Sym VS150 Service Manual

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VS150 / VS2

SERVICE MANUAL

Summary of Contents for Sym VS150

Page 1 VS150 / VS2 SERVICE MANUAL...
Page 2 “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the motorcycle, VS150 / VS2, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.
Page 3 HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service VS150 / VS2 motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
Page 4 10. V-BELT DRIVING SYSTEM/KICK STARTER Mechanism Diagram ··························· 10-1 Driving Belt···········································10-4 Maintenance Description ···················· 10-2 Drive Face·············································10-6 Trouble Diagnosis ······························· 10-2 Clutch Outer/Driven Pulley··················10-9 Left Crankcase Cover ························· 10-3 Mechanism Diagram 3.5~4.5kgf-m 5.0~6.0kgf-m 5.0~6.0kgf-m 10-1...
Page 5 43.800 ID of drive face 39.000~39.025 39.060 Torque value Special Service Tools Driven face nut: 5.0~6.0kgf-m Clutch spring compressor: SYM-2301000 Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: SYM-6204002 Clutch nut wrench 39 x 41 mm: SYM-9020200 Universal holder: SYM-2210100 Bearing driver:...
Page 6 10. V-BELT DRIVING SYSTEM/KICK STARTER Left Crankcase Cover Left crankcase cover removal Remove body cover. Remove kick starter arm ass'y. Remove air cleaner ass'y (2 bolts 6×25). Remove L. Cover fender Comp. Remove L. Crankcase cover (8 special bolts 6×37 ass'y).
Page 7 10. V-BELT DRIVING SYSTEM/KICK STARTER Driving Belt Removal Remove left crankcase cover Hold drive face with universal holder, and remove nut and drive face. Universal holder Hold clutch outer with universal holder, and remove nut and clutch outer. Caution Using special service tools for tightening or loosening the nut.
Page 8 10. V-BELT DRIVING SYSTEM/KICK STARTER Installation Caution Pull out driven face to avoid it closing. Driven face Install driving belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft. On the drive belt another end to the movable drive face.
Page 9 10. V-BELT DRIVING SYSTEM/KICK STARTER Drive Face Removal Remove left crankcase cover. Hold generator flywheel with universal holder, and then remove drive face nut. Remove drive face. Universal holder Remove driving belt and movable drive face comp Movable drive face from crankshaft.
Page 10 10. V-BELT DRIVING SYSTEM/KICK STARTER Inspection Weight roller The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be effect. Check if rollers are worn or damaged. Replace it if necessary.
Page 11 10. V-BELT DRIVING SYSTEM/KICK STARTER With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Movable drive face Drive face boss Install movable drive face comp.
Page 12 10. V-BELT DRIVING SYSTEM/KICK STARTER Clutch Outer/Driven Pulley Clutch nut wrench Disassembly Remove drive belt and clutch outer/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution Do not press the compressor too much.
Page 13 10. V-BELT DRIVING SYSTEM/KICK STARTER Clutch lining Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 2.0 mm Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 163.7 mm Free length Driven pulley...
Page 14 10. V-BELT DRIVING SYSTEM/KICK STARTER Clutch weight Replacement Spring Driving plate Remove snap ring and washer, and then remove clutch weight and spring from driving plate. Caution Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity.
Page 15 10. V-BELT DRIVING SYSTEM/KICK STARTER Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Outer bearing Remove inner bearing. Clipper Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
Page 16 10. V-BELT DRIVING SYSTEM/KICK STARTER Installation of Clutch OUTER/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Specified grease O-ring Movable driven face Install the movable driven face onto driven face.
Page 17 10. V-BELT DRIVING SYSTEM/KICK STARTER Notes: 10-14...
Page 18 11. FINAL DRIVING MECHANISM Mechanism Diagram ··························· 11-1 Inspection of Final Driving Mechanism ······························································· 11-4 Precautions in operation ···················· 11-2 Bearing Replacement ·························· 11-5 Trouble Diagnosis ······························· 11-2 Re-assembly of Final Driving Mechanism Disassembly of Final Driving Mechanism ······························································· 11-8 ······························································...
Page 19 Inner bearing puller: SYM-6204002 Outer bearing puller: SYM-6204001 Drive shaft puller: SYM-1130000-L Drive shaft install bush: SYM-1130010 Extension bush (long): SYM-1130031 Extension bush (short): SYM-1130032 Trouble Diagnosis Engine can be started but motorcycle can not be moved. Damaged driving gear...
Page 20 11. FINAL DRIVING MECHANISM Disassembly of Final Driving Mechanism Remove driven pulley. Drain gear oil out from gear box. Remove gear box cover bolts and then remove the cover and drive shaft. 7 bolts Counter shaft & gear Final shaft & gear Remove final gear and shaft.
Page 21 11. FINAL DRIVING MECHANISM Inspection of Final Driving Mechanism Check if the countershaft is wear or damage. Check if the final shaft and gear are burn, wear or damage. Check bearings on gear box. Bearing Oil seal Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear tightly.
Page 22 11. FINAL DRIVING MECHANISM Bearing Replacement Caution Never install used bearings. Once bearing removed, it has to be replaced with new one. Remove driving shaft bearing and counter shaft bearing from left crankcase using following tools: Special tool: Inner bearing puller Install new drive shaft bearing and counter shaft bearing into left crankcase.
Page 23 11. FINAL DRIVING MECHANISM Install new final shaft seal. Oil seal driver Special tool: Oil seal driver (27*42*7) Install new final shaft bearing. Bearing driver Special tool: Bearing driver (6203/6004UZ) Inner bearing puller Press out the drive shaft from gear box cover. Use shaft protector as operation.
Page 24 11. FINAL DRIVING MECHANISM Install a new drive shaft bearing onto gear box cover. Special tool: Bearing driver (6204) Bearing driver Bearing driver Install a new final shaft bearing and counter shaft bearing onto gear box cover. Special tool: Bearing driver (6203/6004UZ) Bearing driver (6301) Install bush Install drive shaft.
Page 25 11. FINAL DRIVING MECHANISM Re-assembly of Final Driving Mechanism Apply with grease onto the oil seal lip of final driving shaft. Drive shaft Final shaft Install countershaft, counter gear, final shaft and final driving gear. Final drive gear Countershaft Install dowel pin and new gasket. Dowel pin Gasket Install gear box cover and bolts, and tighten.
