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

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-8
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.
Install movable drive face comp. onto crankshaft.
Driven pulley installation
Press driving belt into pulley groove, and then pull
the belt onto drive shaft.
Install drive face, washer and nut.
Caution
Make sure that two sides of pulley surfaces have
to be free of grease.Clean it with cleaning
solvent.
Hold driver face with universal holder.
Tighten nut to specified torque.
Torque value: 5.0~6.0kgf-m
Install left crankcase cover.
Drive face boss
Movable drive face Drive face boss
Crank shaft
Press down
Drive belt
Nut
Drive face

10. V-BELT DRIVING SYSTEM/KICK STARTER
Clutch Outer/Driven Pulley
10-9
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.
Hold the clutch spring compressor onto bench vise,
and then remove mounting nut with special service
tool.
Release the clutch spring compressor and remove
clutch weight and spring from driven pulley.
Remove seal collar from driven pulley.
Remove guide pin, guide pin roller, and movable
driven face, and then remove O-ring & oil seal
seat from movable driven face.
Inspection
Clutch outer
Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.
Service limit: 125.5 mm
Clutch nut wrench
Clutch spring compressor
Collar
Movable driven face Guide pin
Seal
Clutch outer
Inner
diameter
O-ring Guide pin roller
Guide pin

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-10
Clutch lining Clutch lining
Measure each clutch weight thickness. Replace it
if exceeds service limit.
Service limit: 2.0 mm
Driven pulley spring
Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Service limit: 163.7 mm
Driven pulley
Check following items:
yIf both surfaces are damaged or worn.
yIf guide pin groove is damaged or worn.
Replace damaged or worn components.
Measure the outer diameter of driven face and the
inner diameter of movable driven face. Replace it
if exceeds service limit.
Service limit: Outer diameter 33.94 mm
Inner diameter 34.06 mm
Driven Pulley Bearing Inspection
Check if the inner bearing oil seal is damage.
Replace it if necessary.
Check if needle bearing is damage or too big
clearance. Replace it if necessary.
Rotate the inside of inner bearing with fingers to
check if the bearing rotation is in smooth and silent.
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.
Clutch weight
Free length
Driven face
Guide pin groove
Movable driven face
Needle bearing
Outer ball bearing

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-11
Clutch weight Replacement
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.
Check if shock absorption rubber is damage or
deformation. Replace it if necessary.
Apply with grease onto setting pins.
Install new clutch weight onto setting pin and then
push to the specified location.
Apply with grease onto setting pins.
But, the clutch block should not be greased. If so,
replace it.
Caution
Grease or lubricant will damage the clutch weight
and effective the block’s connection capacity.
Install the spring into groove with pliers.
Spring Driving plate
Shock absorption rubber
Clutch weight
Spring
Snap ring
Clutch weight
Shock absorption rubber
Setting pin

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-12
Install snap ring and mounting plate onto setting
pin.
Replacement of Driven Pulley Bearing
Remove inner bearing.
Caution
yIf the inner bearing equipped with oil seal on
side in the driven pulley, then remove the oil
seal firstly.
yIf the pulley equipped with ball bearing, it has to
remove snap ring and then the bearing.
Remove snap ring and then push bearing forward
to other side of inner bearing.
Place new bearing onto proper position and its
sealing end should be forwarded to outside.
Apply with specified oil.
Install new inner bearing.
Caution
yIts sealing end should be forwarded to outside
as bearing installation.
yInstall needle bearing with hydraulic presser.
Install ball bearing by means of hydraulic
presser.
Install snap ring into the groove of driving face.
Align oil seal lip with bearing, and then install the
new oil seal (if necessary).
Bearing end
Clipper
Outer bearing
Snap ring
Inner needle
bearing
Specified oil
Snap ring
Snap ring
Outer bearing
Inner bearing

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-13
Installation of Clutch OUTER/Driven Pulley
Assembly
Install new oil seal and O-ring onto movable driven
face.
Apply with specified grease to lubricate the inside
of movable driven face.
Install the movable driven face onto driven face.
Install the guide pin and guide pin roller.
Install the collar.
Install driving belt, spring and clutch weight COMP.
into clutch spring compressor, and press down the
assembly by turning manual lever until mounting
nut that can be installed.
Hold the compressor by bench vise and tighten
the mounting nut to specified torque with clutch
nut wrench.
Remove the clutch spring compressor.
Torque value: 5.0~6.0kgf-m
Install clutch outer/driven pulley and driving belt
onto driving shaft.
Oil seal
Specified grease
O-ring
Collar
O-ring Guide pin
Guide pin roller
Guide pin
Oil seal
Movable driven face
Clutch nut wrench
Clutch spring compressor

10. V-BELT DRIVING SYSTEM/KICK STARTER
10-14
Notes:

11. FINAL DRIVING MECHANISM
Mechanism Diagram ··························· 11-1
Precautions in operation ···················· 11-2
Trouble Diagnosis······························· 11-2
Disassembly of Final Driving Mechanism
······························································ 11-3
Inspection of Final Driving Mechanism
·······························································11-4
Bearing Replacement ··························11-5
Re-assembly of Final Driving Mechanism
·······························································11-8
Mechanism Diagram
11-1
Bearing 6301C3
Dowel Pin 10x14
Dowel Pin 10x14
Final gear
Bearing 6203U
Bearing 6301C3
Bearing (TMB. 6301)
Bearing 6004U
Drive shaft
Counter shaft
Counter gear
Final shaft
11
Brearing CSB. 204

11. FINAL DRIVING MECHANISM
11-2
Precautions in operation
Specification
Application oil: scooter gear oil
Recommended oil: KING MATE serial gear oils
Oil quantity: 100cc. (100cc when replacing)
Torque value
Gear box cover 1.0~1.4kgf-m
Tools
Special tools
Bearing (6203/6004UZ) driver: SYM-9620000
Bearing (6204) driver: SYM-9110400
Bearing (6301) driver: SYM-9610000
Oil seal (27*42*7) driver: SYM-9125500
Oil seal (20*32*6) driver: SYM-9120200
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.
yDamaged driving gear
yBurnt out driving gear
Noise
yWorn or burnt gear
yWorn gear
Gear oil leaks
yExcessive gear oil.
yWorn or damage oil seal

11. FINAL DRIVING MECHANISM
11-3
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.
Remove final gear and shaft.
Remove counter shaft and gear.
Remove gasket and dowel pin.
Remove the drive shaft.
In order to avoid damaging the gear box cover, in
the cover place a rag between the cover and table.
Caution
yIf non- essential do not remove the drive
shaft from the cover upper side.
yIf remove the drive shaft from the gear box
cover, then its bearing has to be replaced.
7 bolts
Dowel pin
Gasket
Final shaft & gear Counter shaft & gear