Page 2 SERVICE MANUAL Overseas Sales Division Overseas Service Department...
Page 3 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...
Page 4 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.
Page 5: Table Of Contents
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...
Page 6: General Information
. GENERAL INFORMATION VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 ................
Page 7: General Information
VENOX250/250i . GENERAL INFORMATION ENGINE SERIAL NUMBER/IDENTIFICATION Location of Frame Serial Number Vehicle Identification Serial Number Location of Engine Serial Number...
Page 8: Specifications
Air cleaner type Paper element type Fuel capacity 14liter Type Model No. RA50AA Main Jet NO Front:110 Rear:108 Motorcycle name VENOX 250 Venturi dia.(mm) 30 equivalent Overall length (mm) 2325 Throttle type Butterfly type Overall width (mm) Type Overall height (mm)
Page 9: Service Precautions
VENOX250/250i . GENERAL INFORMATION 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.
Page 10 . GENERAL INFORMATION 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.
Page 11 VENOX250/250i . GENERAL INFORMATION If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. Confirm Capacity After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation.
Page 12 . GENERAL INFORMATION VENOX250/250i The connector shall be inserted completely. If the double connector has a lock, lock it at the correct position. Snapping 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.
Page 13 VENOX250/250i . GENERAL INFORMATION After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
Page 14 . GENERAL INFORMATION VENOX250/250i Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
Page 15 VENOX250/250i . GENERAL INFORMATION After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
Page 16 . GENERAL INFORMATION VENOX250/250i Symbols: The following 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 for lubrication. Grease : Use special tool.
Page 17: Service Information
VENOX250/250i . GENERAL INFORMATION SERVICE INFORMATION ENGINE Standard (mm) Service Limit (mm) Item Venox 250 Venox 250 Cylinder head warpage 57.975阡57.99 57.81 Piston O.D.(10mm from bottom of piston skirt) 0.01阡0.35 0.35 Cylinder-to- piston clearance 16.000阡16.006 16.06 Piston pin hole I.D.
Page 18 . GENERAL INFORMATION VENOX250/250i FRAME Standard (mm) Service Limit (mm) Item Venox 250 Venox 250 Axle shaft runout 0.3/100mm Radial Front wheel rim runout Axial Front shock absorber spring free length Rear wheel rim runout Brake drum I.D. Rear Brake lining thickness Front/Rear 5.0/5.0...
Page 19: Torque Values
VENOX250/250i . GENERAL INFORMATION TORQUE VALUES ENGINE Item Thread dia.(mm) Torque (kg-m) Remarks Plate oil flowby M5x12 0.8阡1.2 Connect rod nut M7x0.75 2.0阡2.4 Oil drain M12x15 2.0阡3.0 Plate ball brg holder 6x12 0.8阡1.2 Drum gear shift 6x20 0.8阡1.2 hift fork comp 6x12 0.8阡1.2 Sw assy neutral...
Page 20 . GENERAL INFORMATION VENOX250/250i FRAME Item Thread dia.(mm) Torque (kg-m) Remarks 22x1.0 6.0阡8.0 Strg stem nut Thread comp strg head 26x1.0 0.15阡2.5 Back 90° Top bridge 8x1.25 1.7阡2.1 Bottom bridge 10x1.25 2.4阡3.0 Front axle bolt 14x1.5 6.0阡8.0 Rear axle nut 16x1.5 8.0阡10 Front brake caliper...
Page 21: Special Tools
VENOX250/250i . GENERAL INFORMATION SPECIAL TOOLS Tool Name Tool No. Remarks Lock nut socket wrench E046 Lock nut wrench F006 12-11,12-12 Flywheel holder E021 8-3,8-4 Flywheel puller E042 Valve wrench 2-13 E036 Vacuum & CO adjuster E043 2-14 E045 2-14 Vacuum gauge Valve spring compressor E040...
Page 22: Lubrication Points
. GENERAL INFORMATION VENOX250/250i LUBRICATION POINTS ENGINE Lubrication Points Lubricant Remarks Crankcase sliding and movable parts SAE 5W-50 SF Cylinder movable parts SAE 5W-50 SF Drive chain SAE 80~90 Kick lever movable parts Grease Front suspension SAE 10W 400cc/piece Rear suspension SAE 5W 99cc/piece FRAME...
Page 23: Cable & Harness Routing
VENOX250/250i . GENERAL INFORMATION CABLE & HARNESS ROUTING Clutch Cable Throttle Cable Wire Harness Front Brake Speedometer Cable 1-17...
Page 24 . GENERAL INFORMATION VENOX250/250i Throttle Cable Ignition Coil Radiator 1-18...
Page 25 VENOX250/250i . GENERAL INFORMATION Battery Negative Terminal Battery Positive Terminal Choke Rod A.C.G Cord Air Cleaner Regulator/Rectifier Starter Relay Spark Plug Clutch Cable Rear Stop Switch 1-19...
Page 26 . GENERAL INFORMATION VENOX250/250i Fuse Battery Starter Relay Horn 1-20...
Page 27 VENOX250/250i . GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float valve Clogged fuel filter Fuel reaches Fuel does not...
Page 28 . GENERAL INFORMATION VENOX250/250i ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection/Adjustment Symptom Probable Cause Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Fuel does not Fuel reaches Clogged float valve carburetor reach carburetor Clogged fuel filter Remove spark plug Plug not fouled or Plug fouled or...
Page 29 VENOX250/250i . GENERAL INFORMATION Symptom Inspection/Adjustment Probable Cause Check carburetor insulator rubber for air leaks. Carburetor not securely tightened No air leak Air leaks Faulty intake manifold gasket Deformed or broken carburetor O-ring 1-23...
Page 30 . GENERAL INFORMATION VENOX250/250i POOR PERFORMANCE (ENGINE LACKS POWER) Symptom Inspection/Adjustment Probable Cause Start engine and accelerate lightly for observation Clogged air cleaner Poor fuel flow (Restricted) Engine speed Engine speed does not Clogged fuel tank cap breather hole increases increase sufficiently Clogged exhaust muffler Carburetor fuel level too low...
Page 31 VENOX250/250i . GENERAL INFORMATION POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct Incorrect Faulty A.C. generator Check carburetor pilot screw adjustment Mixture too lean (turn screw in) Correctly adjusted Incorrectly adjusted Mixture too rich (turn screw out)
Page 32 . GENERAL INFORMATION VENOX250/250i POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct Incorrect Loose A.C. generator stator Faulty A.C. generator Check valve clearance Improperly adjusted valve clearance Correct Incorrect Worn valve seat Check fuel tank for fuel supply Empty fuel tank...
Page 33 VENOX250/250i . GENERAL INFORMATION STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of stop switch by applying brake Burned out fuse Weak or dead battery Stoplight does not Stoplight comes on Faulty stop switch come on Loose or disconnected connector Check battery circuit Broken or shorted ignition...
Page 34 . GENERAL INFORMATION VENOX250/250i STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) Steering stem nut too tight Steering is heavy Broken steering steel balls Excessive wheel bearing play Front or rear wheel is Bent rim wobbling Loose axle nut...
Page 35 VENOX250/250i . GENERAL INFORMATION POOR SUSPENSION PERFORMANCE Symptom Probable Cause (Front and rear tire pressures are normal) Weak shock spring Suspension is too soft Excessive load Shock damper oil leaking Bent fork tube or damper rod Suspension is too hard Fork slider and tube binding Fork tube and spring binding Suspension is noisy...
Page 36 . GENERAL INFORMATION VENOX250/250i FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals Burned out fuse Weak or dead battery Signals operate Signals dim, remain Faulty ignition switch properly on or don‘t operate Loose or disconnected connector...
Page 37 VENOX250/250i . GENERAL INFORMATION POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage between battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty coil Normal...
Page 38 . GENERAL INFORMATION VENOX250/250i NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Weak or no spark Good spark Faulty old spark plug Check spark plug cap and ignition coil wire for loose connection Loose spark plug cap Not loose...
Page 39: Inspection/Adjustment
. INSPECTION/ADJUSTMENT VENOX250/250i _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ INSPECTION/ADJUSTMENT _________________________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 2- 1 MAINTENANCE SCHEDULE-------------------------------------------- 2- 2 BRAKE SYSTEM ----------------------------------------------------------- 2- 3 BRAKE SHOE --------------------------------------------------------------- 2- 4 WHEELS/TIRES ------------------------------------------------------------ 2- 4 SUSPENSION---------------------------------------------------------------- 2- 5 CLUTCH---------------------------------------------------------------------- 2- 6 DRIVE CHAIN -------------------------------------------------------------- 2- 7 SPARK PLUG---------------------------------------------------------------- 2- 7 IGNITION TIMING--------------------------------------------------------- 2- 8 THROTTLE OPERATION------------------------------------------------- 2- 8...
Page 40: Inspection/Adjustment
. INSPECTION/ADJUSTMENT VENOX250/250i SERVICE INFORMATION GENERAL ！ WARNING Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. Gasoline is extremely flammable and is explosive under some conditions.
Page 41: Maintenance Schedule