Page 26 11. FINAL DRIVING MECHANISM Apply with grease onto new oil seal lip, and then Oil seal driver install the oil seal. Special tool: Oil seal driver (20*32*6) Install driven pulley/clutch outer/belt. Install movable drive face, drive face and left crankcase. Install rear wheel.
Page 27 11. FINAL DRIVING MECHANISM Notes: 11-10...
Page 28 12. ALTERNATOR/STARTING CLUTCH Mechanism Diagram ··························12-1 Starting Clutch ··································· 12-4 Precautions in Operation···················12-2 A.C.G. Set Installation························ 12-6 Right Crankcase Cover Removal ······12-3 Flywheel Installation·························· 12-7 Flywheel Removal ······························12-4 Right Crankcase Cover Installation·· 12-7 A.C.G. Set Removal····························12-3 Mechanism Diagram Flywheel Comp Cooling Fan Comp Stator Comp.
Page 29 31.804~31.807 31.810 OD of starting clutch gear 42.505~42.510 42.507 Torque value Flywheel nut 5.0~6.0kgf-m Starting clutch hexagon bolt 1.0~1.4kgf-m with adhesive 8 mm bolts 0.8~1.2kgf-m 12 mm bolts 1.0~1.4kgf-m Tools Special tools A.C.G. flywheel puller: SYM-3110A00 Universal holder: SYM-2210100 12-2...
Page 30 12. ALTERNATOR/STARTING CLUTCH Right Crankcase Cover Removal Remove bolts and screws from the right crankcase cover. Remove cooling fan comp. (4 bolts 6×18) and then remove it. Flywheel Removal Hold the flywheel by drive face with universal holder, and remove its nut. Special tool: Universal Holder Pull out flywheel with A.C.G.
Page 31 12. ALTERNATOR/STARTING CLUTCH A.C.G. Set Removal Wire Remove 2 mounted bolts from pulse generator 2 bolts and 2 mounted bolts from wire clamper and then remove it. Remove 2 screws from right crankcase cover and A.C.G. set. 2 bolts 2 bolts Starting Clutch Removal Use special tool for remove starting clutch gear comp.
Page 32 12. ALTERNATOR/STARTING CLUTCH Starting Clutch Inspection Check the starting clutch gear for wear or damage. Measure the ID and OD of the starting clutch gear. Service Limit: ID: 31.810 mm OD: 42.507 mm Check the starting reduction gear and shaft for wear or damage.
Page 33 12. ALTERNATOR/STARTING CLUTCH Remove 3 hexagon bolts with air and hex socket wrenches. Disassembly Install the components in the reverse procedures of removal. Caution Tape a tightening tape onto the thread of hexagon bolt. Torque value: 1.0~1.4kgf-m Installation Install dowel pin and new gasket. Install reduction gear shaft and reduction gear.
Page 34 12. ALTERNATOR/STARTING CLUTCH A.C.G. Set Installation Install the A.C.G. set onto right crankcase cover (2 screws). Install pulse generator (2 screws). Tie the wire harness securely onto the indent of crankcase. Caution Make sure that the wire harness is placed under pulse generator.
Page 35 12. ALTERNATOR/STARTING CLUTCH Notes: 12-8...
Page 36 13. CRANKCASE / CRANK Mechanism Diagram ··························13-1 Disassembly of crankcase ················ 13-3 General information ···························13-2 Crankshaft Inspection ······················· 13-5 Trouble diagnosis ······························13-2 Assembly of crankcase ····················· 13-6 Mechanism Diagram 1.2~1.6kgf-m 1.0~1.5kgf-m 0.8~1.2kgf-m 1.5~3.0kgf-m 13-1...
Page 37 R/L. crank disassemble/ install tool: SYM-1300001-H9A L. crank shaft bearing driver: SYM-9100200-H9A Crank shaft bearing fixing socket: SYM-9100210-H9A Crank shaft puller: SYM-1130000-H9A L. crank shaft oil seal driver (25*40*8): SYM-9121600 Outer bearing puller: SYM-6204010 Inner bearing puller: SYM-6204020 Clutch nut wrench: SYM-9020200...
Page 38 13. CRANKCASE / CRANK Disassembly of crankcase Loosen the bolt and remove the tensioner. Tensioner Cam chain Loosen 2 bolts on the right crankcase. 2 bolts 4 bolts Loosen 4 bolts on the left crankcase. Remove cam chain. Place right crankshaft case downward and left up crankcase.
Page 39 13. CRANKCASE / CRANK Remove crank by left crank shaft. Refer to chapter 2: Special tools Special tool: R/L. crankcase disassemble/install tool (SYM-1120000-H9A) Remove crankshaft from right crankcase. Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface.
Page 40 13. CRANKCASE / CRANK Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm Measure point for the crank big end of the connecting rod. Measure the clearance of the big end at the vertical directions.
Page 41 13. CRANKCASE / CRANK Assembly of crankcase Special tool: R/L. crankcase disassemble/install tool L. crankshaft bearing driver Crankshaft bearing fixing socket Crankshaft puller Clutch nut wrench The new bearing and bearing driver, puts on the left crankcase. Left crank shaft bearing driver Clutch nut Install R/L.
Page 42 13. CRANKCASE / CRANK Install R/L. crankcase disassemble/install tool on Crank shaft the left crankcase. puller Again turns on crankshaft puller on the crankshaft spiral tooth. Caution Crank shaft puller lock into on as far as possible the crank spiral tooth, prevented pulls the bad crank spiral tooth.
Page 43 13. CRANKCASE / CRANK Tighten 4 bolts on the crankcase. 4 bolts Torque value: 0.8~1.2kgf-m Clean the crankshaft. Apply a layer of grease on the lip of oil seal, Puts on the left crank shaft. Install the oil seal in the left crankcase with care not to damage the lip of the oil seal.
Page 44 13. CRANKCASE / CRANK Notes: 13-9...
Page 45 14. BODY COVER Mechanism Diagram ····················· 14-1 Rear carrier·····································14-9 Maintenance··································· 14-2 Body cover ·····································14-10 Front cover····································· 14-3 Inner box·········································14-11 Handle front cover························· 14-4 Floor panel ·····································14-6 Handle rear cover ·························· 14-5 Front fender····································14-13 Side cover ······································ 14-6 Rear fender·····································14-15 Front under spoiler ······················· 14-7 Center fender ·································14-15 Luggage box ··································...
