Sym VS150 User manual

VS150 / VS2
SERVICE MANUAL

1.
FORWARD
This service manual contains the technical data of each component inspection and
repair for the VS150 / VS2 motorcycle. The manual is shown with illustrations and
focused on “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.
Specifications are subject to change without notice.
Service Department
VMEP COMPANY

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.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information and special tools
manual.
The third to the 11th chapters cover engine and driving systems.
The 12th to the 17th chapter is contained the parts set of assembly frame body
and body cover.
The 18th chapter is electrical equipment.
The 19th chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.

10. V-BELT DRIVING SYSTEM/KICK STARTER
Mechanism Diagram ··························· 10-1 Driving Belt···········································10-4
Maintenance Description···················· 10-2 Drive Face·············································10-6
Clutch Outer/Driven Pulley··················10-9Trouble Diagnosis······························· 10-2
Left Crankcase Cover ························· 10-3
Mechanism Diagram
3.5~4.5kgf-m
10-1
5.0~6.0kgf-m
10
5.0~6.0kgf-m

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-2
Maintenance Description
Precautions in Operation
General Information
yDrive face, clutch outer, and driven pulley can be serviced on the motorcycle.
yDriving belt and driving pulley must be free of grease.
Specification Unit：mm
Item Standard value (mm) Limit (mm)
Driving belt width 19.500~20.500 18.500
ID of drive face boss 23.989~24.052 24.060
OD of drive face 23.960~23.974 23.940
OD of roller 17.920~18.080 17.400
ID of clutch outer 125.000~125.200 125.500
Thickness of clutch weight 4.000~4.100 1.200
Free length of driven pulley spring 168.900 163.700
OD of driven pulley 43.65~43.85 43.800
ID of drive face 39.000~39.025 39.060
Torque value
yDriven face nut: 5.0~6.0kgf-m
yClutch outer nut: 5.0~6.0kgf-m
Special Service Tools
Clutch spring compressor: SYM-2301000
Inner bearing puller: SYM-6204002
Clutch nut wrench 39 x 41 mm: SYM-9020200
Universal holder: SYM-2210100
Bearing driver: SYM-9100100
Trouble Diagnosis
Engine can be started but motorcycle can
not be moved
1. Worn driving Belt
2. Worn drive face
3. Worn or damaged clutch weight
4. Broken driven pulley
Shudder or misfire when driving
1. Broken clutch weight
2. Worn clutch weight
Insufficient horsepower or poor high
speed performance
1. Worn driving belt
2. Insufficient spring force of driven pulley
3. Worn roller
4. Driven pulley operation un-smoothly

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-3
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).
Left crankcase cover install
Install left crankcase cover in the reverse
procedures of removal.
Drive face and Driven face Comp.
L. Crank case cover Comp. Kick starter spindle Comp.
Drive face
Kick return spring
Driven faceDrive belt

10. V-BELT DRIVING SYSTEM/KICK STARTER
Driving Belt
10-4
Removal
Remove left crankcase cover
Hold drive face with universal holder, and remove
nut and drive face.
Hold clutch outer with universal holder, and
remove nut and clutch outer.
Caution
yUsing special service tools for tightening or
loosening the nut.
yFixed rear wheel or rear brake will damage
reduction gear system.
Push the driving belt into belt groove as diagram
shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley.Do not remove driving belt.
Remove the driving belt from the groove of driven
pulley.
Inspection
Check the driving belt for crack or wear.Replace it
if necessary.
Measure the width of driving belt as diagram
shown.
Service Limit: 18.5 mm
Replace the belt if exceeds the service limit.
Caution
yUsing the genuine parts for replacement.
yThe surfaces of driving belt or pulley must be
free of grease.
yClean up all grease or dirt before installation.
Nut
Universal holder
Drive belt
Universal holder
Belt tooth
Width

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-5
Installation
Caution
Pull out driven face to avoid it closing.
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.
Install the clutch outer with universal holder, and
then tighten nut to specified torque value.
Torque value: 5.0~6.0kgf-m
Install the drive face with universal holder, and
then tighten nut to specified torque value.
Torque value: 5.0~6.0kgf-m
Driven face
Clutch outer
Nut
Universal holder
Universal holder

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-6
Drive Face
Removal
Remove left crankcase cover.
Hold generator flywheel with universal holder, and
then remove drive face nut.
Remove drive face.
Remove driving belt and movable drive face comp
from crankshaft.
Remove ramp plate.
Remove weight rollers from movable drive face.
Crankshaft Drive face boss
Movable drive face
Ramp plate
Movable drive face
Universal holder
Weight roller

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-7
Inspection
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.
Measure each roller’s outer diameter. Replace it if
exceed the service limit.
Service limit: 17.4 mm
Weight: 14.0 g
Check if drive face boss is worn or damaged and
replace it if necessary.
Measure the outer diameter of movable drive face,
and replace it if it exceed service limit.
Service limit: 23.94 mm
Measure the inner diameter of movable drive face,
and replace it if it exceed service limit.
Service limit: 24.06 mm
Reassembly/installation
Install weight rollers.
Caution
The weight roller two end surfaces are not
certainly same. In order to lengthen the roller life
and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.
Install ramp plate.
Weight roller
Movable drive face
Drive face boss
Weight roller
Closure surface
Guide collar
Ramp plate