. INSPECTION/ADJUSTMENT VENOX250/250i MAINTENANCE SCHEDULE In order to have a safe riding, maintain good performance, prolong the motorcycle service life and reduce pollution, make sure to perform the periodic inspection and maintenance. I: Inspect and clean, lubricate, refill, repair or replace if necessary. A: Adjust C: Clean R: Replace T: Tighten Regular Service Mileage (km) Whichever...
Page 42: Brake System
. INSPECTION/ADJUSTMENT VENOX250/250i BRAKE SYSTEM BRAKE LEVER & PEDAL 《Free Play》 Measure the rear brake pedal free plays. Free Play: Rear: 20阡30mm Adjusting Nut If the free plays do not fall within the limits, adjust by turning the adjusting nuts. Adjusting Nut If the pedal height is unsuitable, turning the adjusting nut.
Page 43: Brake Shoe
Check the tire pressure. ＊ Tire pressure should be checked when the tires are cold. TIRE PRESSURE 1 Rider 2 Riders Front 2.0 kg/cm² 2.0 kg/cm² Rear 2.0 kg/cm² 2.25 kg/cm² TIRE SIZE Model VENOX 250 Item Front 120/80–17 Rear 150/80-15...
Page 44: Suspension
. INSPECTION/ADJUSTMENT VENOX250/250i Check the front and rear axle nuts for looseness. If the axle nuts are loose, tighten them to their specified torques. Torques: Front : 6.0阡8.0kg-m Rear : 8.0阡10.0kg-m Axie Nut “T” Mark SUSPENSION FRONT Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times.
Page 45: Clutch
. INSPECTION/ADJUSTMENT VENOX STEERING HANDLEBAR Check that the control cables do not interfere with handlebar rotation. Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing. Torgue: Steering stem nut: 6.0阡8.0kg-m CLUTCH...
Page 46: Drive Chain
. INSPECTION/ADJUSTMENT VENOX250/250i DRIVE CHAIN Check the drive chain slack. Specified Slack: 10阡20mm Drive Chain Adjustment: Rear Axle Nut First loosen the rear axle nut. Adjust the right and left chain adjusting nuts to align the right and left index marks with the punch marks on the chain adjusters.
Page 47: Ignition Timing
. INSPECTION/ADJUSTMENT VENOX IGNITION TIMING ＊ The CDI ignition timing is not adjustable, a kind of fully transistor ignition. If the timing is incorrect, check the CDI unit, ignition coil and A.C. generator and replace any faulty parts. Remove the ignition timing eye hole cap on the left crankcase cover.
Page 48: Lubrication System
. INSPECTION/ADJUSTMENT VENOX250/250i Lock Nut Adjusting Nut When minor adjustment is required, adjust by turning the adjusting nut on the throttle cable. Choke Rod Check the choke rod operating properly if smoothly or not. Choke Rod Valve Remove the choke rod valve. Check the choke rod valve for wear, fouling and carbon deposits.
Page 49: Oil Filter Screen Replacement
. INSPECTION/ADJUSTMENT VENOX If the oil level is low, add the recommended oil to the proper level. Recommended Oil: SAE 5W-50 API:SF When changing engine oil, be sure to tighten the drain Drain Bolt bolt securely. Check the drain bolt washer for damage. Oil Capacity: Full capacity : 2.5 liter...
Page 50: Cooling System
. INSPECTION/ADJUSTMENT VENOX250/250i Upper Limit COOLING SYSTEM ＊ Place the motorcycle on its main stand on level ground for coolant level check. Check if the coolant level is between the upper and lower limits on the reserve tank. If the coolant level is too low, it means that there are abnormal conditions.
Page 51: Air Cleaner
. INSPECTION/ADJUSTMENT VENOX Screws AIR CLEANER AIR CLEANER REPLACEMENT Remove the right side cover. Remove the air cleaner case cover screws and the cover. Remove the air cleaner element. Check the element and replace it with a new one if it is excessively dirty or damaged.
Page 52: Valve Clearance
. INSPECTION/ADJUSTMENT VENOX250/250i not and operate the step above again. Bolts VALVE CLEARANCE ＊ Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the four cylinder head cover bolts and the cylinder head cover. Front cylinder: Rotate the generator flywheel to bring the camshaft to the top dead center on the compression stroke and align the “T1”...
Page 53 . INSPECTION/ADJUSTMENT VENOX 9.Adjust the CO density of the front/rear carburetor at 3.0±0.5% by turning the pilot screw. 10.Slightly turn the throttle grip for several time again and recheck if the idle speed, vacuum value and CO density is within the specified range. Special Vacuum &...
Page 54 . LUBRICATION SYSTEM VENOX250/250i LUBRICATION SYSTEM...
Page 55: Lubrication System
. LUBRICATION SYSTEM VENOX __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION ..............3-2 TROUBLESHOOTING ............... 3-2 ENGINE OIL/OIL FILTER ..............3-3 OIL PUMP.................... 3-4...
Page 56: Lubrication System
. LUBRICATION SYSTEM VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS The service and maintenance of this section can be accomplished with the engine installed in the frame. Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 57: Engine Oil/Oil Filter
. LUBRICATION SYSTEM VENOX Upper Limit ENGINE OIL/OIL FILTER OIL LEVEL ＊ Place the motorcycle upright on level ground for engine oil level check. Run the engine for 2阡3 minutes and check the oil level after the engine is stopped for 2阡3 minutes. If the level is near the lower limit, fill to the upper limit with the specified engine oil.
Page 58: Oil Pump
. LUBRICATION SYSTEM VENOX250/250i Clutch Cable OIL PUMP REMOVAL 1. Disconnect the clutch cable. 2. Remove the right crankcase cover bolts and right crankcase cover. ＊ When installing, make sure to use a new right crankcase cover gasket. Right Crankcase Cover Bolts Remove the bolt attaching the starter gear.
Page 59 . LUBRICATION SYSTEM VENOX Bolts DISASSEMBLY Remove the three oil pump mounting bolts and the oil pump body. Outer Rotor Feeler Gauge INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.20mm Pump Body Outer Rotor Feeler Gauge Measure the inner rotor-to-outer rotor clearance.
Page 60 . LUBRICATION SYSTEM VENOX250/250i Outer Rotor Pump Shaft ASSEMBLY Install the outer rotor and inner rotor into the pump body. Insert the pump shaft. ＊ Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.
Page 61 . FUEL SYSTEM VENOX250/250i VENOX 250 (CARB)
Page 62 . FUEL SYSTEM VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM __________________________________________________________________________________ SERVICE INFORMATION ..............4- 2 TROUBLESHOOTING ............... 4- 3 CARBURETOR REMOVAL .............. 4- 4 VACUUM CHAMBER................ 4- 5 AIR CUT-OFF VALVE ............... 4- 6 FLOAT CHAMBER ................4- 6 AUTO FUEL VALVE .................
Page 63: Fuel System
. FUEL SYSTEM VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area. Do not bend or twist control cables.
Page 64: Troubleshooting
. FUEL SYSTEM VENOX250/250i TROUBLESHOOTING Engine cranks but won’t start Engine lacks power No fuel in tank Clogged air cleaner No fuel to carburetor Faulty carburetor Cylinder flooded with fuel Faulty ignition system No spark at plug Clogged air cleaner Lean mixture Intake air leak Clogged carburetor fuel jets...
Page 65: Carburetor Removal
. FUEL SYSTEM VENOX250/250i CARBURETOR REMOVAL Screw Remove the seat and fuel tank. Loosen the air cleaner connecting tube band screw. Bolt Remove the five lock bolts. Air Cleaner Remove the carburetor cap. Lock Nut Adjusting Nut Loosen the throttle cable adjusting nut and lock nut, and disconnect the throttle cable from the carburetor.
Page 66: Vacuum Chamber
. FUEL SYSTEM VENOX250/250i Screw VACUUM CHAMBER DISASSEMBLY Remove the four vacuum chamber cover screws and the cover. Vacuum Chamber Cover Spring Remove the spring , vacuum diaphragm and piston. Vacuum Diaphragm Remove the needle holder and jet needle. ＊ Be careful not to damage the vacuum diaphragm.
Page 67: Air Cut-Off Valve
. FUEL SYSTEM VENOX250/250i ASSEMBLY Install the vacuum piston/diaphragm in the carburetor body. Install the spring and then install the vacuum chamber cover. Tighten the four screws. ＊ Be careful not to damage the diaphragm. Hold the vacuum piston while tightening the vacuum chamber cover.
Page 68 . FUEL SYSTEM VENOX250/250i Slow Jet Pilot Screw Needle Jet Remove the main jet, needle jet holder, needle jet, slow jet and pilot screw. ＊ Be careful not to damage the fuel jets and pilot screw. Before removing, turn the pilot screw in and carefully count the number of turns until it seats lightly and then make a note of this.
Page 69: Auto Fuel Valve
. FUEL SYSTEM VENOX250/250i Float Install the float valve, float and float pin. Secure the float pin with the screw. Float Pin Screw Float Level Gauge FLOAT LEVEL INSPECTION ＊ Check the operation of the float valve and float before this inspection. Measure the float level by placing the float level gauge on the float chamber face parallel with the main jet.
Page 70: Air Cleaner
. FUEL SYSTEM VENOX250/250i INSTALLATION Install the fuel tank in the reverse order of removal. AIR CLEANER Bolt 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 sequence is the reverse of removal.
Page 71: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION VENOX250/250i 3.5~4.5kg-m 2.4~3.0kg-m 0.8~1.2kg-m 3.5~4.5kg-m...