Page 46 14. BODY COVER Maintenance Body covers disassemble sequence: Handle front cover Front cover Seat & Luggage box Handle rear cover Front under spoiler Rear carrier Inner box Body cover Right front fender B Left front fender B Rear fender Front fender Center cover Center cover Floor panel...
Page 47 14. BODY COVER Front cover Remove Loosen 8 screws from the front cover. 8 screws Loosen 2 screws bottom of front handle cover. 2 screws Electric cord coupling Remove headlight coupler, and then remove front cover. Installation Install in reverse order of removal procedures. 14-3...
Page 48 14. BODY COVER Handle front cover Disassembly Loosen 4 screws from handle rear cover rear side. 4 Screws Loosen 1 screw from front handle cover. Screw×1 Coupler Remove front winker light cord coupler. Remove the handle front cover. 14-4...
Page 49 14. BODY COVER Handle rear cover Speedometer cable Remover Remove front cover. Remove speedometer cable. Disconnect each switch connectors. Each switch connectors Remove electric line from the electric systems. Loosen 2 screws from the handle rear cover. 2 Screws Loosen 1 screw from backside of the handle rear cover.
Page 50 14. BODY COVER Floor panel Remove Loosen 4 bolts from the right & left step bar. Remove the right & left step bar covers. Side cover Remove Loosen 3 screws from the left side cover. Loosen 3 screws from the right side cover. Remove the right &...
Page 51 14. BODY COVER Front under spoiler Remove Remove front cover. Loosen 4 screws of the inner box side. 4 screws Loosen 2 screws from front side of the front under spoiler. 2 bolts Remove the front under spoiler. Installation Install in reverse order of removal procedures. 14-7...
Page 52 14. BODY COVER Luggage box 4 nuts Remove Open seat. Loosen 4 nuts of the luggage box. Loosen 1 screw & 2 bolts from inside of the luggage box. 2 bolts 1 screw Remove the luggage box. A.I.A.C Tube Installation Install in reverse order of removal procedures.
Page 53 14. BODY COVER Rear carrier Remove Loosen 4 bolts from the rear carrier. 4 bolts Remove the rear carrier. Installation Install in reverse order of removal procedures. 14-9...
Page 54 14. BODY COVER Body cover Seat lock washer Remove Remove luggage box and rear carrier. Remove DC sole cable seat and lock comp. Lock key set spring Loosen 2 bolts from the taillight underneath. Loosen1 bolt 6mm and 2 washer bolts 6x12. 2 bolts Loosen 2 screws from the center cover.
Page 55 14. BODY COVER Inner box Main switch cover Fuel tank cap Remove Remove the front cover. Loosen 1 bolt from the setting at hook and remove the hook. Remove main switch cover. 1 bolt Loosen 2 screws 5x16 from the under spoiler. 2 bolts Remove the inner box.
Page 56 14. BODY COVER Remove the battery. Winker Relay Relay Remove CDI and Relay from front cover. C.D.I Power filter Loosen 4 bolts from the floor panel. Installation Install in reverse order of removal procedures. 14-12...
Page 57 14. BODY COVER Front fender Fr.Inner fender B Remove Remove Fr.Inner fender A & Fr.Inner fender B. (4 screws and 2 bolts) Fr.Inner fender A 4 screws Upward pushes, after causes the tenon to fall off front, again takes out the front inner fender B. Caution When disassemble age must pay attention, whether the tenon is separated from.
Page 58 14. BODY COVER Use drive plus minus, remove front fender (4 screws). 4 bolts Downward presses the front fender, will cause it to be separated from the front cushion, and then take down to front. Installation Install in reverse order of removal procedures. 14-14...
Page 59 14. BODY COVER Rear fender Remove luggage box and seat. Remove rear carrier. Remove body cover. Remove rear fender upper side bolts. (2 bolts) Remove rear inner fender. Remove rear fender as show in this picture. Installation Install in reverse order of removal procedures. Center fender 3 bolts Remove air cleaner.
Page 60 14. BODY COVER Notes: 14-16...
Page 61 15. BRAKE Mechanism Diagram-Front Disk Brake 15-1 Brake fluid replacement / Air-bleed···· 15-7 Mechanism Diagram-Rear Drum Brake 15-2 Disk Brake-Caliper ······························· 15-8 Maintenance Description ······················ 15-3 Brake Disk ············································ 15-9 Trouble Diagnosis ································· 15-4 Disk Brake - Master Cylinder ·············· 15-9 Disk Brake System Inspection ·············...
Page 62 15. BRAKE Mechanism Diagram-Rear Drum Brake 15-2...
Page 63 15. BRAKE Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system. After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system.
Page 64 15. BRAKE Trouble Diagnosis Disk Brake Soft brake lever Uneven brake 1. Air inside the hydraulic system 1. Dirty brake lining/disk 2. Hydraulic system leaking 2. Poor wheel alignment 3. Worn master piston 3. Clogged brake hose 4. Worn brake pad 4.
Page 65 15. BRAKE Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts of.
Page 66 15. BRAKE Adding Brake Fluid Master cylinder Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags.
Page 67 15. BRAKE Brake fluid replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder.
Page 68 15. BRAKE Disk Brake - Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill the brake fluid on painted surfaces. Brake hose bolt Remove two caliper bolts and the caliper. Disassembly Make sure the brake lining condition.
Page 69 15. BRAKE Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: 2.0 mm Micrometer Remove the brake disk from wheel.
Page 70 15. BRAKE Master Cylinder Inspection Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit. Allowable limit: 12.550 mm Inter diameter Measure the outer diameter of the piston.
Page 71 15. BRAKE Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake light switch. 2 bolts Connect brake hoses with 2 new washers. Washer Tighten the brake hose bolt to the specified torque value.
Page 72 15. BRAKE Rear Drum Brake Remove brake drum Remove wheel and brake drum. To use vacuum cleaner or other alternatives to avoid danger caused from dusts. Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts.
Page 73 15. BRAKE Install brake lining Apply with a thin coat of grease to the brake cam Brake cam and the anchor pin. Install brake cam. Never allow brake linings to be contaminated by oil or grease. Wipe off the excessive grease from brake cam Lock pin and the anchor pin.
Page 74 15. BRAKE Notes: 15-14...
