KYMCO Venox 250 User manual

SERVICE MANUAL
Overseas Sales Division
Overseas Service Department

VENOX 250/250i
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.
T100RB50AA

VENOX 250/250i
PREFACE
This Service Manual describes the technical features and servicing
procedures for the KYMCO VENOX 250/250 i.
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.
＊The information, specifications, and
illustrations included in this manual
may be different from the motorcycle
in case specifications are changed.

VENOX 250/250i
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
AFI(AUTOMATIC FUEL INJECTION) .....................................................19

1. GENERAL INFORMATION
1-0
VENOX250/250i
1
__________________________________________________________________________________ 1
__________________________________________________________________________________
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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
VENOX250/250i
ENGINE SERIAL NUMBER/IDENTIFICATION
Location of Fra
m
e Serial Numbe
r
Vehicle Identification Serial Numbe
r
Location of Engine Serial Numbe
r

1. GENERAL INFORMATION
1-2
VENOX250/250i
SPECIFICATIONS
Model No. RA50AA
Motorcycle name VENOX 250
Overall length (mm) 2325
Overall width (mm) 850
Overall height (mm) 1100
Wheel base (mm) 1600
Engine type 4f
Displacement (cc) 249.4
Fuel type 92/95# nonleaded gasoline
Front wheel 82
Rear wheel 101
Dry weight (kg) Total 183
Front wheel 90
Rear wheel 109
Gross weight(kg) Total 199
Front wheel 120/80-17
Tires Rear wheel 150/80-15
Ground clearance (mm) 150
Starting system Starting motor
Type DOHC
Cylinder arrangement cylinder
Combustion chamber type Semi-sphere
Valve train DOHC-8V
Bore x stroke (mm) 58x 47.2
Compression ratio 11
Compression pressure
(kg/cm²) 17
Max. output (ps/rpm) ---
Max. torque (Kg.m/rpm) ---
Open 4˚
Intake
(mm) Close 35˚
Engine
Open 31˚
Port
timing Exhaust
(mm) Close 0˚
Intake 0.10mm
Valve clearance
(cold) Exhaust 0.10mm
Idle speed (rpm) 1300rpm
Lubrication type Forced pressure &
wet sump
Oil pump type Inner/outer rotor
Oil filter type Wire gauze filter
Lubrication System
Oil capacity 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) I30 equivalent
Carburetor
Throttle type Butterfly type
Type CDI
Ignition timing B.T.D.C10° / 1000rpm
Spark plug NGK-CR8E
Ignition System
Spark plug gap 0.6阡0.7mm
Electrical Equipment
Battery Capacity 12V8AH
Clutch Type Wet multi-disc clutch
Type 5-Speed transmission
Operating method Foot operated
Type International type
1st gear 2.773
2nd gear 1.8
3rd gear 1.375
4th gear 1.111
Transmission Gear
Reduction
ratio
5th gear 0.965
Tire pressure
Front 2.0
Fuel S
y
stem Power Drive S
y
stem
(kg/cm²)(2 riders) Rear 2.25
Left 40q
Turning angle Right 40q
Front Disk brake
Moving Device
Brake system type Rear Drum brake
Front Oil damper spring
Damping Device
Suspension Rear Oil damper spring
Frame type Double cradle
VENOX AFI
Air cleaner type Paper element
Fuel capacity 14 liter
Type FUEL INJECTION
SYSTEM
Fuel System
THROTTL
E BODY
SIZE OFF
BORE(mm)
I32
Type Fully Transistor
Ignition timing B.T.D.C10q/1300rpm
Breaker type 
Spark plug
CR8E
Ignition System
Spark plug gap 0.6阡0.7mm
Electrical Equipment
Battery Capacity 12V8AH

1. GENERAL INFORMATION
1-3
VENOX250/250i
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
VENOX250/250i
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.