Page 72 5. ENGINE REMOVAL/INSTALLATION VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION ..............5- 2 ENGINE REMOVAL ................5- 3 ENGINE INSTALLATION ..............5- 6...
Page 73 . ENGINE REMOVAL/INSTALLATION VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS A engine stand or floor jack is required to support and maneuver the engine. The following parts can be serviced with the 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 (Section 9) SPECIFICATIONS...
Page 74 5. ENGINE REMOVAL/INSTALLATION VENOX250/250i Fuel Tank ENGINE REMOVAL Remove the seat and fuel tank. Remove the left and right side cover. Disconnect the fuel tube from the auto fuel valve. Disconnect the speedometer wire coupler from the hardness wire. Generator Wire Coupler Disconnect the A.C.
Page 75 . ENGINE REMOVAL/INSTALLATION VENOX250/250i Remove the exhaust muffler brace lock bolt. Torgue: 3.0~3.6kg-m Bolt Bolt Remove the exhaust muffler hanger lock bolt. Remove the exhaust muffler. Torgue: 3.0~3.6kg-m Clutch Cable Disconnect the clutch cable. Remove the coolant hose. Hose...
Page 76 5. ENGINE REMOVAL/INSTALLATION VENOX250/250i Left Rear Remove the gear shift pedal attaching bolt Crankcase Cover and the gear shift pedal. Remove the three left rear crankcase cover attaching bolts and the cover. Gear Shift Pedal Drive Chain Remove the drive gear attaching bolt. Remove the drive gear and drive chain.
Page 77: Engine Installation
. ENGINE REMOVAL/INSTALLATION VENOX250/250i Lower Bracket Nut Remove the lower bracket bolt and nut. Tilt the engine to dismount the engine from right side. Torgue: 3.5~4.5kg-m ENGINE INSTALLATION Install the engine in the reverse order of removal. Install the engine to its original position with a jack or other adjustable support.
Page 78 . CYLINDER HEAD/VALVES VENOX250/250i VENOX 250 1.0~1.4kg-m 1.0~1.4kg-m...
Page 79 6. CYLINDER HEAD/VALVES VENOX250/250i VENOX 250 i...
Page 80: Cylinder Head/Valves
. CYLINDER HEAD/VALVES VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SERVICE INFORMATION ..............6- 2 TROUBLESHOOTING ............... 6- 3 CYLINDER HEAD BOLTS TORQUE TABLE ......... 6- 4 CYLINDER HEAD COVER REMOVAL .......... 6- 5 ROCKER ARMS DISASSEMBLY............. 6- 7 CYLINDER HEAD ASSEMBLY ............
Page 81: Service Information
6. CYLINDER HEAD/VALVES VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS When assembling, apply engine oil to the valve guide movable parts, valve arm and camshaft sliding surfaces for initial lubrication. The valve rocker arm is lubricated with engine oil through the cylinder head engine oil passages. Clean and unclog the oil passages before cylinder head assembly.
Page 82: Troubleshooting
. CYLINDER HEAD/VALVES VENOX250/250i TROUBLESHOOTING The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler Compression too low Worn or broken valve stem or valve guide Damaged valve stem seal Compression too low Incorrect valve clearance (too small)
Page 83: Cylinder Head Bolts Torque Table
6. CYLINDER HEAD/VALVES VENOX250/250i CYLINDER HEAD BOLTS TORQUE TORQUE TABLE BF 8*71 BF 8*151（washer） BF 8*48 BF 8*131 BF 8*131 Sequence Torque kgf-m Tightening Tightening Tightening Tightening...
Page 84: Cylinder Head Cover Removal
. CYLINDER HEAD/VALVES VENOX250/250i Bolts CYLINDER HEAD COVER REMOVAL Remove the eight cylinder head cover bolts for twin cylinder cover. Remove the cylinder head cover. Inspect the cylinder head cover O-ring for damage or deterioration and replace if necessary. Torgue: 0.8~1.2kg-m Remove the cam chain tensioner cap screw and the O-ring.
Page 85 6. CYLINDER HEAD/VALVES VENOX250/250i Dowel Pins Remove the camshaft holder and dowel pins. Remove the camshaft gear from the cam Cam Chain chain and remove the camshaft. ＊ Suspend the cam chain with a piece of wire to keep it from falling into the crankcase.
Page 86: Rocker Arms Disassembly
. CYLINDER HEAD/VALVES VENOX250/250i Bolt CYLINDER HEAD REMOVAL Remove the cylinder head bolt. Remove the cylinder head. Rocker Arm ROCKER ARMS DISASSEMBLY Remove the rocker arm shafts. Remove the rocker arm. Rocker Arm Shafts Washer Check the rocker arm shafts washer and O-ring for damage or deformation and replace with a new one if necessary.
Page 87 6. CYLINDER HEAD/VALVES VENOX250/250i Measure the diameter of this column. Service Limits: 9.94mm replace if below CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats, washers and valve stem seals with a valve spring compressor. ＊ Be sure to compress the valve springs with a valve spring compressor.
Page 88: Cylinder Head Assembly
. CYLINDER HEAD/VALVES VENOX250/250i VALVE /VALVE GUIDE Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide. Measure each valve stem O.D. Service Limits: 4.90mm replace if below 4.90mm replace if below Valve Guide Measure each valve guide I.D.
Page 89: Cylinder Head Installation
6. CYLINDER HEAD/VALVES VENOX250/250i Plastic Hammer Tap the valve stems gently with a plastic hammer for 2阡3 times to firmly seat the cotters. ＊ Be careful not to damage the valves. ROCKER ARMS INSTALLATION Install the rocker arm shafts bolt and the rocker arm.
Page 90: Crankshaft/Piston/Cylinder
. CRANKSHAFT/PISTON/CYLINDER VENOX250/250i 2.4kg-m 2.4kg-m...
Page 91 . CRANKSHAFT/PISTON/CYLINDER VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKSHAFT/PISTON/CYLINDER __________________________________________________________________________________ SERVICE INFORMATION ..............7- 1 TROUBLESHOOTING ............... 7- 1 CRANKCASE REMOVAL ..............7- 3 CRANKSHAFT REMOVAL............... 7- 4 PISTON REMOVAL ................7- 5 PISTON INSTALLATION ..............7- 6 CYLINDER INSPECTION..............7- 7 CONNECTING ROD BEARING CHOICE ........
Page 92: Crankshaft/Piston/Cylinder
Both of crankcase need to be replaced if anyone crankcase is damaged. After disassembly, clean the removed parts and dry them with compressed air before inspection. SPECIFICATIONS Standard (mm) Service Limit (mm) Item VENOX 250 VENOX 250 I.D. 58.0阡58.015 58.30 Warpage...
Page 93: Crankcase Removal
. CRANKSHAFT/PISTON/CYLINDER VENOX250/250i Bolts CRANKCASE REMOVAL The following parts must be removed before removing the crankcase: Cylinder head /camshaft. Starter motor/generator/left and right crankcase cover/clutch. Clutch/gear shift mechanism. Remove the six attaching bolts on the upper crankcase. Bolts Remove the eleven attaching bolts on the lower crankcase.
Page 94: Crankshaft Removal
. CRANKSHAFT/PISTON/CYLINDER VENOX250/250i Nuts CRANKSHAFT REMOVAL Remove the four attaching nut on the connecting rod cap. Remove the connecting rod cap. Torgue: 2.4kg-m Crankshaft Remove the crankshaft. INSPECTION Measure the crankshaft runout. Service Limit: 0.1mm replace if over...
Page 95: Piston Removal
. CRANKSHAFT/PISTON/CYLINDER VENOX250/250i Piston/Connecting Rod PISTON REMOVAL Remove the piston/connecting rod. Piston Piston Pin Remove the piston pin clip. Take out the piston pin. Clip INSPECTION Inspect the piston, piston pin and piston rings. Remove the piston rings. ＊ Take care not to damage or break the piston rings during removal.
Page 96: Piston Installation
. CRANKSHAFT/PISTON/CYLINDER VENOX250/250i Insert each piston ring into the cylinder bottom. ＊ Use the piston head to push each piston ring into the cylinder. Measure the piston ring end gap. Service Limit: 0.50mm Measure the piston pin hole I.D. Service Limit: 16.012mm replace if over Measure the piston pin O.D.
Page 97: Cylinder Inspection
. CRANKSHAFT/PISTON/CYLINDER VENOX250/250i CYLINDER INSPECTION Inspect the cylinder bore for wear, scratches or damage. Measure the cylinder I.D. at three levels of top, middle and bottom at 90 to the piston pin (in both X and Y directions). Service Limit: 58.30mm replace if over Measure the cylinder-to-piston clearance and take the maximum figure measured.
Page 98 . CRANKSHAFT/PISTON/CYLINDER VENOX250/250i Crank Pin Mark There is a mark on the connecting rod big end. Connecting Rod Crank Pin Bearing Big End Mark Mark Chose(Color) A(Brown) B(Green) B(Green) C(Yellow) First install the plate bearings before the connecting rod big end is installed. ＊...
Page 99: Crank Bearing Choice
. CRANKSHAFT/PISTON/CYLINDER VENOX250/250i A.C.G. Side Mark CRANK BEARING CHOICE Crankcase Crank Pin Bearing Mark Mark Chose(Color) A(Brown) B(Green) B(Green) C(Yellow) One-Way Side Mark Flange First install the plate bearings before installing the upper and lower crankcase. Apply engine oil to the plate bearing on the crankcase.
Page 100 . CRANKSHAFT/PISTON/CYLINDER VENOX250/250i Piston INSTALLATION Install other removed parts in the reverse of order of removal. 7-10...
Page 101 8. GENERATOR/LEFT CRANK CASE COVER VENOX250/250i VENOX 250 7.5~8.5kg- 0.8~1.2kg- VENOX 250i...
Page 102: Generator/Left Crank Case Cover
8. GENERATOR/LEFT CRANK CASE COVER VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERATOR/LEFT CRANK CASE COVER __________________________________________________________________________________ SERVICE INFORMATION ..............8-2 TROUBLESHOOTING ............... 8-2 LEFT CRANKCASE COVER/GENERATOR REMOVAL....8-3 GENERATOR INSTALLATION............8-4...