Page 75 16. STEERING / FRONT WHEEL / FRONT CUSHION Mechanism Diagram ··························16-1 Front Wheel ········································ 16-5 Operational Precautions ····················16-2 Front Cushion ···································· 16-8 Trouble Diagnosis ······························16-2 Steering Stem····································· 16-9 Steering Handle ··································16-3 Mechanism Diagram 4.0~5.0kgf-m 1.0~2.0kgf-m 0.2~0.3kgf-m 2.4~3.0kgf-m 4.0~4.5kgf-m 5.0~7.0kgf-m 16-1...
Page 76 0.2 ~ 0.3kgf-m Locating screw for the speedometer cable 0.15 ~0.3kgf-m Front cushion upper lock bolt 2.4 ~ 3.0kgf-m Special Tools Steering handle top thread wrench SYM-5320000 Inner bearing puller SYM-6204020 Steering nut wrench SYM-6204010 Driver 32*35mm Driver 42*47mm Trouble Diagnosis...
Page 77 16. STEERING / FRONT WHEEL / FRONT CUSHION Steering Handle Removal Remove the handle front cover, handle rear cover and front cover. (Refer to chapter 13) Loosen the lock bolts for the master cylinder of the front brake. Caution Do not let foreign materials enter into the cylinder. Remove throttle holder, cap, cable and grip after mounting screw removed.
Page 78 16. STEERING / FRONT WHEEL / FRONT CUSHION Installation Install handle and align with bolt hole. Install bolt and nut and then tighten it. Torque value: 4.5kgf-m Apply with grease onto throttle cable and the sliding surface of handle. Align the lock pin of the throttle bracket with the hole on the handle, and then install the throttle bracket.
Page 79 16. STEERING / FRONT WHEEL / FRONT CUSHION Front Wheel Remove First by the bracket strut frame base, causes the front wheel to float off. Remove the speedometer cable. Turn loose the axle nut. Pull out the front wheel axle. Remove the front wheel.
Page 80 Remove dust seal, bearing and dist collar from left side. Remove dust seal, bearing and retainer hear box from right side. Special tools: Inner bearing puller (SYM-6204020) Assembly Speedometer gear box Fill out the block of bearing by grease. Dist collar Drive the left bearing, dust seal and install the dist.
Page 81 16. STEERING / FRONT WHEEL / FRONT CUSHION Installation Open out brake lining with brake caliper. Place the front wheel between the front cushion. Caution Gear box groove Align the gear box groove with the stopper flange. Insert the wheel axle into the wheel and the install the wheel axle nut.
Page 82 16. STEERING / FRONT WHEEL / FRONT CUSHION Front Cushion Remove Remove front cover, front under spoiler and front fender. Remove front brake caliper. Remove front wheel. Remove front cushion upper mounting bolts, and then remove front cushion. Installation Align the cover flange with upper level of the cushion clamp, and then tighten bolts.
Page 83 16. STEERING / FRONT WHEEL / FRONT CUSHION Steering Stem Remove Steering lock nut Remove handle, front wheel and front cushion. Remove the steering stem mounting nut. Remove top cone race and front fork. Caution Place the steel ball onto a parts container to prevent from missing.
Page 84 16. STEERING / FRONT WHEEL / FRONT CUSHION Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body. Torque value: 1.0~2.0kgf-m Steering lock nut Install in reverse order of removal procedures. Top cone-race Shake steering handle up &...
Page 85 16. STEERING / FRONT WHEEL / FRONT CUSHION Notes: 16-11...
Page 86 17. REAR WHEEL / REAR FORK / REAR CUSHION Mechanism Diagram ··························· 17-1 Muffler ················································· 17-3 Operational Precaution ······················· 17-2 Rear Wheel ········································· 17-3 Trouble Diagnosis ······························· 17-2 Rear Cushion······································ 17-5 Mechanism Diagram 3.5~4.5kgf-m 2.4~3.0kgf-m 1.0~1.2kgf-m 4.0~5.0kgf-m 10.0~12.0kgf-m 3.2~3.8kgf-m 17-1...
Page 87 17. REAR WHEEL / REAR FORK / REAR CUSHION Operational Precaution General Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation of the tires. Service data Unit: mm Item Standard Allowable Limit Radial Run-out of rear rim Axial...
Page 88 17. REAR WHEEL / REAR FORK / REAR CUSHION Muffler Removal Loosen the 2 nuts from exhaust muffler front side. Loosen the 3 mounting bolts by exhaust muffler right side. Remove the exhaust muffler. Installation Install in reverse order of removal procedures. Caution Replace the front side muffler pipe gasket if worn or deformed.
Page 89 17. REAR WHEEL / REAR FORK / REAR CUSHION Inspection Rear wheel rim Place the wheel rim on a rotational support. Rotate it by hand and measure the run-out with a dial indicator. Run-out limit: 2.0 mm Rear fork bearing Free play Rotate the inner ring of the bearing with a finger.
Page 90 17. REAR WHEEL / REAR FORK / REAR CUSHION Installation Install the rear wheel. Install the inside collar on the rear fork. Install the rear fork onto the rear wheel shaft. Mount the outside collar on the rear fork. Tighten the rear wheel shaft nut. Install the rear fork mounting bolts and tighten the bolts.
Page 91 17. REAR WHEEL / REAR FORK / REAR CUSHION Notes: 17-6...
Page 92 18. ELECTRICAL SYSTEM Mechanism Diagram ··························18-1 Meters················································18-11 Maintenance Data·······························18-2 Light / Bulb········································18-12 Technical Specification······················18-2 Switch / Horn·····································18-14 Trouble Diagnosis ······························18-3 Fuel Unit ············································18-17 Battery ·················································18-4 Charging System ································18-5 Ignition System···································18-8 Starting System ··································18-10 Mechanism Diagram Headlight relay Regulator rectifier C.D.I. unit Horn Winker relay Main switch...
Page 93 18. ELECTRICAL SYSTEM Maintenance Data Operational precaution When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) The model of the spark plug and the tightening torque. The ignition timing.
Page 94 18. ELECTRICAL SYSTEM Trouble Diagnosis No voltage Charging system does not operate Battery discharged properly The cable disconnected Burnt fuse The fuse is blown Poor contact, open or short circuit Improper operation of the main switch Poor regulator Poor ACG Low voltage The battery is not fully charged Engine does not crank smoothly...
