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
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9
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CLUTCH, FREEWHEEL
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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