KYMCO Venox 250 Motorcycle Cruiser Manuals

Manuals and User Guides for KYMCO Venox 250 Motorcycle Cruiser. We have 4 KYMCO Venox 250 Motorcycle Cruiser manuals available for free PDF download: Service Manual, Driver Manual

KYMCO Venox 250 Service Manual (200 pages)

Brand: KYMCO | Category: Motorcycle | Size: 30 MB

Table of Contents
3
General Information
4
- Engine Serial Number/Identification
  5
- Specifications
  6
- Service Precautions
  7
- Service Information
  15
- Torque Values
  17
- Lubrication Points
  20
- Wiring Diagram
  21
- Cable & Harness Routing
  22
- Troubleshooting
  26
- Engine will Not Start or Is Hard to Start
  26
- Engine Stops Immediately after It Starts
  27
- Poor Performance (Engine Lacks Power)
  29
- Poor Performance (Especially at Idle and Low Speeds)
  30
- Poor Performance (at High Speed)
  31
- Starter Motor
  32
- Steering Handlebar Does Not Track Straight
  33
- Poor Suspension Performance
  34
- Poor Brake Performance
  34
- Fuel Gauge
  35
- Poor Charging (Battery over Discharging or Overcharging)
  36
- No Spark at Spark Plug
  37
Inspection/Adjustment
38
- Inspection/Adjustment
  39
- Service Information
  39
- Maintenance Schedule
  40
- Brake System
  41
- Brake Fluid
  42
- Brake Shoe
  42
- Wheels/Tires
  42
  - Front
    43
  - Rear
    43
- Suspension
  43
- Clutch
  44
- Steering Handlebar
  44
- Drive Chain
  45
- Electrical Equipment
  45
- Spark Plug
  45
- Ignition Timing
  46
- Throttle Operation
  46
- Lubrication System
  47
- Oil Filter Screen Replacement
  48
- Cooling System
  49
- Air Cleaner
  50
  - Change Interval
    50
  - Cylinder Compression
    50
- Valve Clearance
  51
- Idle Speed Adjustment
  51
- Others
  52
Lubrication System
54
- Lubrication System
  55
- Service Information
  55
- Troubleshooting
  55
- Engine Oil/Oil Filter
  56
- Oil Pump
  57
- Fuel System
  60
- Service Information
  62
Fuel System
63
- Troubleshooting
  63
- Carburetor Removal
  64
- Vacuum Chamber Disassembly
  65
- Air Cut-Off Valve
  66
- Float Chamber
  66
- Auto Fuel Valve
  68
- Float Level Inspection
  68
- Air Cleaner
  69
Engine Removal/Installation
70
Engine Removal/Installation
71
- Engine Removal
  73
- Engine Installation
  76
- Cylinder Head/Valves
  77
Cylinder Head/Valves
78
- Service Information
  79
- Troubleshooting
  80
- Cylinder Head Bolts Torque Table
  81
- Cylinder Head Cover Removal
  82
  - Camshaft Inspection
    83
  - Cylinder Head Removal
    84
- Rocker Arms Disassembly
  84
  - Cylinder Head Disassembly
    85
  - Valve Spring Free Length
    85
- Cylinder Head Assembly
  86
- Valve/Valve Guide
  86
- Cylinder Head Installation
  87
- Rocker Arms Installation
  87
Camshaft/Piston/Cylinder
88
Crankshaft/Piston/Cylinder
89
- Crankshaft/Piston/Cylinder
  90
- Service Information
  90
- Specifications
  90
- Troubleshooting
  90
- Crankcase Removal
  91
- Crankshaft Removal
  92
- Piston Removal
  93
- Piston Installation
  94
- Connecting Rod Bearing Choice
  95
- Cylinder Inspection
  95
- Crank Bearing Choice
  97
Generator/Left Crankcase Cover
99
Generator/Left Crank Case Cover
100
- Generator/Left Crank Case Cover
  101
- Service Information
  101
- Troubleshooting
  101
- Left Crankcase Cover/Generator Removal
  102
- Generator Installation
  103
Clutch/Gear Shift Mechanism
104
Clutch/Gear Shift Mechanism
105
- Clutch/Gear Shift Mechanism
  106
- Service Information
  106
- Troubleshooting
  107
- Right Crankcase Cover Removal
  108
- One Way Clutch Removal
  108
- Clutch Removal
  110
- Clutch Friction Disk
  111
- Clutch Tension Spring
  111
- Clutch Plate
  112
- Clutch Outer
  112
- Oil Pump Drive Sprocket/Bush
  112
- Transmission System
  113
Transmission System
114
- Service Information
  115
- Transmission System
  115
- Troubleshooting
  116
- Gear Shift Mechanism Remove
  117
- Crankcase Removal
  118
- Gear/Shaft Collar Inspection
  118
- Transmission Fork/Drum
  120
- Transmission Gears Removal
  121
- Main Shaft/Countershaft Inspection
  122
- Bearing Inspection
  122
- Bearing Replacement
  123
- Main Shaft/Countershaft Installation
  123
- Cooling System
  125
- Schematic Drawing
  125
Cooling System
126
- Cooling System
  127
- Service Information
  127
- Troubleshooting
  127
- Cooling System Testing
  129
- Radiator Cap Inspection
  129
- Radiator Removal
  129
  - Radiator Disassembly
    130
  - Fan Motor Inspectment
    131
  - Radiator Installation
    131
- Thermostatic Switch Inspectment
  131
- Mechanical Seal (Water Seal) Inspection
  132
- Water Pump
  132
  - Water Pump Installation
    132
  - Water Pump Removal
    132
- Thermosensor
  133
- Thermostat
  133
Front Wheel/Suspension/Steering
136
Front Wheel/Suspension/Steering
137
- Front Wheel/Suspension/Steering
  138
- Service Information
  138
- Troubleshooting
  139
- Handlebar
  140
- Front Wheel
  142
  - Throttle Pipe Installation
    142
  - Wheel Rim Inspection
    143
- Front Fork
  146
- Steering Stem
  147
- Steering Stem Installation
  148
- Bottom Cone Race Replacement
  148
- Rear Wheel/Brake/Suspension
  149
Rear Wheel/Brake/Suspension
150
- Rear Wheel/Brake/Suspension
  151
- Service Information
  151
- Troubleshooting
  152
- Rear Wheel
  153
- Rear Brake
  155
- Rear Shock Absorber
  158
- Rear Fork
  158
- Rear Fender
  159
Hydraulic Brake
160
Hydraulic Brake
161
- Hydraulic Brake
  162
- Service Information
  162
- Troubleshooting
  163
- Brake Fluid Change/Air Bleed
  164
  - Brake Fluid Refilling
    164
  - Brake System Bleeding
    164
  - Brake Pad Replacement
    165
- Brake Pad/Disk
  165
- Brake Disk
  166
- Brake Master Cylinder
  166
- Brake Caliper
  168
Ignition System
171
- Ignition System
  172
- Service Information
  173
- Troubleshooting
  174
- Continuity Test
  175
- Ignition Coil
  175
- CDI Unit
  176
- Pulser Coil
  177
Charging System
178
- Charging System
  179
- Service Information
  180
- Troubleshooting
  181
- Battery Charging
  182
- A.C. Generator
  183
- Regulator/Rectifier
  183
Starting System
185
- Starting System
  186
- Service Information
  187
- Troubleshooting
  187
- Starter Motor Installation
  188
- Clutch Diode
  189
- Starter Relay
  189
Starter Motor Removal
188
Lights/Instrument/Switches/Horn
190
- Lights/Instrument/Switches/Horn
  191
- Service Information
  191
  - Headlight
    192
  - Instrument (Speedometer)
    192
- Ignition Switch
  193
- Stop Light/Tail Light
  193
- Turn Signal Light
  193
  - Horn Button
    194
  - Starter Button
    194
- Handlebar Switches
  195
  - Horn
    195
  - Headlight Switch
    196
  - Turn Signal Switch
    196
  - Dimmer Switch
    197
  - Engine Stop Switch
    197
- Fuel Unit
  197
- Clutch Switch
  198
- Throttle Position Sensor
  199
- Side Stand Switch
  199
- Oil Pressure Switch
  199

