What to do if the clearance between the rotor side and body exceeds the limit in my Sym VS150 Motorcycle?
If the clearance between the rotor side and body exceeds the limit, reduce the clearance to within the specified limits.
General| Front Brake | Disc |
|---|---|
| Rear Brake | Drum |
| Starting System | Electric & Kick |
| Front Suspension | Telescopic Fork |
| Engine Type | Single cylinder, 4-stroke, air-cooled |
| Bore x Stroke | 57.3 mm x 57.8 mm |
Explanation of symbols and marks used to indicate service needs and procedures in the manual.
Important safety precautions related to engine operation, fuel handling, and hot components.
Guidelines for performing service operations, including using genuine parts and proper tool usage.
Technical specifications for the motorcycle models LH12W/LH18W, covering dimensions, weight, and engine.
Standard and engine torque values for various bolts and nuts, crucial for correct assembly.
Diagnostic procedures for common engine starting and running issues, with probable causes.
Illustrations showing lubrication points on the motorcycle for maintenance.
Operational precautions for servicing the motorcycle, including handling fuel lines and cables.
Recommended maintenance schedule based on mileage intervals for various motorcycle components.
Procedures for inspecting and adjusting fuel lines and the throttle cable for smooth operation.
Instructions for removing, cleaning, and replacing the air cleaner element.
Steps for inspecting, measuring gap, and installing the spark plug with correct torque.
Procedure for checking and adjusting valve clearance using a feeler gauge at specified engine temperatures.
Guide for adjusting carburetor idle speed and emission control in idle speed.
Procedure for checking ignition timing using an ignition lamp and testing CDI functionality.
Method for testing cylinder compression pressure and diagnosing low pressure issues.
Instructions for inspecting and replacing the drive belt, including width limit specifications.
Guidance on checking brake system hoses and brake fluid levels for safety.
Precautions and recommendations for handling brake fluid, including mixing and contamination.
Procedure for checking brake lining wear and replacing the lining when the wear limit is reached.
Information on the function and operation of the brake light switch and starter interlock.
Procedure for adjusting the headlight beam distance according to regulations.
Method for checking clutch disc condition and replacing it if worn or damaged.
Checks for side stand spring damage, looseness, and smooth operation.
Warning regarding riding with poor cushion and its impact on stability and drive-ability.
Instructions to perform periodical maintenance and check all nuts and bolts for secure tightening.
Procedure for checking tire pressure and thread depth, and replacing tires based on specifications.
Guidance on checking and adjusting the steering handle top bearing for smooth turning.
List of specialized tools required for various maintenance procedures.
General precautions for engine oil pump and gear oil replacement operations.
Procedure for checking engine oil level and changing engine oil, including torque values.
Steps for draining engine oil, cleaning the oil strainer, and replacing the O-ring.
Detailed instructions for oil pump removal, disassembly, inspection, and re-assembly.
Procedure for inspecting and changing gear oil, including quantity and torque specifications.
Safety precautions for working with gasoline and fuel system components.
Common fuel system issues like poor engine start, stalling, rough idle, and their probable causes.
Step-by-step guide for removing the carburetor and its associated components.
Procedure for removing, inspecting, and installing the vacuum chamber and its components.
Inspection of the air cut-off valve, including vacuum testing and replacement criteria.
Inspection, removal, and installation procedures for the auto by-starter system.
Disassembly, checking, and cleaning procedures for the carburetor float chamber and its jets.
Instructions for removing and installing the fuel unit and the fuel tank.
Procedure for removing, installing, and cleaning the air cleaner element.
General precautions for engine removal, emphasizing the use of special tools and supported lifting.
Detailed steps for removing the engine, including disconnecting various components and covers.
Instructions for removing engine hanger mounting bolts and nuts to detach the engine.
Procedure for pressing out and installing engine hanger and cushion rubber bushes.
Steps for installing the engine hanger onto the engine and tightening mounting bolts.
Guidance on installing the engine, with safety precautions and alignment checks.
Exploded view of the cylinder head and valve components with torque specifications indicated.
Maintenance and service precautions for cylinder head, valve, camshaft, and rocker arm.
Diagnosis of engine performance issues related to low/high compression pressure and noise generation.
Step-by-step instructions for removing the cylinder head, including disconnecting various components.
Procedures for disassembling the cylinder head, including valve spring removal and stem seal replacement.
Methods for inspecting cylinder head warp, valve spring length, valve stem, and valve guide.
Detailed process for replacing valve stem and correcting valve seats after guide replacement.
Inspection and service procedures for valve seats, including grinding and contact surface checks.
Steps for reassembling the cylinder head, including valve installation and spring compression.
Procedure for installing the cylinder head, including gasket, chain guide, and tensioner adjustments.
Method for adjusting valve clearance using a feeler gauge and checking oil flow after assembly.
Diagram of cylinder and piston components with torque values.
Precautionary notes stating that cylinder and piston service requires engine removal.
Diagnosis for engine issues like low compression, knock, noise, and overheating related to cylinder/piston.
Instructions for removing the cylinder, coolant hose, and gasket, including inspection of cylinder bore.
Procedure for removing the piston pin and piston rings, including inspection of ring grooves.
Guidelines for cleaning piston parts and installing piston rings with correct gap placement.
Steps for installing the piston and pin, and installing the cylinder with lubrication and proper alignment.
Diagram of the V-belt driving system and kick starter components with torque values.
General information and specifications for drive face, clutch outer, and driven pulley service.
Diagnosis for issues like engine start failure, shudder, misfire, and poor high-speed performance.