Page 95 18. ELECTRICAL SYSTEM Battery Removal Loosen 2 bolts and remove the battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the motorcycle. 2 bolts Voltage Check Use the digital voltmeter to check the voltage of the battery.
Page 96 18. ELECTRICAL SYSTEM Charging System Charging circuit Main switch Green Black Yellow Yellow Fuse 20A Yellow Pink Battery Yellow Regulator rectifier Green Green Auto by-starter AC. Generator Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Connect an ammeter between the negative cable terminal and the battery negative terminal.
Page 97 18. ELECTRICAL SYSTEM Connect a tachometer. Inspection on Charging Voltage Turn on the headlight to high beam and start the engine. Voltmeter Accelerate the engine to the specified revolution per minute and measure the charging voltage. Ammeter Specified Charging Current: 1.2 A / 6000 rpm Control Charging Voltage: 14.5 + 0.5 V / 2000 rpm...
Page 98 18. ELECTRICAL SYSTEM Inspection on regulator rectifier Remove the front cover. Disconnect two 3 pin couplers of the regulator rectifier. Inspection the rectifier coupler to the wire harness passes the condition. Item Check Points Standard Value Main switch Battery voltage R –...
Page 99 18. ELECTRICAL SYSTEM Ignition System Ignition circuit diagram C.D.I unit Disconnect connectors of the C.D.I unit. Check the following connectors as indicated in the table at the harness side. Item Points to check Result Main switch Black ~ Green Pulse generator Blue/yellow ~ Green 100~130Ω...
Page 100 18. ELECTRICAL SYSTEM Inspection on Ignition Coil Remove the luggage box. Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding. Ω ± 10% Standard resistance: 0.17 Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding.
Page 101 18. ELECTRICAL SYSTEM Starting System Starting circuit diagram Battery Start Inspection on starter relay Open the main switch. Press the brake. Push down the starter switch. If a sound of “Looh Looh” is heard, it indicates the relay function normally. Remove the luggage box.
Page 102 18. ELECTRICAL SYSTEM Removal of Starter motor Remove the battery cover (5 screws). Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove the luggage box. Remove the air cleaner. Loosen the lock bolts and remove the starter motor.
Page 103 18. ELECTRICAL SYSTEM Light / Bulb Replacing bulb for headlight Remove the front cover. Headlight adjustment screw Disconnect the terminal coupler and the rubber Headlight Position light sleeve from the headlight. Remove the bulb spring holder and the bulb. Position light Headlight Replace with new bulb if necessary.
Page 104 18. ELECTRICAL SYSTEM Replacing the Front winker light Bulb Loosen fixing screws and remove the handle front cover (screws x 3). Replace with new front winker light bulb. Replacing Bulb of taillight Remove the taillight lens (2 screws). 2 Screws Replace taillight or winker light bulb.
Page 105 18. ELECTRICAL SYSTEM Switch / Horn Main switch Main Switch Inspection Remove the front cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below: BAT1 BAT2 Position LOCK Wire Color Black Green Replacement of main switch Disconnect the coupler of the main switch and loosen the lock bolts (bolt x 2).
Page 106 18. ELECTRICAL SYSTEM Dimmer and Passing switch PASS Position PASS Dimmer and passing switch Wire color BR/W Winker switch Dimmer and passing switch Position FROM R PUSH OFF Winker switch FROM L Horn switch Light Wire color Gray Orange Blue Horn switch Position FREE...
Page 107 18. ELECTRICAL SYSTEM Brake Switch While grasp the brake lever firmly, the terminals of white/green and green/yellow of the brake should have continuity. Replace the switch if damaged. Brake switch Horn Remove the front cover. Horn Apply 12 V power source to two terminals of the horn, the horn should sound.
Page 108 18. ELECTRICAL SYSTEM Fuel Unit Open the seat. Fuel unit coupler Remove the luggage box. Remove the rear carrier. Remove the body cover. Disconnect the coupler of the fuel unit. Fuel unit Remove the fuel unit (screws x 4). Caution Great care shall be taken not to damage or bend the float arm of the gauge.
Page 109 18. ELECTRICAL SYSTEM Notes: 18-18...
Page 110 19. ELECTRICAL DIAGRAM 19-1...
Page 111 19. ELECTRICAL DIAGRAM Notes: 19-2...
Page 112 CONTENTS Page Content Index 3-1 ~ 3-18 GENERAL INFORMATION 4-1 ~ 4-13 SERVICE MAINTENANCE INFORMATION 5-1 ~5-8 LUBRICATION SYSTEM 6-1 ~ 6-12 FUEL SYSTEM 7-1 ~ 7-8 ENGINE REMOVAL 8-1 ~ 8-14 CYLINDER HEAD/VALVE 9-1 ~ 9-8 CYLINDER/PISTON 10-1 ~10-14 “V”...
Page 113 MECHANISM ILLUSTRATIONS VS150/VS2 Light switch Front winker Start switch Key set Head light Battery cover ass’y Dimmer switch Open switch Winker switch Horn switch Handle lever Fuel cap ass’y Tail light Stop light Air cleaner Kick starter Luggage box Fuel tank...
Page 114 3. GENERAL INFORMATION Symbols and Marks....... 3-1 Specifications........3-10 General safety........3-2 Torque Values ........3-11 Service Precautions ......3-3 Troubles Diagnosis ......3-13 Specifications ........3-9 Parts to Be Greased ......3-17 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.
Page 115 3. GENERAL INFORMATION General safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you ‧ Battery emits explosive gases; flame is strictly have to run your engine in a closed area, be sure prohibited.
Page 116 3. GENERAL INFORMATION Service Precautions Always use with VMEP genuine parts and Never bend or twist a control cable to prevent recommended oils. Using non-designed parts unsmooth control and premature worn out. for VMEP motorcycle may damage the motorcycle. Rubber parts may become deteriorated when old, and prone to be damaged by solvent and oil.
Page 117 3. GENERAL INFORMATION The length of bolts and screws for assemblies, Remove residues of the old gasket or sealant cover plates or boxes is different from one before reinstallation, grind with a grindstone if another, be sure they are correctly installed. In the contact surface has any damage.
Page 118 3. GENERAL INFORMATION Lubricate the rotation face with specified After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly. And the two posts of battery have to be greased after connected the cables.
