Sym VS150 - User Manual

195 pages

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VS150 / VS2

SERVICE MANUAL

Main Page

1. aHome page.pdf1
1. Forward.pdf2
10. V-Belt Driving System.pdf4
- Mechanism Diagram4
- Maintenance Description5
- Trouble Diagnosis5
- Left Crankcase Cover6
- Driving Belt7
- Drive Face9
- Clutch Outer/Driven Pulley12
11. Final Drive System.pdf18
- Mechanism Diagram18
- Precautions in operation19
- Trouble Diagnosis19
- Disassembly of Final Driving Mechanism20
- Inspection of Final Driving Mechanism21
- Bearing Replacement22
- Re-assembly of Final Driving Mechanism25
12. ACG & Start one way clutch.pdf28
- Mechanism Diagram28
- Precautions in Operation29
- Right Crankcase Cover Removal30
- Flywheel Removal30
- A.C.G. Set Removal31
- Starting Clutch Removal31
- A.C.G. Set Installation34
- Flywheel Installation34
- Right Crankcase Cover Installation34
13. Crankcase & Crank.pdf36
- Mechanism Diagram36
- General information37
- Trouble diagnosis37
- Disassembly of crankcase38
- Crankshaft Inspection40
- Assembly of crankcase41
14. Body Cover.pdf45
- Mechanism Diagram45
- Maintenance46
- Front cover47
- Handle front cover48
- Handle rear cover49
- Floor panel50
- Side cover50
- Front under spoiler51
- Luggage box52
- Rear carrier53
- Body cover54
- Inner box55
- Front fender57
- Rear fender59
- Center fender59
15. Brake.pdf61
- Mechanism Diagram-Front Disk Brake61
- Mechanism Diagram-Rear Drum Brake62
- Maintenance Description63
- Trouble Diagnosis64
- Disk Brake System Inspection65
- Adding Brake Fluid66
- Brake fluid replacement / Air-bleed67
- Disk Brake - Caliper68
- Brake Disk69
- Disk Brake - Master Cylinder69
- Rear Drum Brake72
16. Steering & Cushion & Wheel (E).pdf75
- Mechanism Diagram75
- Operational Precautions76
- Trouble Diagnosis76
- 76
- Steering Handle77
- Front Wheel79
- Front Cushion82
- Steering Stem83
17. Rear Wheel & Fork & Cushion (E).pdf86
- Mechanism Diagram86
- Operational Precaution87
- Trouble Diagnosis87
- Muffler88
- Rear Wheel88
- Rear Cushion90
18. Electrical System.pdf92
- Mechanism Diagram92
- Maintenance Data93
- Technical Specification93
- Trouble Diagnosis94
- Battery95
- Charging System96
- Ignition System99
- Starting System101
- Meters102
- Light / Bulb103
- Switch / Horn105
- Fuel Unit108
19. Electrical Dfiagram.pdf110
2. Contents.pdf112
- GENERAL INFORMATION112
- SERVICE MAINTENANCE INFORMATION112
  - LUBRICATION SYSTEM112
- CRANKSHAFT/ CRANKCASE112
  - BODY COVER112
3. General Information.pdf114
- Symbols and Marks114
- General safety115
- Service Precautions116
- Specifications122
- Specifications123
- Torque Values124
- Troubles Diagnosis126
- Parts to Be Greased130
4. Maintenance Information.pdf132
- Precautions in Operation132
- Periodical Maintenance Schedule133
  - C133
  - C133
  - R133
  - R133
  - I133
  - A133
- Fuel Lines / Cable134
- Air Cleaner135
- Spark Plug135
- Valve Clearance136
- Carburetor Idle Speed Adjustment137
- Ignition System138
- Cylinder Compression Pressure138
- Drive Belt139
- Brake System (Front Disk Brake)139
- Brake Light Switch/Starting Inhibitor Switch141
- Head light Beam Distance141
- Clutch Disc Wear141
- Side Stand142
- Cushion142
- Nuts, Bolts Tightness142
- Wheel/Tire143
- Steering Handle Top Bearing143
5. Lubrication System.pdf145
- Precautions in Operation146
- Troubleshooting146
- Engine Oil147
- Engine Oil Strainer Clean147
- Oil Pump148
- Gear Oil151
6. Fuel System.pdf153
- Precautions in Operation154
- Trouble Diagnosis155
- Carburetor removal156
- Vacuum chamber156
- Air Cut-Off Valve158
- Auto By-Starter159
- Float Chamber160
- Fuel Tank162
- Air Cleaner163
7. Engine Removal.pdf165
- Precautions in Operation165
- Removal of Engine166
- Engine Hanger removal169
- Removal of Engine Hanger Bush170
- Engine Hanger Installation171
- Engine Installation171
8.Cylinder Head & Valve.pdf173
- Mechanism Diagram173
- Precautions in Operation174
- Troubleshooting175
- Cylinder Head Removal176
- Cylinder Head Disassembly178
- Cylinder Head Inspection179
- Valve Stem Replacement180
- Valve Seat Inspection and Service181
- Cylinder Head Reassembly183
- Cylinder Head Installation184
- Valve Clearance Adjustment186
9. Cylinder & Piston.pdf188
- Mechanism Diagram188
- Precautions in Operation189
- Trouble Diagnosis189
- Cylinder Removal190
- Piston Removal191
- Piston Ring Installation193
- Piston Installation194
- Cylinder Installation194

Questions and Answers

P
peterturnerJul 28, 2025
What to do if the clearance between the rotor side and body exceeds the limit in my Sym VS150 Motorcycle?
- G
  garciamarthaJul 28, 2025
  If the clearance between the rotor side and body exceeds the limit, reduce the clearance to within the specified limits.

Sym VS150 Specifications

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