Instructions for removing and installing the left crankcase cover, including related components.
Procedure for removing, inspecting, and installing the driving belt and driven pulley.
Instructions for removing, inspecting, and installing the drive face, including weight rollers and ramp plate.
Disassembly and inspection of the clutch outer and driven pulley, including spring and weight replacement.
Diagram of the final driving mechanism with bearings and shafts, including torque specification.
Precautions for using scooter gear oil and recommended torque values for the gear box cover.
Diagnosis for engine starting failure, noise, and gear oil leaks in the final drive mechanism.
Steps for disassembling the final driving mechanism, including draining oil and removing covers.
Inspection procedures for countershaft, final shaft, gears, bearings, and oil seals.
Instructions for replacing bearings in the final drive mechanism using specialized tools.
Steps for reassembling the final driving mechanism, including shaft installation and cover tightening.
Diagram of alternator and starting clutch components with torque values.
Operational precautions and specifications for the starting clutch gear and torque values.
Procedure for removing the right crankcase cover, dowel pin, and gasket.
Steps for removing the A.C.G. set and pulse generator from the crankcase cover.
Instructions for removing the left crankcase cover and flywheel, including nut removal.
Procedure for removing and inspecting the starting driven gear and clutch components.
Diagram of crankcase and crank components with torque values for assembly.
Operational precautions for crankcase disassembly and replacement of crankshaft bearings.
Steps for disassembling the crankcase, including cam chain removal and bolt loosening.
Methods for inspecting crankshaft clearances, run-out, and bearing condition.
Procedures for assembling the crankcase, including bearing installation and shaft fitting.
Diagram of the cooling system components, including radiator, pump, and thermostat.
Safety precautions for working with hot coolant and general information on system service.
Flowchart for diagnosing high engine temperature issues and identifying potential causes.
Procedure for testing the radiator filler cap and performing coolant changes.
Instructions for checking radiator for leaks, cleaning, and removing the radiator and fan.
Procedure for inspecting and removing the water pump, including seal and bearing replacement.
Instructions for removing, inspecting, and installing the thermostat and its sensor.
Exploded view of the motorcycle's body cover components.
Body cover disassembly sequence and general precautions for assembly/disassembly.
Instructions for removing and installing the front cover, including associated electrical connections.
Procedure for removing and installing the handle front cover, including screws and couplers.
Steps for removing and installing the handle rear cover, including speedometer cable and switch connectors.
Instructions for removing and installing the left and right side covers.
Procedure for removing and installing the front under spoiler.
Instructions for removing and installing the luggage box, including seat and body cover fasteners.
Procedure for removing and installing the rear carrier.
Steps for removing and installing the main body covers, including tail light and seat lock cables.
Instructions for removing and installing the inner box and main switch cover.
Procedure for removing and installing the floor panel, including battery and CDI unit.
Instructions for removing and installing the front fender, including speedometer cable and brake pipe clip.
Procedure for removing and installing the rear fender.
Instructions for removing and installing the center fender.
Diagram of the front disk brake system components with torque specifications.
Diagram of the rear drum brake system components.
Operational precautions for brake system maintenance, including fluid handling and caliper removal.
Diagnosis for disk and drum brake issues like soft lever, hard operation, unevenness, and noise.
Visual inspection of brake system components, including brake tube, handle operation, and fluid level.
Procedure for adding brake fluid to the master cylinder and cleaning the brake disk.
Steps for replacing brake fluid and bleeding air from the brake system.
Procedure for removing, disassembling, and installing the brake caliper and its linings.
Inspection of brake disk for wear, thickness, deformation, and bend.
Procedure for removing, inspecting, and assembling the master cylinder components.
Diagram of steering, front wheel, and front cushion components with torque values.
Precautions regarding tire service and torque values for steering and front wheel components.
Diagnosis for steering issues like hard steering, tilted handlebar, rim run-out, and front cushion noise.
Instructions for removing and installing the steering handle, including throttle and brake lever components.
Procedure for removing, inspecting, and assembling the front wheel, axle, and bearings.
Instructions for removing and installing the front cushion, including mounting bolts and cover alignment.
Procedure for removing, installing, and adjusting the steering stem, including bearing seats and cone races.
Diagram of rear wheel, fork, and cushion components with torque values.
Precautions for tire service and torque values for rear wheel, fork, and cushion components.
Diagnosis for rear wheel run-out, soft cushion, noisy brake, and poor brake performance.
Instructions for removing and installing the muffler, including gasket replacement.
Procedure for removing the rear wheel, including exhaust muffler and rear fork components.
Instructions for removing and installing the rear cushion, with replacement precautions.
Diagram of the motorcycle's electrical system components.
Operational precautions, charging system specifications, and ignition system details.
Specifications for charging system (battery) and ignition system (spark plug, coil).
Diagnosis for electrical system issues like no voltage, low voltage, no spark, and starter problems.
Procedure for battery removal, voltage check, and charging instructions.
Inspection of charging circuit, current leakage, and charging voltage.
Inspection and replacement procedures for ignition coil, exciting coil, and pulse generator.
Inspection of starter relay and removal/installation of the starter motor.
Procedure for removing and installing the meter assembly and speedometer.
Instructions for replacing headlight and position light bulbs.
Inspection and replacement of main switch, handle switches, and horn.
Procedure for removing and testing the fuel unit and its resistance readings.
Inspection and testing procedure for the cooling fan thermo switch operation.
Procedure for testing the thermo unit resistance at different temperatures.
Procedure for testing the water temperature meter by grounding and checking needle movement.
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