Page 119 3. GENERAL INFORMATION When separating a connector, it locker has to Insert the terminal completely. be unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot. operation. Do not let boot open facing up. Secure wires and wire harnesses to the frame Do not pull the wires as removing a connector with respective wire bands at the designated or wires.
Page 120 3. GENERAL INFORMATION Do not let the wire harness contact with rotating, Protect wires or wire harnesses with electrical moving or vibrating components as routing the tape or tube if they contact a sharp edge or harness. corner. Thoroughly clean the surface where tape is to be applied.
Page 121 3. GENERAL INFORMATION Do not let the wire harness been twisted as With sand paper to clean rust on connector installation. pins/terminals if found. And then conduct connection operation later. Clean rust Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.
Page 122 3. GENERAL INFORMATION Specifications MAKER VMEP MODEL HA15A6-4 (VS2) Overall Length 1910 mm Front Telescopic Fork Suspension System Overall Width 740 mm Rear Twin Unit Swing Overall Height 1125 mm Front 110 / 80 – 12 61L Tire Specifications Wheel Base 1345 mm Rear 130 / 70 –...
Page 123 3. GENERAL INFORMATION Specifications MAKER VMEP MODEL Overall Length 1910 mm Front Telescopic Fork Suspension System Overall Width 740 mm Rear Twin Unit Swing Overall Height 1125 mm Front 110 / 80 -12 61L Tire Specifications Wheel Base 1345 mm Rear 130 / 70 -12 64L Front...
Page 124 3. GENERAL INFORMATION Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference Type Type Tighten Torque Tighten Torque 5 mm bolt、nut 0.45~0.6kgf-m 5 mm screw...
Page 125 3. GENERAL INFORMATION Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks Stopper nut for engine hanger 1.8~2.2 rubber Engine hanger nut 4.0~5.0 Engine hanger bolt 4.0~5.0 Engine connection bolt 3.5~4.5 Front wheel axle nut 5.0~7.0 Rear wheel shaft nut 10.0~12.0 Rear fork 4.0~5.0...
Page 126 3. GENERAL INFORMATION Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor 1. No fuel in fuel tank 2.
Page 127 3. GENERAL INFORMATION B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed Air cleaner clogged Poor fuel supply Engine speed can be Engine speed can not be Lines in fuel tank evaporation system increased.
Page 128 3. GENERAL INFORMATION C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Normal Abnormal 1. Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor Good Poor...
Page 129 3. GENERAL INFORMATION E. Clutch, driving and driving pulley PROBABLE CAUSES FAULT CONDITIONS Drive belt worn out or deformation Ramp plate of movable drive face damaged Engine can be started but Driving pulley spring broken motorcycle can not be moved. Clutch weights broken Drive slide-shaft gear groove broken Transmission gear damaged...
Page 130 3. GENERAL INFORMATION Parts to Be Greased Acceleration cable/ Front & rear brake lever pivot Steering shaft bearing Seat catch Speedometer gear/ Rear wheel bearing front wheel bearing Side stand pivot Main stand pivot 3-17...
Page 131 3. GENERAL INFORMATION Notes: 3-18...
Page 132 4. MAINTENANCE INFORMATION Precautions in Operation ······················ 4-1 Brake Light Switch/Starting Inhibitor Switch ················································· 4-10 Periodical Maintenance Schedule ········ 4-2 Headlight Beam Distance ·················· 4-10 Fuel Lines / Cable ·································· 4-3 Clutch Disc Wear································ 4-10 Air Cleaner·············································· 4-4 Side Stand··········································· 4-11 Spark Plug ··············································...
Page 133 Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.
Page 134 4. MAINTENANCE INFORMATION Fuel Lines / Cable Fuel filter Vacuum hose Remove luggage box. Remove rear carrier. Remove body covers. Check all lines, and replace it when they are deterioration, damage or leaking. Fuel hose Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.
Page 135 4. MAINTENANCE INFORMATION Air Cleaner 6 screws Air Cleaner Element Remove 6 screws from the air cleaner cover and then remove the cover. Remove 6 screws, and then remove the air 6 screws cleaner element. Caution The air cleaner element is made of paper so do not soap it into water or wash it with water.
Page 136 4. MAINTENANCE INFORMATION Valve Clearance Timing mark Caution Checks and adjustment must be performed when the engine temperature is below 35℃. Remove trunk. Remove central cover. Remove valve adjustment cap. Remove cylinder head side cover. Turn camshaft bolt in C.W. direction and let the “T” mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke.
Page 137 4. MAINTENANCE INFORMATION Carburetor Idle Speed Adjustment Ignition cable Caution Inspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted. Idle speed check and adjustment have to be done after engine is being warm up. (It is enough that operates engine from stop to running for 10 minutes.) Park the motorcycle with main stand and warm up...
Page 138 4. MAINTENANCE INFORMATION Ignition System Caution C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for checking whether CDI function is in normal or not. Remove right side cover. Remove ignition timing hole cap located in front upper side of engine right cover.
Page 139 4. MAINTENANCE INFORMATION Drive Belt Remove mounting bolt located under air cleaner. Remove Kick Stater Arm Ass Remove 3 bolts of the engine left side cover and the cover. Check if the belt is crack or worn out. Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it.
Page 140 4. MAINTENANCE INFORMATION Filling Out Brake Fluid Tighten the drain valve, and add brake fluid. Screws Operate the brake lever so that brake fluid Master cylinder cap contents inside the brake system hoses. Diaphragm plate Air Bleed Operation Upper Diaphragm Connect a transparent hose to draining valve.
Page 141 4. MAINTENANCE INFORMATION Make sure the brake lining condition. Replace Brake lining wear Lining limitation groove the lining if the brake lining wear limitation groove close to the brake disc. Brake Lining Replacement Compress the caliper and let the brake lining out of the caliper mounting plate.
Page 142 4. MAINTENANCE INFORMATION Side Stand Check side stand spring for damage or looseness. Press down side stand and pull it with spring gauge. If gauge reading is over 2 kg, it means that the spring capacity is in normal. Check if side stand set is operated smoothly. Make sure that side stand is no bending or deformation.
Page 143 4. MAINTENANCE INFORMATION Wheel/Tire Caution Tire pressure check should be done as cold engine. Check if tire surface is ticked with nails, stones or other materials. Appointed tire pressure Tire size Front tire Rear tire Load for Tire 1.75 2.25 under 90 Kg pressure as cold engine...