Page 103: Service Information
8. GENERATOR/LEFT CRANK CASE COVER VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS The starter motor, generator, left crankcase cover and starter clutch can be serviced in the frame. Do not install the starter clutch forcedly. Install the generator by aligning the groove in the flywheel with the key on the crankshaft. TORQUE VALUE Flywheel nut: 7.5阡8.5kg-m SPECIAL TOOLS...
Page 104: Left Crankcase Cover/Generator Removal
VENOX250/250i 8. GENERATOR/LEFT CRANK CASE COVER Generator Wire Coupler LEFT CRANKCASE COVER/ GENERATOR REMOVAL Remove the seat and fuel tank. Remove the left and right side cover. Disconnect the fuel tube from the auto fuel valve. Disconnect the A.C. generator and starter motor wire coupler.
Page 105: Generator Installation
8. GENERATOR/LEFT CRANK CASE COVER VENOX250/250i Flywheel Puller Install the flywheel puller. Flywheel Remove the flywheel using a flywheel puller. GENERATOR INSTALLATION Groove Install the generator flywheel. Hold the flywheel with a flywheel holder and tighten the flywheel lock bolt. ＊...
Page 106: Clutch/Gear Shift Mechanism
. CLUTCH/GEAR SHIFT MECHANISM VENOX250/250i 1.8~2.5kg- 7.5~8.5kg- 5.5~6.5kg- 0.8~1.2kg-...
Page 107 . CLUTCH/GEAR SHIFT MECHANISM VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CLUTCH/GEAR SHIFT MECHANISM __________________________________________________________________________________ SERVICE INFORMATION ..............9-2 TROUBLESHOOTING ............... 9-3 RIGHT CRANKCASE COVER REMOVAL ........9-4 ONE WAY CLUTCH REMOVAL............9-4 CLUTCH REMOVAL ................. 9-6...
Page 108: Clutch/Gear Shift Mechanism
. CLUTCH/GEAR SHIFT MECHANISM VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS The clutch and gear shift mechanism can be serviced in the frame. Install the clutch plates in the same chamfer direction. Install the thrust washer with the chamfer facing up and the flat facing down. SPECIFICATIONS Item Standard (mm)
Page 109: Troubleshooting
. CLUTCH/GEAR SHIFT MECHANISM VENOX250/250i TROUBLESHOOTING Clutch slips during acceleration Clutch won’t operate and motorcycle moves slowly No free play Worn friction disk Excessive free play Weak spring Bent clutch plate Clutch won’t operate Too much pressure on clutch lever Excessive free play Kinked, twisted or damaged clutch cable Bent clutch plate...
Page 110: Right Crankcase Cover Removal
. CLUTCH/GEAR SHIFT MECHANISM VENOX250/250i Right Crankcase Cover RIGHT CRANKCASE COVER REMOVAL Drain the engine oil. Disconnect the clutch cable. Remove the right crankcase cover attaching bolts and right crankcase cover. Bolts Remove the right crankcase cover. Bolt ONE-WAY CLUTCH REMOVAL Remove the one-way clutch mounting bolt and one-way clutch.
Page 111 . CLUTCH/GEAR SHIFT MECHANISM VENOX250/250i Measure the starter gear shaft O.D. and I.D. Service Limit: O.D. 42.0mm replace if over. I.D. 32.20mm replace if below. One-Way Clutch Remove the one-way clutch rollers, plungers and springs. Bearing Check the one-way clutch bearing for smooth turning.
Page 112: Clutch Removal
. CLUTCH/GEAR SHIFT MECHANISM VENOX250/250i INSTALLATION Install the one-way clutch and starter reduction gear in the reverse order of removal. Align the flange of the one-way clutch with the crank mark. CLUTCH REMOVAL Clutch Lifter Tension Springs Remove the four clutch lifter bolts. Remove the clutch lifter and four tension springs.
Page 113 . CLUTCH/GEAR SHIFT MECHANISM VENOX250/250i Clutch Center Remove the clutch center, clutch friction disks and plates. Remove the washer, clutch outer. Washer Clutch Outer INSPECTION CLUTCH TENSION SPRING Measure each clutch tension spring free length. Service Limit: 31.0mm replace if below CLUTCH FRICTION DISK Clutch Friction Disk Measure each clutch friction disk thickness.
Page 114 . CLUTCH/GEAR SHIFT MECHANISM VENOX250/250i CLUTCH PLATE Measure each clutch plate bending using a feeler gauge. Service Limit: 0.10mm replace if over Feeler Gauge Clutch Plate Clutch Outer CLUTCH OUTER Inspect the clutch outer groove for scratches caused by the friction disks. Measure the clutch outer I.D.
Page 115: Transmission System
.TRANSMISSION SYSTEM VENOX250/250i 10-0...
Page 116 .TRANSMISSION SYSTEM VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ TRANSMISSION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION ..............10- 2 TROUBLESHOOTING ............... 10- 3 GEAR SHIFT MECHANISM REMOVAL......... 10- 4 CRANKCASE REMOVAL ..............10- 5 10-1...
Page 117: Transmission System
.TRANSMISSION SYSTEM VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS During crankcase separation, do not separate the crankcase halves with an iron hammer to avoid crankcase deformation or damage. After separation, be careful not to damage the right and left crankcase mating surfaces to avoid oil leakage.
Page 118: Troubleshooting
.TRANSMISSION SYSTEM VENOX250/250i TROUBLESHOOTING Excessive engine noise Worn main shaft journal bearing Worn crankshaft pin bearing Worn transmission bearings Transmission gear tripping Worn gear teeth Bent transmission fork Bent transmission fork shaft Damaged gear shift cam stopper Hard shifting Improperly adjusted clutch Bent or damaged transmission fork Bent transmission fork shaft Bent gear shift spindle...
Page 119: Gear Shift Mechanism Removal
.TRANSMISSION SYSTEM VENOX250/250i Bolts GEAR SHIFT MECHANISM REMOVE Remove the gear shift pedal. Remove the two water pump attaching bolts and remove the water pump. Water Pump Bolts Remove the three gear shift mechanism cover attaching bolts. Cover Remove the gear shift mechanism cover. Gear Shift Spindle Remove the gear shift spindle.
Page 120: Crankcase Removal
.TRANSMISSION SYSTEM VENOX250/250i Gear Shift Cam Remove the stopper and spring attaching bolts. Remove the gear shift cam bolt. Remove the gear shift cam and set pin. Stopper Spring Ball Bearing Holder Drum Stopper Spring GEAR/SHAFT COLLAR INSPECTION Check the drum stopper and spring for Washer damage, or change shape.
Page 121 .TRANSMISSION SYSTEM VENOX250/250i Bolts Remove the eleven lower crankcase attaching bolts. Separate the upper and lower crankcase halves. Slightly tap the crankcase to separate the crankcase halves using a plastic hammer. Clip Remove the main/counter shaft ball bearing clip. ＊ Be careful not to lose the ball bearing clip.
Page 122 .TRANSMISSION SYSTEM VENOX250/250i Transmission Fork Remove the transmission fork shaft and transmission forks. Remove the transmission drum. Transmission Drum INSPECTION TRANSMISSION FORK/DRUM Inspect each transmission fork for bending or damage. Measure each transmission fork claw thickness. Service Limit: 5.0mm replace if below Measure each transmission fork shaft hole I.D.
Page 123 .TRANSMISSION SYSTEM VENOX250/250i Left Center Right INSTALLATION The installation sequence is the reverse of removal. ＊ Transmission fork make is as follows R(right),C(center),L(left). Main Shaft TRANSMISSION GEARS REMOVAL Remove the transmission main shaft and counter shaft from the upper crankcase. ＊...
Page 124 .TRANSMISSION SYSTEM VENOX250/250i Measure each shaft collar I.D./O.D. Service Limits: Main shaft 4th gear collar I.D.22.081mm replace if over Main shaft 4th gear collar O.D.24.919mm replace if below Main shaft 5th gear collar O.D.24.927mm replace if below Countershaft 1st gear collar I.D.20.081mm replace if over Countershaft 1st gear collar O.D.22.919mm replace if below...
Page 125 .TRANSMISSION SYSTEM VENOX250/250i BEARING REPLACEMENT Remove the main shaft and countershaft bearings from the main shaft and countershaft using a bearing remover. Special Bearing Remover Bearing Remover Drive the new bearing into the shaft using a bearing driver. ＊ The flange of the oil seal should fix in the groove of the upper crankcase.
Page 126 .TRANSMISSION SYSTEM VENOX250/250i INSTALLATION The installation sequence is the reverse of removal. 10-11...
Page 127: Cooling System
. COOLING SYSTEM VENOX250/250i SCHEMATIC DRAWING 0.8~1.2kg-m 11-0...
Page 128 . COOLING SYSTEM VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 11- 2 TROUBLESHOOTING----------------------------------------------------- 11- 2 COOLING SYSTEM TESTING------------------------------------------- 11- 4 RADIATOR REMOVAL --------------------------------------------------- 11- 4 THERMOSTATIC SWITCH INSPECTMENT ------------------------- 11- 6 WATER PUMP -------------------------------------------------------------- 11- 7 THERMOSENSOR---------------------------------------------------------- 11- 8 THERMOSTAT-------------------------------------------------------------- 11- 8 11-1...
Page 129: Cooling System
. COOLING SYSTEM VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS The engine must be cool before servicing the cooling system. When the coolant temperature is over 100℃, never remove the radiator cap to release the pressure because the boiling coolant may cause danger. Avoid spilling coolant on painted surfaces because the coolant will corrode the painted surfaces.
