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VS150
Sym VS150 User Manual
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10. AL
TERNA
T
OR/ST
ARTING
CLUTCH
10-6
Remove 3 hexagon bolts with air and hex socket
wrenches.
Disassembly
Install the component
s in the reverse procedures
of removal.
Caution
T
ape a tightening tape o
nto the thread of hexagon
bolt.
Torque value: 1.0~1.4kgf-m
Installation
Install reduction gear shaf
t and reduction gear
.
Install st
arting clutch gear onto crankshaft.
T
o this chapter content
s
118
120
Table of Contents
1. General Information
6
Table of Contents
6
General Safety
7
Service Precautions
8
Specifications
14
Lubrication System
14
Specifications
15
Torque Values
16
Troubles Diagnosis
18
Parts to be Greased
22
2. Maintenance Information
24
Periodical Maintenance Schedule
25
Fuel Lines / Cable
26
Maintenance Information
26
Air Cleaner
27
Spark Plug
27
Valve Clearance
28
Carburetor Idle Speed Adjustment
29
Cylinder Compression Pressure
30
Ignition System
30
Brake System (Front Disk Brake)
31
Drive Belt
31
Brake Light Switch/Starting Inhibitor
33
Clutch Disc Wear
33
Headlight Beam Distance
33
Switch
33
Cushion
34
Nuts, Bolts Tightness
34
Side Stand
34
Steering Handle Top Bearing
35
Wheel/Tire
35
Special Tools List
36
3. Lubrication System
40
Lubrication System
40
Precautions in Operation
41
Troubleshooting
41
Engine Oil
42
Engine Oil Strainer Clean
42
Oil Pump
43
Gear Oil
46
4. Fuel System
48
Fuel System
48
Precautions in Operation
49
Fuel System
49
Trouble Diagnosis
50
Carburetor Removal
51
Vacuum Chamber
51
Air Cut-Off Valve
53
Auto By-Starter
54
Float Chamber
55
Fuel Tank
57
Air Cleaner
58
5. Engine Removal
60
Engine Removal
60
Removal of Engine
61
Engine Hanger Removal
64
Removal of Engine Hanger Bush
65
Engine Hanger Installation
66
Engine Installation
66
6. Cylinder Head/Valve
68
Cylinder Head/Valve
68
Precautions in Operation
69
Troubleshooting
70
Cylinder Head Removal
71
Cylinder Head Disassembly
73
Cylinder Head Inspection
74
Valve Stem Replacement
75
Valve Seat Inspection and Service
76
Cylinder Head Reassembly
78
Cylinder Head Installation
79
Valve Clearance Adjustment
81
7. Cylinder/Piston
82
Cylinder/Piston
82
Precautions in Operation
83
Trouble Diagnosis
83
Cylinder Removal
84
Piston Removal
85
Piston Ring Installation
87
Cylinder Installation
88
Piston Installation
88
8. V-Belt Driving System/Kick Starter
90
Maintenance Description
91
Trouble Diagnosis
91
Left Crankcase Cover
92
Driving Belt
93
Drive Face
95
Clutch Outer/Driven Pulley
98
Final Driving Mechanism
104
Bearing Replacement
108
10. Alternator/Starting Clutch
114
Alternator
114
Precautions in Operation
115
A.C.G. Set Removal
116
Flywheel Removal
116
Right Crankcase Cover Removal
116
Starting Clutch
117
A.C.G. Set Installation
120
Flywheel Installation
120
Right Crankcase Cover Installation
120
11. Crankcase / Crank
122
General Information
123
Trouble Diagnosis
123
Disassembly of Crankcase
124
Crankshaft Inspection
126
Assembly of Crankcase
127
12. Cooling System
130
Cooling System
130
General Information
131
Trouble Diagnosis
131
System Test
134
Radiator
135
Water Pump
137
Thermostat
141
13. Body Cover
144
Maintenance
145
Front Cover
146
Handle Front Cover
147
Handle Rear Cover
148
Side Cover
149
Front under Spoiler
150
Luggage Box
151
Rear Carrier
152
13. Body Cover
153
Inner Box
154
Floor Panel
155
Front Fender
156
Center Fender
158
Rear Fender
158
14. Brake
160
Mechanism Diagram-Rear Drum Brake
161
Maintenance Description
162
Trouble Diagnosis
163
Disk Brake System Inspection
164
Adding Brake Fluid
165
Brake Fluid Replacement / Air-Bleed
166
Disk Brake-Caliper
167
Brake Disk
168
Disk Brake - Master Cylinder
168
Rear Drum Brake
171
15. Steering / Front Wheel / Front Cushion
174
Operational Precautions
175
Trouble Diagnosis
175
Steering Handle
176
Front Wheel
178
Front Cushion
181
Steering Stem
182
16. Rear Wheel / Rear Fork / Rear Cushion
184
Operational Precaution
185
Trouble Diagnosis
185
Muffler
186
Rear Wheel
186
Rear Cushion
188
17. Electrical System
190
Electrical System
190
Maintenance Data
191
Technical Specification
191
Trouble Diagnosis
192
Battery
193
Charging System
194
Ignition System
197
Starting System
199
Meters
200
Light / Bulb
201
Switch / Horn
203
Fuel Unit
206
Cooling Fan Thermo Switch
207
Thermo Unit
208
Water Temperature Meter
208
Electrical Diagram
210
4
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Sym VS150 Specifications
General
Brand
Sym
Model
VS150
Category
Motorcycle
Language
English
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