Page 144 4. MAINTENANCE INFORMATION Notes: 4-13...
Page 145 5. LUBRICATION SYSTEM Precautions in Operation ···················· 5-2 Engine Oil Strainer Clean ···················· 5-3 Troubleshooting ·································· 52 Oil Pump ··············································· 5-4 Engine Oil ············································· 5-3 Gear Oil ················································· 5-7 Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route Spray Lubrication Con-Rod Spray Lubrication Press-In Lubrication...
Page 146 SAE 20W-50 (Recommended King serial oils) Gear oil Disassembly: 150 cc Change: 120 cc Gear oil viscosity SAE 90 (Recommended SYM Hypoid gear oils) Unit: mm Items Standard (mm) Limit (mm) Inner rotor clearance 0.15 0.20 Oil pump Clearance between outer rotor and body 0.15~0.20...
Page 147 5. LUBRICATION SYSTEM Engine Oil Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
Page 148 5. LUBRICATION SYSTEM Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10). Remove snap ring and take out oil pump. Clip Make sure that pump shaft can be rotated freely. Remove 3 bolts on the oil pump, and then remove oil pump.
Page 149 5. LUBRICATION SYSTEM Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm pump body inner rotor outer rotor Oil Pump Re-assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor.
Page 150 5. LUBRICATION SYSTEM Oil Pump Installation Install the oil pump, and then tighten bolts. Torque value：0.8~1.2kgf-m Make sure that oil pump shaft can be rotated freely. Install oil pump driving gear and then install snap ring onto oil pump shaft. Install starting gear and generator.
Page 151 5. LUBRICATION SYSTEM Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand. Turn off engine and remove oil inspection bolt. Gear oil Inspection Bolt Gear lubrication oil quantity has to be measured with measure device. If oil level is too low, add gear oil.
Page 152 5. LUBRICATION SYSTEM Notes:...
Page 153 6. FUEL SYSTEM Precautions in Operation....6-2 Auto By-Starter ........6-7 Trouble Diagnosis.......6-3 Float Chamber........6-8 Carburetor removal......6-4 Fuel Tank ..........6-10 Vacuum chamber ........6-4 Air Cleaner.......... 6-11 Air Cut-Off Valve .........6-6...
Page 154 6. FUEL SYSTEM Precautions in Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly There is a drain screw in the float chamber for draining residual gasoline.
Page 155 6. FUEL SYSTEM Trouble Diagnosis Poor engine start Mixture too lean No fuel in fuel tank Clogged fuel injector Clogged fuel tube Vacuum piston stick and closed Too much fuel in cylinder Malfunction of float valve No spark from spark plug(malfunction of ignition Fuel level too low in float chamber system ) Clogged fuel tank cap vent...
Page 156 6. FUEL SYSTEM Carburetor removal Air cleaner clamp Throttle cable Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Disconnect automatic by-starter connector. Release the clamp strip of air cleaner. Auto by-starter Remove fuel pipe, vacuum hose.
Page 157 6. FUEL SYSTEM Check if the vacuum piston for wear out, crack or other damage. Check if the diaphragm for damage or crack. Installation Spring Needle seat Install needle, spring and needle seat to vacuum piston. Piston Needle Install vacuum piston to carburetor body and align the indent on the diaphragm.
Page 158 6. FUEL SYSTEM Air Cut-Off Valve Inspection Disconnect vacuum hose and air vent hose from the air cut-off valve. Connect a hose from vacuum hose connector to vacuum pump. Connect air pump to air vent hose. Apply with specified vacuum to air cut-off valve. Vacuum value: 420~500 mm-Hg Pump compressed air from air pump to air vent hose.
Page 159 6. FUEL SYSTEM Auto By-Starter Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the auto by-starter. Resistance value: Max. 10Ω (Measured after engine stopped for more than 10 minutes) Replace the auto starter with a new one if resistance value exceeds standard.
Page 160 6. FUEL SYSTEM Float Chamber Disassembly Remove 4 mounting screws and remove float chamber cover. Remove the float pin and float. Checking Check float valve and valve seat for damage, Float 4 Screws blocking. Check float valve for wearing, and check valve seat face for wear, dirt.
Page 161 6. FUEL SYSTEM Assembly Install main jet, fuel needle jet holder, fuel needle jet slow jet and pilot screw. Caution Set the pilot screw in according to number of turns noted before it was removed. Install the float valve, float, and float pin. Checking fuel level Caution Pilot screw...
Page 162 6. FUEL SYSTEM Fuel Tank Fuel unit removal Open the seat. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (4 bolts).) Remove body cover. Disconnect fuel unit connector. Remove fuel unit. Caution ․Do not bend the float arm of fuel unit Fuel unit connector ․Do not fill out too much fuel to fuel tank.
Page 163 6. FUEL SYSTEM Air Cleaner Clamp strip of air cleaner Removal Open the seat. Remove the luggage box (6 bolts and 1 screw). Loosen the clamp strip of air cleaner. Remove the Vapor hose. Remove the Air cleaner (2 bolts). Installation Install the tank in the reverse order of removal.
Page 164 6. FUEL SYSTEM Notes: 6-12...
Page 165 7. ENGINE REMOVAL Precautions in Operation ....7-1 Removal of Engine Hanger Bush ..7-6 Removal of Engine ......7-2 Engine Hanger Installation ....7-7 Engine Hanger removal.......7-5 Engine Installation.........7-7 Precautions in Operation General Information The engine has to be supported with special service tools that can be lifted or adjustable. The following parts can be serviced as engine mounted on frame.
Page 166 7. ENGINE REMOVAL Removal of Engine Auto by-starter & A.C.G. coupler Open seat and remove the luggage box (6 bolts and 1 screw). Remove rear carrier (4 bolts). Remove battery cover (2 screws). Remove battery negative (-) position. Remove battery positive (+) position. Remove tail light connector.
Page 167 7. ENGINE REMOVAL Remove right and left body cover. Remove right and left pillion step ass'y Remove the fuel pump. Fuel pump Remove the muffler (3 bolts, 2 nuts). 3 bolts 2 nuts Remove rear inner fender Right side Left side 2 Bolts 2 Bolts...
Page 168 7. ENGINE REMOVAL Remove the mounting bolt of right-rear cushion. Remove the rear fork mounting bolt. (2 bolts) Remove rear wheel axle mounting nut. Rear wheel axle nut 3 Bolts Remove rear fork and collars. Remove rear wheel. Remove the mounting bolt of left-rear cushion. Left-rear cushion bolt...
