Kymco Service Repair Manual Venox 250

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🏷️ Basic Information Identification Make: Kymco Model: Venox 250 Codes Product Code Identifier: Kymco Venox 250 Service Repair Manual 👋 Introduction Market Position Vehicle Segment: Cruiser Motorcycle Target Audience: Riders...

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Type: Motorcycle

Vendor:

Sku: 247772

Tags: Kymco Motorcycle Motorcycles Venox 250

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Description

🏷️ Basic Information

Identification

Make:

Kymco

Model:

Venox 250

Codes

Product Code Identifier:

Kymco Venox 250 Service Repair Manual

👋 Introduction

Market Position

Vehicle Segment:

Cruiser Motorcycle

Target Audience:

Riders seeking a comfortable, stylish cruiser with a focus on touring and relaxed riding.

Competitive Analysis

Key Competitors:

Yamaha Virago 250, Honda Rebel 250, Kawasaki Vulcan 500 (for larger displacement comparison).

Key Features

Design Philosophy:

Classic cruiser styling with modern reliability and performance.

Engine Configuration:

V-twin engine offering distinctive character and torque delivery.

Ergonomics:

Low seat height and swept-back handlebars for comfortable riding posture.

📋 Manual Details

Coverage Areas

Documentation Type:

Service Repair Manual

Scope:

COMPLETE

Page Count

Estimated Pages:

300-500

Manual Type

Type:

Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full disassembly, inspection, repair, and reassembly of the engine.

Engine Fuel System:

Carburetor system (if applicable), fuel pump, fuel filter, fuel lines, fuel tank inspection and cleaning.

Engine Ignition System:

Spark plugs, ignition coils, CDI unit, wiring diagrams for ignition.

Cooling System:

Radiator, cooling fan, coolant hoses, thermostat, coolant replacement and bleeding.

Exhaust System:

Muffler, exhaust pipes, catalytic converter (if equipped), inspection and replacement.

Transmission Drivetrain:

Clutch operation, gear shifting mechanism, final drive (belt or chain drive inspection and maintenance).

Chassis Frame:

Frame inspection for damage, steering head bearing maintenance, swingarm pivot maintenance.

Suspension Front:

Front fork disassembly, seal replacement, oil level and type, spring inspection.

Suspension Rear:

Rear shock absorber inspection, adjustment (if applicable), linkage maintenance.

Braking System Front:

Brake calipers, brake pads, brake discs, master cylinder, brake fluid, bleeding procedure.

Braking System Rear:

Rear brake caliper (if applicable), brake pads, brake disc, master cylinder, brake fluid, bleeding procedure.

Wheel Tire Assembly:

Wheel bearing maintenance, tire pressure, tire wear inspection, wheel balancing (if applicable).

Electrical System:

Battery maintenance, charging system (stator, rectifier/regulator), starter motor, lighting system, switchgear.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems.

Bodywork Chassis:

Body panel removal and installation, fairings, seat, fuel tank removal and installation.

Controls:

Throttle controls, clutch lever, brake levers, cable adjustments.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, chain/belt adjustment and lubrication, brake fluid checks, tire pressure checks.

Troubleshooting:

Diagnostic procedures for common problems and fault finding guides.

Engine Repair:

Engine rebuild procedures, valve clearance adjustment, piston and cylinder inspection, crankshaft and connecting rod checks.

Transmission Repair:

Clutch replacement, transmission component inspection and replacement.

Suspension Repair:

Front fork seal replacement, rear shock absorber replacement, steering bearing service.

Brake System Overhaul:

Brake pad replacement, brake disc replacement, caliper overhaul, master cylinder replacement, brake bleeding.

Electrical Diagnostics:

Testing of charging system, ignition system, starter system, and lighting components.

Carburetor Tuning:

Carburetor adjustment, cleaning, and synchronization (if applicable).

Cooling System Service:

Coolant flush and refill, thermostat replacement, fan operation checks.

Wheel Bearing Replacement:

Front and rear wheel bearing inspection and replacement.

Technical Depth

Level Of Detail:

Comprehensive, from basic maintenance to complete engine and component rebuilds.

Diagnostic Capabilities:

Includes detailed diagnostic trees and fault code interpretation (if applicable).