KYMCO Venox 250 Service Manual (243 pages)

Brand: KYMCO | Category: Motorcycle | Size: 23 MB

Table of Contents

5
- General Information
  6
- General Information
  7
- Specifications
  8
- Service Precautions
  9
  - Service Information
    17
- Torque Values
  19
- Special Tools
  21
- Lubrication Points
  22
  - Cable & Harness Routing
    23
2. Inspection/Adjustment

39
- Inspection/Adjustment
  39
  - Inspection/Adjustment
    40
  - Service Information
    40
  - Rear Axle Nut
    40
  - Maintenance Schedule
    41
  - Brake System
    42
  - Brake Shoe
    43
  - Wheels/Tires
    43
  - Suspension
    44
  - Clutch
    45
  - Steering Handlebar
    45
  - Drive Chain
    46
  - Spark Plug
    46
  - Ignition Timing
    47
  - Throttle Operation
    47
  - Lubrication System
    48
  - Oil Filter Screen Replacement
    49
  - Cooling System
    50
  - Air Cleaner
    51
  - Valve Clearance
    52
3. Lubrication System

55
- Lubrication System
  55
  - Lubrication System
    56
  - Service Information
    56
  - Troubleshooting
    56
  - Engine Oil/Oil Filter
    57
  - Oil Pump
    58
4. Fuel System

62
- Fuel System
  63
  - Service Information
    63
  - Troubleshooting
    64
  - Carburetor Removal
    65
  - Vacuum Chamber
    66
  - Air Cut-Off Valve
    67
  - Float Chamber
    67
  - Auto Fuel Valve
    69
  - Air Cleaner
    70
  - Idle Speed Adjustmemt
    70
- Engine Removal/Installation
  71
  - Engine Installation
    77
6. Cylinder Head/Valves

