9. Clutch, freewheel KYMCO VENOX 250 9 Drum 2.3 kgm Clutch pressure plate 6 pieces 6 piece drum 6.0 kgm 8.

0 kg-m Left Plate Tamper 1.0 kgm 9-1 9. Clutch, freewheel KYMCO VENOX 250 ________________________________________________________________________________ __ ________________________________________________________________________________ __ ________________________________________________________________________________ __ ________________________________________________________________________________ __ 9 ________________________________________________________________________________ __ CLUTCH, FREEWHEEL ________________________________________________________________________________ __ GENERAL INFORMATION ................................................ ... 3.9 ANA LYSIS OF PROBLEMS ............................................ ............ FREE WHEEL ............................................. 9-4 ........................ . CLUTCH .............................................. 9-5 .................... .............. 9-7 9-2 9. Clutch, freewheel GENERAL INFORMATION KYMCO VENOX 250 * Removing the clutch inspection and the freehub can run with the engine mounted on the frame. Standard Specifications (mm) 3.7 to 3.8 0 to 0.05 27.95 to 27.97 32.0 32.30 42.6 29.0 28.97 to 28.99 22.02 to 22.04 32.0 to 32.025 from 42.175 to 42.2 29.0 to 29.030 Service limit (mm) 31.0 3.4 0.1 32.2 27.80 42 28.80 22.20 2

9.4 is 42 0 32.2 29.20 Clutch spring free length Thickness Deformation clutch driven plates clutch driv ing plates diameter Inside diameter flange freewheel freewheel freewheel flange diameter Inside diameter clutch gear Compass D. external D. Oil Pump Internal ge ar shaft D. external freewheel D. Internal oil pump inside diameter crown Tighte ning Nut central screw shaft clutch clutch clutch screw fastening screw freewhee l clutch Without Special Tools Keyword clutch nut removal 1.0 kgm kgm kgm 6.0 2.3 8.0 kgm (left-hand screw) 9-3 9. Clutch, freewheel ANALYSIS OF PROBLEMS The drag sled acceleration clutch cable free play enough worn clutch plates spri ngs clutch weakened KYMCO VENOX 250 The clutch is hard to operate - the clutch cable bent, damaged or bare - pusher device damaged the vehicle moves with changing neutral - clutch plates deformed The change does not work properly - Excessive clutch cable free play 9-4 9. Clutch, freewheel FREEWHEEL Removing Drain the engine oil Disconnect the clutch cable. Remove the screws on the right side cover. KYMCO VENOX 250 Right side cover Remove the right side cover screws. * Be careful not smarrier dell'ingranagio th e tree for reference, and its compass. Lives Left Shaft gear Remove the screw that holds the freewheel freewheel screw torque: 8.0 kgm * The screw the freewheel and LH. Remove the freewheel. Inspection of the freewheel Measure the outside diameter of the freewheel Servic e limit OD. freewheel: 27.80 mm Dep. if sup. 9-5 9. Clutch, freewheel Measure the inside diameter and outside of the flange OD limit abuse. Flange: 42 .0 mm Dep. if inf. Diam ext. Flange: 32.2 mm Dep. if sup. . KYMCO VENOX 250 Remove from freewheeling rolls, caps and springs. Freewheeling Check the wheel bearing free is good. Replace if it shows signs of wear or damag

e. Bearing Remove the gear reduction Gear reduction 9-6 9. Clutch, freewheel Installing freewheel Install components in reverse order to removal. KYMCO VENOX 250 CLUTCH Removal Remove the freewheel. Remove the four screws on the pressure plate. Remo ve the pressure plate and the four clutch springs. Screws tightening torque clut ch springs: 1.0 kgm Pressure plat Soft Clutch Remove the lock nut of the clutch using a clamp to immobilize the clutch. Screws tightening torque spring clutch: 6.0 kgm Without Special Tools friction clutch nut removal wrench Without clutch Key ring clutch disassembly Remove the washer. * To install, mount the washer with the convex side facing ou t. 9-7 9. Clutch, freewheel Remove the clutch drum along with the clutch and clutch drum. KYMCO VENOX 250 Clutch drum Remove the washer and clutch. Washer Clutch bell Survey Measure the length of each clutch spring clutch spring free length Servic e limit: 31.0 mm Dep. if inf. Measure the length of each of the driving plates clutch disc clutch Service limi t: 3.4 mm Dep. if sup. Clutch wire 9-8

9. Clutch, freewheel Inspection clutch wires measure the deformation of each of the driving plates cl utch disc clutch wire service limit: 0.1 mm Dep. if sup. KYMCO VENOX 250 Feeler Clutch Disc Inspection Check clutch disk locations for signs of wear or damage. Measure the inside diameter of the bell Diam Service limit ext. Bell: 46.50 mm Dep. if sup. Clutch bell Survey gear oil pump / bush Measure the diameter of the inner and outer sleeve S ervice limit Dia ext. Bushing: 22.20 mm Dep. if sup. OD. Bushing: 28.80 mm Dep. if inf. Measure the inside diameter of the gear oil pump. Service limit Dia ext. Gear: 29.20 mm Dep. if sup. INSTALLATION removal steps in reverse. Refer exploded page 9-1 for details. 9-9