Page 130 . COOLING SYSTEM VENOX250/250i SPECIFICATIONS Radiator cap relief pressure 0.9 0.15kg/cm² Begins to open 80 2℃ Thermostat temperature Full-open 90℃ Valve lift 3.5阡4.5mm Radiator: 560cc Coolant capacity Total system 1030cc Reserve tank: 240cc COOLANT GRAVITY Temp. ℃ Coolant concentration 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.009 0.997 1.018 1.107 1.017 1.016 1.015 1.014 0.013 1.011 1.009 1.007 1.005 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019...
Page 131: Cooling System Testing
. COOLING SYSTEM VENOX250/250i Radiator Tester COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. ＊ Apply water to the cap sealing surface before testing.
Page 132 . COOLING SYSTEM VENOX250/250i Loosen the hose band and disconnect the upper hose from the radiator. Upper Hose Disconnect the thermostatic switch wire Fan Motor Wire Coupler coupler. Disconnect the fan motor wire coupler. Thermostatic Switch Wire Coupler Remove the two bolts on the radiator. Bolts Bolts RADIATOR DISASSEMBLY...
Page 133: Thermostatic Switch Inspectment
. COOLING SYSTEM VENOX250/250i FAN MOTOR INSPECTMENT Check fan motor by battery. THERMOSTATIC SWITCH INSPECTMENT When coolant temperature lower then 90±2 ℃ the thermostatic switch OFF. When coolant temperature over 90±2℃ the thermostatic switch ON. RADIATOR INSTALLATION The installation sequence is the reverse of removal.
Page 134: Water Pump
. COOLING SYSTEM VENOX250/250i WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the water pump. Water Pump Telltale Hole Outlet Cupreous Iron Pipe WATER PUMP REMOVAL Remove the coolant inlet hose and outlet cupreous iron pipe.
Page 135: Thermosensor
. COOLING SYSTEM VENOX250/250i Thermosensor THERMOSENSOR THERMOSENSOR REMOVAL Remove the seat, fuel tank and left/right side cover. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire Thermosensor THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up.
Page 136 . COOLING SYSTEM VENOX250/250i Bolts Remove the two bolts and separate the thermostat housing halves. Torgue: 0.8~1.2 kg-m Thermostat Thermostat Remove the thermostat from the thermostat housing. THERMOSTAT INSPECTION Thermostat Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation.
Page 137 . COOLING SYSTEM VENOX250/250i THERMOSTAT INSTALLATION The installation sequence is the reverse of removal. ＊ Replace the O-ring with a new one and apply sealant to it. Fill the radiator system with the specified coolant. Thermostat Housing 11-10...
Page 138 VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING 6.0~8.0kg-m 1.7~2.1kg-m 0.15~0.25kg-m 2.4~3.0kg-m 6.0~8.0kg-m 12-0...
Page 139: Front Wheel/Suspension/Steering
12. FRONT WHEEL/SUSPENSION/STEERING VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRONT WHEEL/SUSPENSION/STEERING __________________________________________________________________________________ SERVICE INFORMATION ..............12- 2 TROUBLESHOOTING ............... 12- 3 HANDLEBAR..................12- 4 FRONT WHEEL .................. 12- 6 FRONT FORK ..................12-10 STEERING STEM ................12-11 12-1...
Page 140: Service Information
VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION GENERAL INSTRUCTIONS SPECIFICATIONS Item Standard (mm) Service Limit (mm) Front axle shaft runout Axial Front wheel rim runout Radial Front fork spring free length 334.5 Front fork tube runout Front fork oil capacity 400cc/SAE10W SPECIAL TOOLS Steering stem wrench Bearing driver handle...
Page 141: Troubleshooting
VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING Hard steering Insufficient tire pressure Excessively tightened steering stem nut Damaged steering stem bearings Damaged steering stem bearing races Steers to one side or does not track straight Uneven front shock absorbers Bent front fork Bent front axle or uneven tire Front wheel wobbling Improperly tightened axle nut...
Page 142: Handlebar
VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING Throttle Housing HANDLEBAR REMOVAL Remove two screws attaching the throttle housing and the throttle housing. Screws Master Cylinder Throttle Pipe Disconnect the throttle cable from the throttle grip and then remove the throttle pipe from the handlebar. Throttle Cable Bolts Remove the two master cylinder holder...
Page 143 VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING Upper Fork Bridge Remove the four upper fork bridge bolts to remove the handlebar. Bolts INSTALLATION Place the handlebar on the upper fork bridge seat. Install the upper fork bridge set plates onto the handlebar. First tighten the front bolts and then the rear bolts.
Page 144: Front Wheel
VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING THROTTLE PIPE INSTALLATION Clean the handlebar surface and install the throttle pipe. Check the throttle grip for proper operation. Connect the throttle cable to the throttle grip. Apply grease to the throttle cable. Install the throttle housing by aligning the pin on the housing with the punch hole in the handlebar.
Page 145 VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING INSPECTION Set the axle in V blocks and measure the runout. Service Limit: 0.2mm replace if over WHEEL RIM INSPECTION Place the front wheel in a turning stand. Spin the wheel by hand and measure the rim runout by using a dial gauge.
Page 146 VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING Axle Collar Remove the axle collar and dust seal from the right side of the wheel. Remove the dust seal. Bolts Remove the six bolts and the brake disk. Dust Seal Bearing Remover Drive out the wheel bearings and distance collar.
Page 147 VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING Dust Seal Install the brake disk and tighten the six bolts. Apply grease to the dust seal and install it. Brake Disk Groove Install the speedometer gearbox by aligning the tabs with the grooves. Flange Tab Speedometer Gearbox Apply grease to the speedometer gearbox and dust seal, then install them to the wheel...
Page 148: Front Fork
VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING Groove INSTALLATION Install the front wheel onto the front fork, aligning the tab on the front fork with the groove in the speedometer gearbox. Speedometer Cable Insert the axle shaft and tighten the axle nut. Torque: 6.0阡8.0kg-m Connect the speedometer cable and secure it with the screw.
Page 149: Steering Stem
VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING Brake Bolts Remove the two bolts attaching the brake C li caliper holder. Signal Light Upper Fork Remove the two headlight holder screws. Holder Bridge Remove the upper fork bridge mount bolt. Remove the turn signal light holder screw. Remove the lower fork bridge mount bolt and then remove the right and left front forks.
Page 150 VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING BOTTOM CONE RACE REPLACEMENT Drive out the bottom cone race. Drive in a new bottom cone race onto the steering stem. Bottom Cone R ace Top Cone STEERING STEM INSTALLATION Apply grease to the top and bottom ball races and steel balls.
Page 151 VENOX250/250i 12. FRONT WHEEL/SUSPENSION/STEERING 12-13...
Page 152: Rear Wheel/Brake/Suspension
. REAR WHEEL/BRAKE/SUSPENSION VENOX250/250i 3.5~4.5kg-m 8.0~10.0kg-m 0.8~1.2kg-m 3.0~4.0kg-m 6.0~8.0kg-m 2.4~3.0kg-m 3.5~4.5kg-m 13-0...
Page 153 VENOX250/250i . REAR WHEEL/BRAKE/SUSPENSION __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR WHEEL/BRAKE/SUSPENSION __________________________________________________________________________________ SERVICE INFORMATION ..............13- 2 TROUBLESHOOTING ............... 13- 3 REAR WHEEL..................13- 4 REAR BRAKE ..................13- 6 REAR SHOCK ABSORBER............... 13- 9 REAR FORK..................13- 9 REAR Fender ..................13-10 13-1...
Page 154 . REAR WHEEL/BRAKE/SUSPENSION VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS When installing the drive chain joint clip, the cutout of the clip should be opposite to the rotating direction. After the drive chain is adjusted, make sure that the rear brake pedal free play is normal and adjust it if necessary.
Page 155: Troubleshooting
. REAR WHEEL/BRAKE/SUSPENSION VENOX250/250i TROUBLESHOOTING Rear wheel wobbling Poor brake performance Bent rim Improperly adjusted brake Worn rear wheel bearing Worn brake linings Loose or broken wheel spoke wires Contaminated or damaged brake linings Faulty tire Worn brake cam Improperly tightened axle nut Worn brake drum Loose rear fork pivot nut Improperly installed brake linings...
Page 156: Rear Brake
. REAR WHEEL/BRAKE/SUSPENSION VENOX250/250i Rear Brake Panel REAR WHEEL REMOVAL Remove the rear axle nut. Remove the rear brake adjusting nut. Rear Brake Adjusting Nut Rear Axle Nut Remove the rear brake panel fixing arm bolt. Remove the bushing. Remove the rear brake panel. Loose both of the chain adjuster nut.
Page 157 . REAR WHEEL/BRAKE/SUSPENSION VENOX250/250i Check the wheel bearing play by placing the wheel in a turning stand and spinning the wheel by hand. Axial Radial Check the drive chain gear teeth for wear or damage. Replace the drive chain gear if necessary. Replace Good ＊...