Torque Specifications:

All critical fasteners have specified torque values for proper assembly.

Clearances Tolerances:

Specifications for valve clearances, piston-to-cylinder wall, etc.

Special Tools:

Lists any specific tools required for certain procedures.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Searchability:

Searchable text for quick information retrieval.

Print Quality

Image Resolution:

High-resolution diagrams and images for clarity.

Readability:

Designed for clear reading on digital devices and printable for workshop use.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, V-twin, SOHC, liquid-cooled

Displacement:

249.2 cc (15.2 cu. in.)

Bore X Stroke:

50.0 mm x 63.0 mm (approximate, needs verification from manual)

Compression Ratio:

10.2:1 (approximate, needs verification from manual)

Performance

Horsepower:

Approximately 18-20 HP (at flywheel, needs verification)

Torque:

Approximately 17-19 Nm (at flywheel, needs verification)

Fuel System

Fuel Delivery:

Carburetor (likely dual Keihin carburetors, needs verification)

Fuel Type:

Unleaded gasoline

Lubrication

Oil Type:

API SG or higher, SAE 10W-40 motorcycle oil recommended (verify manual specification)

Oil Capacity:

Approximately 1.5 - 1.8 Liters (with filter change, verify manual specification)

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Clutch Type:

Wet, multi-plate

Final Drive:

Belt drive (common for this era/style, needs verification)

Features

Gear Ratios:

Specific gear ratios available in the manual.

📐 Dimensions

Exterior

Length:

Approximately 2220 mm (needs verification)

Width:

Approximately 820 mm (needs verification)

Height:

Approximately 1130 mm (needs verification)

Wheelbase:

Approximately 1570 mm (needs verification)

Weights

Dry Weight:

Approximately 170-180 kg (needs verification)

Fuel Tank Capacity:

Approximately 14 Liters (needs verification)

🛡️ Safety Features

Ratings

Crash Test Data:

Motorcycle safety is primarily rider skill and equipment; specific crash ratings are not typically issued for motorcycles.

Active Features

Braking System Type:

Disc brakes front and rear (likely single disc front, drum or disc rear depending on model year/spec)

Passive Features

Lighting:

Headlight, taillight, brake light, turn signals.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog speedometer, tachometer (if equipped), odometer, trip meter, indicator lights for turn signals, high beam, neutral, oil pressure.

Driver Assistance

ABS Availability:

ABS was not a common feature on this model during its primary production run, but specific markets might have had variations. Manual will confirm.

Connectivity

Connectivity Features:

N/A for this model; basic electrical systems only.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000 - 5,000 km or 6-12 months (verify manual).

Oil Filter Replacement:

With every oil change (verify manual).

Spark Plug Service:

Inspect every 6,000 km, replace as needed (verify manual).

Air Filter Cleaning Replacement:

Clean every 6,000 km, replace as needed (verify manual).

Brake Fluid Flush:

Every 2 years (verify manual).

Fluid Specifications

Engine Oil Specification:

SAE 10W-40, API SG or higher, JASO MA approved motorcycle oil.

Coolant Type:

Permanent type antifreeze coolant (ethylene glycol-based), 50/50 mix with distilled water (verify manual).

Brake Fluid Type:

DOT 4 (verify manual).

Known Issues

Carburetor Synchronization:

Can sometimes require periodic synchronization for smooth idle and throttle response.

Belt Drive Wear:

If belt driven, regular inspection for wear, tension, and proper alignment is crucial.

Charging System Reliability:

Older models might experience stator or regulator/rectifier failures; troubleshooting is detailed in the manual.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Kymco (Kwang Yang Motor Co., Ltd.) is a Taiwanese manufacturer established in 1964, known for producing scooters, motorcycles, and ATVs.

Model Evolution

Venox Lineage:

The Venox 250 was Kymco's entry into the mid-size cruiser market, designed to offer a comfortable and stylish option.

Production

Production Years:

Typically produced from the early 2000s through the late 2000s/early 2010s (specific years vary by region).

Manufacturing Location:

Taiwan

🏆 Awards & Recognition

Recognitions

Industry Accolades:

Specific industry awards for the Kymco Venox 250 are not widely publicized. Its recognition typically comes from user reviews and its value proposition in the entry-level cruiser segment.