operation
47
Lubrication System
48
Oil Filter Screen Replacement
49
Cooling System
50
Air Cleaner
51
Valve Clearance
52
3. Lubrication System
55
Lubrication System
55
Lubrication System
56
Service Information
56
Troubleshooting
56
Engine Oil/Oil Filter
57
Oil Pump
58
4. Fuel System
62
Fuel System
63
Service Information
63
Troubleshooting
64
Carburetor Removal
65
Vacuum Chamber
66
Air Cut-Off Valve
67
Float Chamber
67
Auto Fuel Valve
69
Air Cleaner
70
Idle Speed Adjustmemt
70
Engine Removal/Installation
71
Engine Installation
77
6. Cylinder Head/Valves
80
Cylinder Head/Valves
80
Service Information
81
Troubleshooting
82
Cylinder Head Bolts Torque Table
83
Cylinder Head Cover Removal
84
Rocker Arms Disassembly
86
Cylinder Head Assembly
88
Cylinder Head Installation
89
Crankshaft/Piston/Cylinder
90
Crankshaft/Piston/Cylinder 7
91
Crankshaft/Piston/Cylinder
92
Service Information
92
Troubleshooting
92
Crankcase Removal
93
Crankshaft Removal
94
Piston Removal
95
Piston Installation
96
Connecting Rod Bearing Choice
97
Cylinder Inspection
97
Crank Bearing Choice
99
Generator/Left Crank Case Cover
102
Service Information
103
Troubleshooting
103
Left Crankcase Cover/Generator Removal
104
Generator Installation
105
Clutch/Gear Shift Mechanism
106
9. Clutch/Gear Shift Mechanism
107
Clutch/Gear Shift Mechanism
108
Service Information
108
Troubleshooting
109
One Way Clutch Removal
110
Right Crankcase Cover Removal
110
Clutch Removal
112
Transmission System
115
10.Transmission System
116
Service Information
117
Transmission System
117
Troubleshooting
118
Gear Shift Mechanism Removal
119
Crankcase Removal
120
Cooling System
127
11. Cooling System 11
128
Cooling System
129
Service Information
129
Troubleshooting
129
Cooling System Testing
131
Radiator Removal
131
Thermostatic Switch Inspectment
133
Water Pump
134
Thermosensor
135
Thermostat
135
Front Wheel/Suspension/Steering
139
Service Information
140
Troubleshooting
141
Handlebar
142
Master Cylinder Holder
142
Front Wheel
144
Front Fork
148
Steering Stem
149
Rear Wheel/Brake/Suspension
152
. Rear Wheel/Brake/Suspension 13
153
Rear Fork Pivot Nut
155
Rear Wheel
155
Troubleshooting
155
Rear Brake
156
Rear Fork
161
Rear Shock Absorber
161
REAR Fender
162
Hydraulic Brake
163
14. Hydraulic Brake
164
Troubleshooting
166
Brake Fluid Change/Air Bleed
167
Brake Pad/Disk
168
Brake Master Cylinder
169
Brake Caliper
171
15. Ignition System
174
Ignition System
174
Ignition System
176
Service Information
176
Troubleshooting
177
Ignition Coil
178
CDI Unit
179
Pulser Coil
180
16. Charging System
181
Charging System
181
Charging System
183
Service Information
183
Troubleshooting
184
Battery
185
Battery Charging
185
A.C. Generator
186
Regulator/Rectifier
186
17. Starting System 17
188
Starting System
188
Starting System
189
Service Information
190
Troubleshooting
190
Starter Motor
191
Starter Relay
192
Clutch Diode
192
Lights/Instrument/Switches/Horn
193
Service Information
194
Troubleshooting
194
Ignition Switch
196
Stop Light/Tail Light
196
Turn Signal Light
196
Starter Button/Horn Button / Fuel Gauge
197
Handlebar Switches
198
Fuel Unit
200
19. Afi (Automatic Fuel Injection) 19
204
Afi(Automatic Fuel Injection)
204
System Location-2
209
Troubleshooting
210
Self-Diagnostic Procedures Without Diagnostic Tool
211
Self-Diagnostic Procedures Using Diagnostic Tool (Pda)
219
Fuel Pump
229
Fuel Pump Relay
231
Tilt Switch
232
Engine Control Unit (Ecu)
233
Fuel Injector
234
Wts Sensor
235
O2/O2 Ht Sensor
236
Throttle Body/Map/Isc/Tps
237
T-Map Sensor
240
Diagnostic Tool Connector
241
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KYMCO Venox 250 Specifications
General
Brand
KYMCO
Model
Venox 250
Category
Motorcycle
Language
English
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