Page 158 . REAR WHEEL/BRAKE/SUSPENSION VENOX250/250i ASSEMBLY Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. ＊ Drive in the bearings squarely. Install the bearings with the sealed end facing out. Special Bearing driver handle Attachment,37×40mm...
Page 159 . REAR WHEEL/BRAKE/SUSPENSION VENOX250/250i Measure the brake drum I.D. Service Limit: 161.3mm replace if over DISASSEMBLY Brake Remove the springs and brake shoes. Springs Brake Cam Remove the brake arm bolt to remove the brake arm. Remove the dust seal. Remove the brake cam.
Page 160 . REAR WHEEL/BRAKE/SUSPENSION VENOX250/250i Brake Cam Apply grease to the brake cam and anchor pin, then install the brake cam to the brake panel. Apply engine oil to the dust seal and install it to the brake cam. Install the wear indicator plate on the brake cam, aligning the mark on the plate with the groove on the brake cam.
Page 161: Rear Shock Absorber
. REAR WHEEL/BRAKE/SUSPENSION VENOX250/250i Upper Mount REAR SHOCK ABSORBER REMOVAL/INSTALLATION Remove the shock absorber upper mount nuts and washers and then press down the motorcycle to pull out the shock absorbers. Remove the shock absorber lower mount bolts to remove the rear shock absorbers. INSTALLATION The installation sequence is the reverse of removal.
Page 162: Rear Fender
. REAR WHEEL/BRAKE/SUSPENSION VENOX250/250i REAR FENDER REMOVAL Remove the rear carrier. Rear Fender Disconnect the turn signal light, 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.
Page 163: Hydraulic Brake
. HYDRAULIC BRAKE VENOX250/250i 0.8~1.2kg- 3.0~4.0kg- 2.4~3.0kg- 14-0...
Page 164 . HYDRAULIC BRAKE VENOX250/250i ______________________________________________ ______________ ______________________________________________ ______________ ______________________________________________ ______________ ______________________________________________ ______________ ______________________________________________ ______________ HYDRAULIC BRAKE ______________________________________________ ______________ SERVICE INFORMATION ..............14- 2 TROUBLESHOOTING ............... 14- 3 BRAKE FLUID CHANGE/AIR BLEED..........14- 4 BRAKE PAD/DISK ................14- 5 BRAKE MASTER CYLINDER ............14- 6 BRAKE CALIPER ................
Page 165 . HYDRAULIC BRAKE VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS Drain the brake fluid from the hydraulic brake system before disassembly. Do not allow any foreign matters entering the brake reservoir when filling the brake reservoir with brake fluid. Be careful not to splash brake fluid on any coated surfaces and instrument covers to avoid damage.
Page 166: Troubleshooting
. HYDRAULIC BRAKE VENOX250/250i TROUBLESHOOTING Loose brake lever Air in hydraulic brake system Brake fluid level too low Hydraulic brake system leakage Tight brake lever Seized piston Clogged hydraulic brake system Smooth or worn brake pad Hard braking Seized hydraulic brake system Seized piston Poor brake performance Contaminated brake pad surface...
Page 167: Brake Fluid Change/Air Bleed
. HYDRAULIC BRAKE VENOX250/250i Screws BRAKE FLUID CHANGE/AIR BLEED Place the motorcycle on its main stand on level ground and set the handlebar upright. Remove the two screws attaching the brake fluid reservoir cap. ＊ Use towel to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid.
Page 168: Brake Pad/Disk
. HYDRAULIC BRAKE VENOX250/250i Bolts BRAKE PAD/DISK BRAKE PAD REPLACEMENT Remove the two bolts attaching the brake caliper holder. ＊ The brake pads can be replaced without removing the brake fluid tube. Remove the brake caliper. Remove the brake pad pin bolt and then Brake Caliper remove the pad pin bolt and brake pads.
Page 169: Brake Master Cylinder
. HYDRAULIC BRAKE VENOX250/250i BRAKE DISK Measure the brake disk thickness. Service Limit: 3.0mm Measure the brake disk runout. Service Limit: 0.3mm BRAKE MASTER CYLINDER REMOVAL Drain the brake fluid from the hydraulic Fluid Tube brake system. ＊ Do not splash brake fluid onto any rubber, plastic and coated parts.
Page 170 . HYDRAULIC BRAKE VENOX250/250i INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75mm replace if over Measure the brake master cylinder piston O.D. Service Limit: 12.64mm replace if below ASSEMBLY Before assembly, apply brake fluid to all removed parts.
Page 171: Brake Caliper
. HYDRAULIC BRAKE VENOX250/250i Place the brake master cylinder on the handlebar and install the master cylinder holder with the “UP” mark facing up, aligning the tab on the holder with the hole in the handlebar. First tighten the upper bolt and then tighten the lower bolt.
Page 172 . HYDRAULIC BRAKE VENOX250/250i Compressed Air Remove the pistons from the brake caliper. Use compressed air to press out the pistons through the brake fluid inlet opening and place a towel under the caliper to avoid contamination caused by the removed pistons.
Page 173 . HYDRAULIC BRAKE VENOX250/250i ASSEMBLY Clean all removed parts. Apply silicon grease to the pistons and oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the oil seals and then install the brake caliper pistons with the grooved side facing out.
Page 174: Ignition System
. IGNITION SYSTEM VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION ..............15-2 TROUBLESHOOTING ............... 15-3 IGNITION COIL.................. 15-4 CDI UNIT..................... 15-5 PULSER COIL ..................15-6 15-0...
Page 175 . IGNITION SYSTEM VENOX250/250i Battery Ignition Switch Ignition Coil Pulser Coil 15-1...
Page 176: Ignition System
. IGNITION SYSTEM VENOX250/250i SERVICE INFORMATION GENERAL INSTRUCTIONS Inspect the ignition system according to the sequence specified in the Troubleshooting 15-3. The ignition system has a CPU in the CDI unit, so the ignition timing is not adjustable. Do not drop or impact the CDI unit with strong force to avoid damage. Be careful when removing it.
Page 177: Troubleshooting
. IGNITION SYSTEM VENOX250/250i TROUBLESHOOTING Engine stalls immediately after it starts Weak spark Improper ignition timing Faulty CDI unit No spark at plug Faulty ignition switch Poorly connected, broken 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...
Page 178: Ignition Coil
. IGNITION SYSTEM VENOX250/250i IGNITION COIL Ignition Coil CONTINUITY TEST Disconnect the ignition coil primary wire coupler and measure the resistance between the ignition coil primary wire terminals. Resistance: 3.57 ~4.83 Measure the secondary coil resistance Spark Plug Cap between the spark plug wire and the primary coil terminal.
Page 179: Cdi Unit
. IGNITION SYSTEM VENOX250/250i CDI Unit CDI UNIT INSPECTION Disconnect the CDI unit coupler. Check for continuity with the coupler on the hardness wire side and CDI unit. Inspection table is as follows. ＊ The CDI unit is fully transistorized. For accurate testing, it is necessary to use a specified tester.
Page 180: Pulser Coil
. IGNITION SYSTEM 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: 396阡594 Picture C Picture D 15-6...
Page 181: Charging System
. CHARGING SYSTEM VENOX250/250i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CHARGING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION ..............16-2 TROUBLESHOOTING ............... 16-3 BATTERY.................... 16-4 BATTERY CHARGING..............16-4 A.C. GENERATOR ................16-5 REGULATOR/RECTIFIER..............16-5 16-0...
Page 182 . CHARGING SYSTEM VENOX250/250i REG/REC Ignition Switch 16-1...
Page 183: Charging System
When inspecting the A.C. generator, use an electric tester. Route the charging system wires properly to avoid short-current due to wires being twisted or kinked. SPECIFICATIONS VENOX 250 Battery capacity 12V8AH Battery Electrolyte specific gravity 1.32...
Page 184: Troubleshooting
. CHARGING SYSTEM VENOX250/250i TROUBLESHOOTING No power Dead battery Low fluid level Disconnected battery cable Faulty ignition switch Low power Weak battery Loose battery connection (terminal) Charging system failure Faulty regulator/rectifier Intermittent power Loose battery cable connection Loose charging system connection Loose lighting system connection Charging system failure Loose, broken or short-current or connector...
Page 185: Battery
. CHARGING SYSTEM VENOX250/250i BATTERY REMOVAL Remove the seat. Remove the left side cover. First disconnect the battery negative cable and then the positive cable. Remove the two battery set plate lock nuts. BATTERY CHARGING Connect the charger positive cable to the battery positive cable.
Page 186: A.c. Generator
. CHARGING SYSTEM VENOX250/250i LIMIT VOLTAGE TEST: Start the engine and gradually increase the engine speed to measure the limit voltage. Limit Voltage: 14.5 0.5V/5000rpm Note: Test when the battery is fully charged. ＊ When testing the limit voltage, also use a tachometer for operation.
Page 187 . CHARGING SYSTEM VENOX250/250i INSPECTION Normal Red/White Remove the regulator/rectifier wire coupler. Direction Check the continuity between the wire terminals. Normal Direction: Continuity (+) Probe (-) Probe Yellow Green Red/White Yellow Reverse Direction Green Reverse Direction: No Continuity (+) Probe (-) Probe Green Yellow...
