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2004 Yamaha VINO/Classic (50cc) Motorcycle Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: VINO / Classic Year: 2004 Engine Displacement: 50cc Vehicle Type: Motorcycle / Scooter Codes Chassis Code Prefix: SA13 👋 Introduction Market Position Segment:...
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Tipo: Motocicletas
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SKU: 409508
2004 Yamaha VINO/Classic (50cc) Motorcycle Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
VINO / Classic
Year:
2004
Engine Displacement:
50cc
Vehicle Type:
Motorcycle / Scooter
Codes
Chassis Code Prefix:
SA13
👋 Introduction
Market Position
Segment:
Lightweight urban scooter, entry-level rider segment, commuter market.
Competitive Analysis
Key Competitors:
Honda Dio, Suzuki Address, Kymco Agility 50, various other 50cc scooters of the era.
Key Features
Model Advantages:
Yamaha's reputation for reliability, user-friendly operation, stylish retro 'Classic' variant design, economical operation.
Manual Purpose
Target Audience:
Yamaha Dealership Technicians, Independent Repair Shops, DIY Enthusiasts, Owners seeking in-depth maintenance knowledge.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Comprehensive service and repair procedures
Page Count
Estimated Page Count:
200-300
Manual Type
Manual Category:
Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine System:
Complete engine overhaul, diagnostics, tuning, component replacement (cylinder, piston, crankshaft, valve train), lubrication system.
Fuel System:
Carburetor identification, adjustment, cleaning, fuel pump operation (if applicable), fuel filter replacement, fuel tank maintenance.
Cooling System:
Air-cooled system maintenance, cooling fin cleaning, temperature sensor checks.
Ignition System:
CDI unit, spark plug specifications and replacement, ignition timing checks, stator and coil testing.
Transmission System:
Automatic Continuously Variable Transmission (CVT) system, variator maintenance, clutch assembly inspection and replacement, drive belt inspection and replacement, gear oil specification and change intervals.
Electrical System:
Wiring diagrams, battery maintenance and testing, starter motor operation, lighting system (headlight, taillight, turn signals), charging system (generator/alternator), fuses, horn, electrical component troubleshooting.
Braking System:
Front and rear brake system maintenance, brake fluid specifications and replacement, brake pad wear inspection and replacement, brake cable adjustment, drum brake servicing.
Suspension System:
Front fork service (oil level, seal replacement), rear shock absorber inspection and replacement, linkage lubrication.
Steering System:
Handlebar assembly, steering stem bearing inspection and lubrication, steering lock operation.
Chassis And Bodywork:
Frame inspection, body panel removal and installation, seat, luggage rack, fairings, fenders, stand maintenance.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, tire pressure checks, brake adjustments, drive belt inspection.
Troubleshooting Guides:
Diagnostic flowcharts for common starting, running, and electrical issues. Symptom-based troubleshooting.
Repair Procedures:
Step-by-step instructions for engine rebuilds, transmission servicing, electrical component replacement, brake caliper overhauls.
Technical Specifications:
Torque values for critical fasteners, engine tuning parameters, fluid capacities, electrical resistance values.
Technical Depth
Diagnostic Capabilities:
Covers basic diagnostic procedures and component testing using common tools. Advanced electronic diagnostics not typically required for this model.
Rebuild Scope:
Provides detailed instructions for complete engine and transmission overhauls, suitable for professional technicians or experienced DIY enthusiasts.
📊 Manual Specifications
File Format
Digital File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Image Resolution:
High-resolution for clear illustrations and diagrams.
Binding Type
Original Binding:
Staple-bound or perfect-bound (as per original Yamaha specification).
Paper Type
Original Paper Quality:
Durable, high-quality paper designed for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Air-cooled, SOHC, 2-valve
Bore X Stroke:
39.0 mm x 41.4 mm (approx.)
Compression Ratio:
12.0 : 1 (approx.)