80
- Cylinder Head/Valves
  80
  - Service Information
    81
  - Troubleshooting
    82
  - Cylinder Head Bolts Torque Table
    83
  - Cylinder Head Cover Removal
    84
  - Rocker Arms Disassembly
    86
  - Cylinder Head Assembly
    88
  - Cylinder Head Installation
    89
- Crankshaft/Piston/Cylinder
  90
Crankshaft/Piston/Cylinder 7

91
- Crankshaft/Piston/Cylinder
  92
- Service Information
  92
- Troubleshooting
  92
- Crankcase Removal
  93
- Crankshaft Removal
  94
- Piston Removal
  95
- Piston Installation
  96
- Connecting Rod Bearing Choice
  97
- Cylinder Inspection
  97
- Crank Bearing Choice
  99
Generator/Left Crank Case Cover

102
- Service Information
  103
- Troubleshooting
  103
- Left Crankcase Cover/Generator Removal
  104
- Generator Installation
  105
- Clutch/Gear Shift Mechanism
  106
9. Clutch/Gear Shift Mechanism

107
- Clutch/Gear Shift Mechanism
  108
- Service Information
  108
- Troubleshooting
  109
- One Way Clutch Removal
  110
- Right Crankcase Cover Removal
  110
- Clutch Removal
  112
- Transmission System
  115
10.Transmission System

116
- Service Information
  117
- Transmission System
  117
- Troubleshooting
  118
- Gear Shift Mechanism Removal
  119
- Crankcase Removal
  120
- Cooling System
  127
11. Cooling System 11

128
- Cooling System
  129
- Service Information
  129
- Troubleshooting
  129
- Cooling System Testing
  131
- Radiator Removal
  131
- Thermostatic Switch Inspectment
  133
- Water Pump
  134
- Thermosensor
  135
- Thermostat
  135
Front Wheel/Suspension/Steering

139
- Service Information
  140
- Troubleshooting
  141
- Handlebar
  142
- Master Cylinder Holder
  142
- Front Wheel
  144
- Front Fork
  148
- Steering Stem
  149
- Rear Wheel/Brake/Suspension
  152
. Rear Wheel/Brake/Suspension 13

153
- Rear Fork Pivot Nut
  155
- Rear Wheel
  155
- Troubleshooting
  155
- Rear Brake
  156
- Rear Fork
  161
- Rear Shock Absorber
  161
- REAR Fender
  162
- Hydraulic Brake
  163
14. Hydraulic Brake

164
- Troubleshooting
  166
- Brake Fluid Change/Air Bleed
  167
- Brake Pad/Disk
  168
- Brake Master Cylinder
  169
- Brake Caliper
  171
15. Ignition System

174
- Ignition System
  174
  - Ignition System
    176
  - Service Information
    176
  - Troubleshooting
    177
  - Ignition Coil
    178
  - CDI Unit
    179
  - Pulser Coil
    180
16. Charging System

181
- Charging System
  181
  - Charging System
    183
  - Service Information
    183
  - Troubleshooting
    184
  - Battery
    185
  - Battery Charging
    185
  - A.C. Generator
    186
  - Regulator/Rectifier
    186
17. Starting System 17

188
- Starting System
  188
  - Starting System
    189
  - Service Information
    190
  - Troubleshooting
    190
  - Starter Motor
    191
  - Starter Relay
    192
  - Clutch Diode
    192
Lights/Instrument/Switches/Horn

193
- Service Information
  194
- Troubleshooting
  194
- Ignition Switch
  196
- Stop Light/Tail Light
  196
- Turn Signal Light
  196
- Starter Button/Horn Button / Fuel Gauge
  197
- Handlebar Switches
  198
- Fuel Unit
  200
19. Afi (Automatic Fuel Injection) 19

204
- Afi(Automatic Fuel Injection)
  204
- System Location-2
  209
- Troubleshooting
  210
- Self-Diagnostic Procedures Without Diagnostic Tool
  211
- Self-Diagnostic Procedures Using Diagnostic Tool (Pda)
  219
- Fuel Pump
  229
- Fuel Pump Relay
  231
- Tilt Switch
  232
- Engine Control Unit (Ecu)
  233
- Fuel Injector
  234
- Wts Sensor
  235
- O2/O2 Ht Sensor
  236
- Throttle Body/Map/Isc/Tps
  237
- T-Map Sensor
  240
- Diagnostic Tool Connector
  241

KYMCO Venox 250 Driver Manual (51 pages)

Brand: KYMCO | Category: Motorcycle | Size: 3 MB

KYMCO Venox 250 Driver Manual (51 pages)

Brand: KYMCO | Category: Motorcycle | Size: 3 MB

KYMCO Categories

Scooter Offroad Vehicle Motorcycle Wheelchair Engine

More KYMCO Manuals

KYMCO Venox 250 Motorcycle Cruiser Manuals

KYMCO Venox 250 Service Manual (200 pages)

Table of Contents

KYMCO Venox 250 Service Manual (243 pages)

Table of Contents

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

KYMCO Venox 250 Driver Manual (51 pages)

KYMCO Venox 250 Driver Manual (51 pages)

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