Page 188: Starting System
. STARTING SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION ..............17-2 TROUBLESHOOTING ............... 17-2 STARTER MOTOR ................17-3 STARTER RELAY ................17-4 CLUTCH DIODE................. 17-4 17-0...
Page 189: Starting System
. STARTING SYSTEM Engine Stop Switch Clutch Diode Neutral Switch Side Stand Switch Starter Motor 17-1...
Page 190: Service Information
. STARTING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS The removal of starter motor can be accomplished with the engine installed in the frame. When connecting the starting system wires, connect them securely to avoid hard starting due to poor connection. TROUBLESHOOTING Starter motor won’t turn Lack of power Fuse burned out...
Page 191: Starter Motor
. STARTING SYSTEM STARTER MOTOR REMOVAL Remove the two starter motor mounting bolts and the motor. ＊ Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn the ignition switch on to check if the starter motor operates properly.
Page 192: Starter Relay
. STARTING SYSTEM STARTER RELAY INSPECTION Turn the ignition switch ON and the starter relay is normal if you hear a “click” when the starter button is depressed. If there is no click sound: Inspect the starter relay voltage Inspect the starter relay ground circuit Check for continuity between the starter relay yellow/red and green/red wire terminals...
Page 193: Lights/Instrument/Switches/Horn
VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/INSTRUMENT/SWITCHES/HORN __________________________________________________________________________________ SERVICE INFORMATION ..............18-1 TROUBLESHOOTING ............... 18-1 HEADLIGHT/INSTRUMENT ............18-2 TURN SIGNAL LIGHT............... 18-3 STOP LIGHT/TAIL LIGHT ..............18-3 IGNITION SWITCH................18-3 STARTER BUTTON/HORN BUTTON / FUEL GAUGE....18-4 HANDLEBAR SWITCHES..............18-5 FUEL UNIT..................
Page 194: Service Information
VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN SERVICE INFORMATION GENERAL INSTRUCTIONS All plastic plugs have locking tabs that must be released before disconnecting. An electric tester must be used for checking the continuity between two points. The electric tester also contains a voltmeter which can be used to measure voltage. Different bulbs have different specifications.
Page 195 VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN HEADLIGHT REMOVAL Remove the left sides of attaching bolts and screws on headlight fairing to dismantle the fairing. Remove the headlight unit and disconnect the headlight wire coupler. Screws Bulb Bulb Socket Remove the headlight bulb and bulb socket. Check the bulb for damage and replace with a new one if necessary.
Page 196: Turn Signal Light
VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN Bulb TURN SIGNAL LIGHT Remove the turn signal light shell and the bulb. Check the bulb for damage and replace with a new one if necessary. The installation sequence is the reverse of removal. STOP LIGHT/TAIL LIGHT Remove the two taillight shell screws and the shell.
Page 197: Starter Button/Horn Button / Fuel Gauge
VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN INSPECTION Check for continuity between the wires indicated below. Color Black Red/White Position ○ ○ STARTER BUTTON Disconnect the right switch wire coupler. Check for continuity between the black/white and yellow/red wires. Color Black/White Yellow/Red Position FREE ○...
Page 198: Handlebar Switches
VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN HORN The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals. Replace the horn if it does not sound. Horn FUEL GAUGE Disconnect the fuel gauge and fuel unit wire couplers.
Page 199 VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN REAR STOP SWITCH Remove the right side cover. Disconnect the rear stop switch wire coupler. Check for continuity between the rear stop switch wires. Brake pedal depressed: Continuity. Brake pedal released: No continuity. Rear Brake TURN SIGNAL SWITCH Switch Turn Signal Coupler...
Page 200: Fuel Unit
VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN ENGINE STOP SWITCH Disconnect the engine stop switch wire coupler. Check for continuity between the engine stop switch wires. Color Black/White Black/Green Position ○ ○ Switch Engine Stop Coupler DIMMER SWITCH Disconnect the dimmer switch wire coupler. Check for continuity between the dimmer switch wires.
Page 201 VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN INSPECTION Check the fuel unit O-ring for wear, damage or deformation. Replace if necessary. Measure the continuity between the fuel unit wire terminals with the float at the upper (Full) and lower (Empty) positions. Resistances: Upper (Full): No continuity Lower (Empty): Continuity Connect the fuel unit wire coupler to the wire harness and turn the ignition switch...
Page 202 VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN THROTTLE POSITION SENSOR Disconnect the throttle position sensor wire coupler on carburetor. Check for the resistance among three wires of the throttle position sensor. Unit:K ∞ 0~5±1 ∞ 0~5±1 Throttle Position Sensor SIDE STAND SWITCH Side Stand Switch Wire Coupler Disconnect the side stand switch wire coupler.
Page 203 VENOX250/250i 18. LIGHTS/INSTRUMENT/SWITCHES/HORN Thermostatic Switch Wire THERMOSTATIC SWITCH INSPECTION Start and run the engine to make the water temperature reaches 90℃±2℃ and check if the cooling fan motor operates. Lower the water temperature to 87℃ and check if the fan motor stops. If the fan motor does not start, disconnect the wires from the thermostatic switch and then connect a jumper wire between the...
Page 204: Afi(Automatic Fuel Injection)
19. AFI (AUTOMATIC FUEL INJECTION) __________________________________________________________________________________ __________________________________________________________________________________ AFI (AUTOMATIC FUEL INJECTION) __________________________________________________________________________________ SYSTEM DIAGRAM---------------------------------------------------------- 19-01 SERVICE INFORMATION -------------------------------------------------- 19-03 SYSTEM LOCATION-1 ------------------------------------------------------ 19-04 SYSTEM LOCATION-2 ------------------------------------------------------ 19-05 TROUBLESHOOTING ------------------------------------------------------- 19-06 19-07 SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL ---------- ----- 19-15 SELF-DIAGNOSTIC PROCEDURES USING DIAGNOSTIC TOOL (PDA) FUEL PUMP -------------------------------------------------------------------- 19-25 FUEL PUMP RELAY --------------------------------------------------------- 19-27 TILT SWITCH ------------------------------------------------------------------ 19-28...
Page 205 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i VENOX 250i (AFI) 19-1...
Page 206 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i SYSTEM DIAGRAM 19-2...
Page 207 VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) SERVICE INFORMATION GENERAL INSTRUCTIONS ● This section covers service of the fuel system. ● These services can be done with the engine installed in the frame. ● Be sure to relieve the fuel pressure before fuel pump or fuel hose removal. ●...
Page 208 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i SYSTEM LOCATION-1 WATER TEMPERATURE SENSOR I.S..C TILT SWITCH IGNTION DRIVER CRANK POSITION SENSOR THROTTLE BODY (FUEL INJECTER & TPS) 19-4...
Page 209: System Location-2
VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) SYSTEM LOCATION-2 FUEL PUMP T-MAP SENSOR O2 SENSOR MAP SENSOR CRANK POSITION SENSOR 19-5...
Page 210: Troubleshooting
19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i TROUBLESHOOTING Engine would not start Backfiring or misfiring during acceleration Intake air leak Ignition system malfunction Fuel contaminated/deteriorated Pinched or clogged fuel hose Faulty fuel pump Clogged fuel filter Sticking fuel injector needle Faulty fuel pump operating system Engine stall, hard to start, rough idling Poor performance (drive ability) and poor Intake air leak...
Page 211: Self-Diagnostic Procedures Without Diagnostic Tool
VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL ＊ Without diagnostics program (D tool 5.0) can be performed condition. SELF-DIAGNOSTIC PROCEDURES STEP-1 “key OFF ”→ The throttle should be open and hold fully CELP LAMP STEP-2 “key ON ” →the CELP lamp will light for two second then off.
Page 212 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i CELP lamp show as a model Light Dark Light Dark KEY-ON THROTTLRE CLOSE Light Dark 19-8...
Page 213 VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) MALFUNCTION INDICATOR LAMP (CLEP) FAILURE CODES Lamp Fault description Priority Fault management Code Code Confirm whether the output voltage of the sensor is within specification? Check whether the output pin position of P0105 Atmospheric the sensor is correct or open circuit Pressure occurs?