Performance
Horsepower Output:
Approx. 4.0 - 4.5 PS @ 7000-7500 RPM
Torque Output:
Approx. 4.0 - 4.5 Nm @ 6000-6500 RPM
Fuel System
Carburetor Model:
Mikuni VM12 (or similar) - specific model number likely detailed in manual.
Fuel Type:
Unleaded Gasoline (Minimum 87 Octane)
Lubrication
Engine Oil Type:
SAE 10W-30 or 10W-40 API SE or SF (specific viscosity may vary by climate).
Engine Oil Capacity:
0.8 Liters (approx. for oil change), 0.9 Liters (with filter replacement).
Ignition
Spark Plug Type:
NGK CR6HSA or similar (gap: 0.6-0.7 mm)
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Optional
Transmission Variants:
N/A (CVT is standard)
Features
Drive Belt Dimensions:
Specific dimensions and part number available in manual (e.g., 17.5 x 669 mm).
Gear Reduction Ratio:
Refer to manual for specific ratios; typical for 50cc scooters.
Fluid Specifications
Gear Oil Type:
Yamalube Gear Oil 80W or equivalent SAE 80W GL-4 gear oil.
Fluid Capacities
Gear Oil Capacity:
0.11 Liters (approx.)
📐 Dimensions
Exterior
Overall Length:
Approx. 1740 mm
Overall Width:
Approx. 660 mm
Overall Height:
Approx. 1055 mm
Wheelbase:
Approx. 1240 mm
Weights
Wet Weight:
Approx. 80-85 kg
Maximum Load Capacity:
Refer to manual; typically around 150-180 kg including rider and cargo.
Cargo
Underseat Storage:
Sufficient for a helmet and small items (specific dimensions available in manual).
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Scooters typically do not undergo the same crash testing as automobiles).
Active Features
Braking System:
Front: Drum brake; Rear: Drum brake.
Lighting:
Halogen headlight, LED taillight, amber turn signals.
Passive Features
Frame Construction:
Steel tube frame for rigidity and durability.
Mirrors:
Adjustable mirrors for rear visibility.
💡 Technology Features
Infotainment
Dashboard Display:
Analog speedometer, fuel gauge (if equipped), indicator lights (turn signals, high beam, engine warning).
Driver Assistance
ABS Availability:
N/A (ABS was not a standard or optional feature on this model).
Connectivity
Bluetooth Usb:
N/A (Basic scooter technology of the era).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 km or 6 months, whichever comes first.
Air Filter Cleaning:
Every 3,000 km or 6 months; replace as needed.
Spark Plug Check And Clean:
Every 4,000 km.
Drive Belt Inspection:
Every 6,000 km; replace if worn or damaged.
Brake Fluid Change:
Every 2 years or 12,000 km.
Fluid Specifications
Coolant Type:
N/A (Air-cooled engine).
Known Issues
Common Wear Items:
Drive belt, variator rollers, brake pads, spark plug, air filter, starter motor brushes (common to many scooters).
Carburetor Tuning:
May require periodic cleaning and adjustment due to fuel quality variations or age.
Electrical Connections:
Corrosion on electrical connectors can sometimes lead to intermittent issues, especially in humid climates.
📚 Vehicle History
Brand Heritage
Yamaha Motorcycles:
Yamaha Motor Company, Ltd. is a Japanese manufacturer renowned for its motorcycles, musical instruments, and other powered products. Founded in 1955, Yamaha has a long history of innovation and performance in the motorcycle industry.
Model Evolution
Vino Lineage:
The Vino series, known for its retro styling, has been a popular model for Yamaha, particularly in markets valuing style and urban mobility. The 'Classic' variant emphasizes this vintage aesthetic.
Production
Manufacturing Location:
Primarily manufactured in Japan and/or Southeast Asia (e.g., Indonesia, Taiwan) depending on market.
🏆 Awards & Recognition
Recognitions
Consumer Reviews:
Generally positive for reliability and ease of use within its class. Specific awards unlikely for individual model year.
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