Page 169 7. ENGINE REMOVAL Remove the right and left side engine hanger Left side mounting bolts and nuts, then remove engine. Caution ․Support engine and frame separately with special supporters to prevent from engine or frame falling down. Engine hanger nut and bolt Right side Engine mounting nut and bolt Engine Hanger removal...
Page 170 7. ENGINE REMOVAL Removal of Engine Hanger Bush Bush Check if engine hanger bush and cushion rubber bush for damage. Pressing out If engine hanger and the rear cushion rubber bush damaged. Then with the bush remover/presser, Ø 30mm & Ø 22mm to press the bush out, and replace it with new one.
Page 171 7. ENGINE REMOVAL Engine Hanger Installation Install engine hanger onto engine. Install engine mounting bolts & nuts and then tighten the nuts. Torque value: 4.0~5.0kgf-m Engine Installation Check if the bush of engine hanger parts and cushion for damage. Install engine in the reverse procedures of removal.
Page 172 7. ENGINE REMOVAL Notes:...
Page 173 8. CYLINDER HEAD/VALVE Mechanism Diagram ··························· 8-1 Valve Stem Replacement··················· 8-8 Precautions in Operation ··················· 8-2 Valve Seat Inspection and Service ··· 8-9 Troubleshooting·································· 8-3 Cylinder Head Reassembly ··············· 8-11 Cylinder Head Removal······················ 8-4 Cylinder Head Installation ················· 8-12 Cylinder Head Disassembly··············· 8-6 Valve Clearance Adjustment·············...
Page 174 8. CYLINDER HEAD/VALVE Precautions in Operation General Information This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. Cylinder head service can be carried out when engine is in frame. Specification Item Standard Limit Compression pressure...
Page 175 8. CYLINDER HEAD/VALVE Troubleshooting Engine performance will be effect by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1. Valve Improper valve adjustment Burnt or bent valve Improper valve timing Valve spring damage...
Page 176 8. CYLINDER HEAD/VALVE Cylinder Head Removal Remove seat, luggage box and body cover. Vacuum tube Remove engine. (Refer to chapter 5) Remove the clamp strip bolt of carburetor, and disconnect vacuum tube from the carburetor insulator. Clamp strip Remove holing cap for the adjustment bolt of cam chain tensioner, and then loosen the tensioner by turning a flat-driver in C.W direction.
Page 177 8. CYLINDER HEAD/VALVE Remove the 2 cylinder head mounting bolts from 4 Nuts cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Cylinder head mounting Remove the A.I.C.V Ass'y take out side. Remove the cylinder head as shown figure. Remove the Reed valve Comp.
Page 178 Thus, press length is based on the valve cotter in which can be removed. Special Service Tool: Valve spring remover (SYM-1471110) Valve spring installer (SYM-1471120) Remove valve stem guide seal. Clean carbon deposits in combustion chamber.
Page 179 8. CYLINDER HEAD/VALVE Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge. Service limit: 0.5 mm Valve spring free length Measure the free length of intake and exhaust valve springs.
Page 180 8. CYLINDER HEAD/VALVE Caution If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide. Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve guide, replace valve stem too.
Page 181 8. CYLINDER HEAD/VALVE Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution Do not let emery enter into between valve stem and valve guide.
Page 182 8. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower past out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width. 1.0mm Caution Make sure that all roughness and uneven faces had been ground.
Page 183 Special Service Tool: Valve spring remover (SYM-1471110) Valve spring installer (SYM-1471120) Tap valve stem to make valve retainer and valve stem sealing properly. Caution Place and hold cylinder head on to working table so that can prevent from valve damaged.
Page 184 8. CYLINDER HEAD/VALVE Cylinder Head Installation Install a new O-ring into the indent of carburetor insulator, and then install the insulator onto cylinder head with 2 bolts. Carburetor insulator Install camshaft into cylinder head, and align rocker pin with rocker arm pin hole.Then, insert the rocker arm pin.
Page 185 8. CYLINDER HEAD/VALVE Tighten 4 nuts and washers on the cylinder head upper side, and then tighten 2 cylinder head mounting bolts of cylinder head side cover. Install Reed valve and A.I.C.V Unit. Torque value: 2.0~2.4kgf-m Install and tighten spark plug Torque value: 2.0~2.4kgf-m Caution This model is equipped with more precision...
Page 186 8. CYLINDER HEAD/VALVE Valve Clearance Adjustment Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge. After valve clearance had been adjusted to standard value, hold adjustment bolt and then tighten the Adjustment nut.
Page 187 8. CYLINDER HEAD/VALVE Notes: 8-15...
Page 188 9. CYLINDER/PISTON Mechanism Diagram ······························ 9-1 Piston Removal ··································9-4 Precautions in Operation ······················ 9-2 Piston Ring Installation ·····················9-6 Trouble Diagnosis·································· 9-2 Piston Installation ······························9-7 Cylinder Removal··································· 9-3 Cylinder Installation ···························9-7 Mechanism Diagram...
Page 189 9. CYLINDER/PISTON Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit：mm Item Standard Limit 57.400~57.415 57.416 Cylinder Bend 0.050 Top ring 0.015~0.050 0.090 Clearance between piston rings ring 0.015~0.050 0.090 Top ring...
Page 190 9. CYLINDER/PISTON Cylinder Removal Remove cylinder head (refer to chapter 6). Remove cylinder. Remove cylinder gasket and dowel pin. Cover the holes of crankcase and cam chain with a piece of cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase.
Page 191 9. CYLINDER/PISTON Piston Removal Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other foreign materials falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring.
Page 192 9. CYLINDER/PISTON Measure the outer diameter of piston pin by micrometer. Service Limit: 15.04 mm Measure the inner diameter of connecting rod small end. Service Limit: 15.06 mm Measure the inner diameter of piston pin hole. Service Limit: 15.04 mm Calculate clearance between piston pin and its hole.
Page 193 9. CYLINDER/PISTON Piston Ring Installation Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side.
Page 194 9. CYLINDER/PISTON Piston Installation Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring. Caution Do not let the opening of piston pin snap ring align with the opening piston ring.
Page 195 9. CYLINDER/PISTON Notes:...

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Sym VS150 Service Manual

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