Page 214 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i Lamp Fault description Priority Fault management Code Code Confirm whether the resistance of the sensor exist open or short circuit? Confirm whether the output pin position of the sensor is correct or open circuit occurs?(the ECU pin 20) P0134 (Fr) O2...
Page 215 VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) Lamp Fault description Priority Fault management Code Code Confirm whether the output pin position of the relay connector is correct or open circuit occurs(ECU pin 105)? If the check result of step1 is OK and P0230 Fuel Pump the error code still exists, then replace...
Page 216 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i Lamp Fault description Priority Fault management Code Code Check whether the output pin position of the sensor is correct? P0340 Camshaft Position Check whether the connector of the sensor Sensor/Circuit is connected securely or open circuit Malfunction occurs? Check whether the clearance between the...
Page 217 VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) Lamp Fault description Priority Fault management Code Code Confirm whether the output pin position of the relay connector is P0480 Fan Relay/Circuit correct or open circuit occurs(ECU pin Malfunction 111)? If the check result of step1 is OK and the error code still exists, then replace the relay according to the part-exchanging process to confirm...
Page 218 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i Lamp Fault description Priority Fault management Code Code Confirm whether the output pin position of the sensor is correct or short P1121 TPS Output Range circuit occurs? Malfunction Replace with a new sensor according to the part-exchanging process to confirm whether the error code still exists? Check whether the output pin position...
Page 219: Self-Diagnostic Procedures Using Diagnostic Tool (Pda)
Diagnostic Cable PROCEDURES USING DIAGNOSTIC TOOL (PDA) You have to 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. PDA Cable SELF-DIAGNOSTIC PROCEDURES 1.
Page 220 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i 5. Turn PDA on and select the word “START”. (START) 6. Select the word “PROGRAMS” PROGRAMS 7. Select “Dtool 5.0” 8. Select “OK”. “Dtool 5.0” “OK” 9. Select “Find ECU”, then system automatic select “ECU Type” ”...
Page 221 VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) 10. Select “SET”, then select “Language” Choice you want. “SET” “Language” 10. Select “ ？ ” to appear failure codes. Picture than Select “Load DTC” If the problems have been corrected, then select “Clear DTC” to clear failure codes. Load DTC Clear DTC 19-17...
Page 222 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i AFI SIGNAL DATA READ SIGNAL DATA PROCEDURES 1.Select “ ”, then select “Run” to read signal data. Select “PageUp” to enter next page. Select “PageDn” to enter last page. PageDn&PageUP ITEM PARAMETER FOOTNOTES SPACE Engine Sensors voltage .supply 5±0.1 V...
Page 223 VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) Coolant temperature 80˚C↑check data Engine speed(Idle) 1300 ± 100 rpm Repair Battery voltage >12 V Adjust Intake air pressure; 72 ~80.5 kpa (Engine Coolant temperature ℃ Warm ISC motor Duty 15 ~30 % after) TPS voltage(Idle) 0.68±0.05 V New bike 2.5%↓...
Page 224 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i PAGE 04 PAGE 03 PAGE 05 PAGE 06 19-20...
Page 225 VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) PAGE-07 PAGE-08 PAGE-10 PAGE-09 19-21...
Page 226 VENOX250/250i RRPAIR &ADJUST 1.Select “ ”, then select “Run” VENOX 250 i has.3 pages about adjust function：※ Idle co adjust function、Parts turning function check . Only on link, you should be adjust &parts check. Page 1 01 Choice 02 Choice...
Page 227 VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) Page 2 STEP-1 Choise Signal data to adjust item 1. Idle Control Adaption 2. Engine Temp (Coolant) 3. Idle Speed Setpoint 4. Injection Duration(Fr,Re) 5. Ign, Advance(Fr,Re) 6. Isc Output Duty STEP-2 Start test , Your choise STEP-3 Adjust measure 19-23...
Page 228 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i Page 3 STEP-1 Choise Parts turning function item check 1. Oil Pump Relay 2. Cooling Fan Relay 3. Engine Check Lamp 4. O2 Heater RelaY STEP-2 Start test ,Your choise item STEP-3 Adjust &Test Test Open &...
Page 229: Fuel Pump
VENOX250/250i 19. AFI (AUTOMATIC FUEL INJECTION) FUEL PUMP INSPECTIION Engine stop switch is at “RUN” Disconnect the fuel pump/fuel unit connector. Connect the multi-meter (+) probe to the Red/Black terminal and the multi-meter (-) probe to the Green terminal. Turn the ignition switch to “ON” and measure the voltage between the terminals.
Page 230 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i REMOVAL Disconnect the tank cover 4 screws.removal tank Cover. 8 screws Remove the clamp & eight screws, then remove the fuel pump and O-ring. Clamp 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.
Page 231: Fuel Pump Relay
19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i FUEL PUMP RELAY Battery INSPECTION Remove the fuel pump relay. Connect the ohmmeter to the fuel pump relay connector terminals. Connection: Black – Red/Black Connect he 12 V battery to the following fuel cut-off relay connector terminals Fuel pump Relay Connection: Blue/Black –...
Page 232: Tilt Switch
19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i TILT SWITCH INSPECTION Support the bike level surface. Engine stop switch is at “RUN”. Turn the ignition switch to “OFF” Remove the screws, washers and tilt switch. ＊ Do not disconnect the tilt switch connector during inspection.
Page 233: Engine Control Unit (Ecu)
19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i ENGINE CONTROL UNIT (ECU) REMOVAL/INSTALLATION ＊ ● Do not disconnect or connect the ECU connector during the ignition switch “ON”; it may cause the ECU damage. ● The throttle position sensor (TPS) and idle air bypass valve (ISC) have to reset when the throttle body MAP, TPS, ISC or ECU has been reinstalled...
Page 234: Fuel Injector
19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i FUEL INJECTOR INSPECTION Disconnect the fuel injector connector. Measure the resistance between 2 pins of the fuel injector connector. Standard: 11.7±0.6 Ω (at 20°C/68°) REMOVAL Disconnect the fuel injector connector and from fuel injector. Remove the bolt, then pull fuel pipe and fuel injector as assembly out from intake manifold.
Page 235: Wts Sensor
19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i WTS SENSOR REMOVAL /INSTALLATION ＊ Replace the WTS sensor while the engine is cold. Drain the coolant from the cooling system Disconnect the WTS sensor connector from the sensor. Remove the WTS sensor and O-ring Install the new O-ring and WTS sensor.
Page 236: O2/O2 Ht Sensor
19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i O2/O2 HT SENSOR O2 sensor data should be outputted only when its temperature over 350°C. O2 heater heat O2 sensor to over 350°C earlier than exhaust muffler. The data of O2 sensor is one of the data that control fuel injector operation.
Page 237: Throttle Body/Map/Isc/Tps
19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i THROTTLE BODY/MAP/ISC/TPS Turn ignition switch off and set up center stand when do the replacement. ● Check and confirm the voltage above 12V by a voltmeter after replacement. ● Check and confirm the other connectors are assembled correctly after replacement.
Page 238 19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i ISC INSPECTION REMOVAL Disconnect the ISC connector. Removal the clamp & 2 screws, then remove the I.S.C THROTTLE BODY REMOVAL Tube Remove the3 connector.(Tank inside) and tube disconnect the tank then connectors 19-34...
Page 239 19. AFI (AUTOMATIC FUEL INJECTION) 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 &connect pipe 19-35...
Page 240: T-Map Sensor
19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i T-MAP SENSOR REMOVE Remove T-MAP sensor connector &M4X2 Screws. Remove T-MAP sensor 19-36...
Page 241: Diagnostic Tool Connector
19. AFI (AUTOMATIC FUEL INJECTION) VENOX250/250i DIAGNOSTIC TOOL CONNECTOR INSPECTION Put 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 (+) –...
Page 242 WIRING DIAGRAM VENOX250/250I VENOX 250...
Page 243 WIRING DIAGRAM VENOX250/250I VENOX 250i...

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Venox 250i

KYMCO Venox 250 Service Manual

Table of Contents

2. Inspection/Adjustment

3. Lubrication System

4. Fuel System

6. Cylinder Head/Valves

Crankshaft/Piston/Cylinder 7

Generator/Left Crank Case Cover

9. Clutch/Gear Shift Mechanism

10.Transmission System

11. Cooling System 11

Front Wheel/Suspension/Steering

. Rear Wheel/Brake/Suspension 13

14. Hydraulic Brake

15. Ignition System

16. Charging System

17. Starting System 17

Lights/Instrument/Switches/Horn

19. Afi (Automatic Fuel Injection) 19

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Summary of Contents for KYMCO Venox 250