2004 Vino 2T - Rebuild For Daily Commute

[Colter]

Hello Everyone!

I have acquired a 2004 Yamaha Vino (2T) that has the following aftermarket stuff on it:

1. Off-brand 70CC BBK Kit
2. Technigas Silent Pro
3. DR Pulley Variator Kit (5g Rollers)
4. NCY Clutch Kit (Yellow Springs, yellow Coil)
5. Some off-brand 17mm Carb with an auto-choke.

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I'm going to rebuild it. Here's what I've ordered after reading up around here:

Parts:
1. Polini 70cc Cast Iron BBK
2. Polini Sport Crankshaft
3. Dellorto PHBN 17.5mm Carb (Manual Choke)
4. Yasuni R Exhaust
5. New Spark Plug

Accessories:
1. New intake and CVT Gasket
2. New Throttle Cable (direct fits the new carb without having to modify it).
3. Carbon Reeds (going to leave the intake stock otherwise)
4. Manual Choke Cable
5. Main Jet Set for the Carb (75-98)
6. 6G Roller Set and 7G Roller Set (I thought proper to have when tuning it in after the build).

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What I want is a stable scooter with known reliable parts that will last. I plan to commute on it, so I'd like for it to comfortably cruise around 40-45mph with a burst capability to 65mph (I want the ability to get out of the way when needed). I'm not a novice, I do have a few years of tinkering and rebuilding mechanics behind me, though I would not say I'm an expert by any means.

I'm going to try and document my journey here for others. I'm not trying to race this thing; I want a quick and reliable scooter. I think there may be a lot of others out there like me that would find this information and experience useful to reference. As I searched, while there's a TON of info, I think an overall rebuild thread for a decent commuter would be a great resource to add.

I'd like to involve the community as much as possible if you guys are willing. Any observations or opinions as I go here would be fantastic (I take criticism well, so don't be shy about it). I'll still be vigorously searching the forum as well for already well-repeated advice.

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To start, I have three questions:

1. Does anyone have anything to add to my direction above I may be missing? I already posted about the crankshaft tools I'd need, but if you see anything else, please feel free to let me know. The Devil is in the details, and almost everything I stumble upon could mean a week delay as I'll have to order it in.

2. As I'm building this, I've run across a few threads talking about the CDI and stock rev limiters. With all this going in, is there anything I need to do to the ignition? I don't want to blow the scoot up, ever, so if a rev limiter is not going to hinder the capability I want out of it, then maybe I should ignore it. I most likely won't be the only one riding it either, so if we can protect it, then we should.

3. All the lights on the scooter have been replaced with LED's. My buddy's wife, who had this before me, was super on top of safety. So, he replaced all the stock dim lights with really bright LEDs. They work great. However, the front headlight dims a ton on idle and brightens with a little throttle. Is there anything I can do to boost the power levels at idle and make the draws more stable? The battery is brand new.

There will undoubtedly be more questions and challenges as I go along.

Thanks, everyone, I'm excited to get moving on this new garage project.

[oldgeek]

Your top speed of 65 Mph may be a bit difficult to achieve depending on rider weight. Stock CDI is fine, no rev limiter IIRC. CF reeds not recommended due to durability, and you would likely have to make/cut your own as they are not like standard minarelli. Stock airbox is recommended to make tuning less painful. You may need more weights to dial in the variator to your liking. Decent tires, Michelin S1's would be a good choice. +50 MPH on 10" wheels is sketchy at best.
The Vino is a BLAST have fun with it!

[pinkscoot]

That looks like a fun build. I have a Vino clone with slightly larger tires and 45mph on them is a white knuckle ride. OldGeek had a 50mph Vino and I got the chance to ride it and it was one nice ride. I never saw better than 45mph on it because my brain kept saying "are you F'ing crazy" I also have 2 Vinos that have the parts to make one good one so I'll enjoy your thread.

[ryan_ott]

I think the only time you’ll see 65 is down hill. You’ve got parts for a decent, reliable build but not to the level for 65mph, 50-55 is more realistic. You might want to add gears to your list, somewhere between 10:1-11:1 final drive is preferred. TBH I’m not sure what the Vino ratios are. I would also go with a fresh belt, springs and service the rear TD. I’m sure it would be a blast once done.

[geoffh]

Colter,I commute daily on my jog,your speeds are a bit ambitious I stick at 49cc and rev around 5 6k just fast enough to keep up with the cagers,you wil need a stock of exhaust gaskets and studs,a puncture kit and brake light switches.while your in there a new coil and petcock and hoses won,t hurt.temp and rev counter is a must for a 70.you also need a bad weather/breakdown plan.

Geoff

[tiny]

I agree with most guys here.
I had an '01 Vino my wife drives an '03 both our top speeds were/are close to 90kph/55mph with a comfortable crusing speed of 70-75kph/45mph at 50cc engine size.
With small skinny 90/90r10 wheels and tyres and old style front suspension at speeds over 80 it gets sketchy. You might get lucky to top out at 60mph but with the Vino styled and built for comfort not speed i wouldn't recommend it.

[aeroxbud]

I'm not sure what the gearing is on a vino. But the Polini Sport is fairly low reving. With some good torque. So like Ryan said it might go best with a gear up kit.
You could always fit one later if needed.

[aeroxbud]

Here is an interesting blog on sports 70cc kits and gearing. Might be worth a read www.pedparts.co.uk/blog/do-i-need-a-gearup-kit-with-a-malossi-or-polini-sport-70cc-kit

[Colter]

You guys are great. I'm on a lot of different community platforms across numerous industries and classic forums always seem to be the best for wholesome community building. Thank you all for just being here and willing to contribute.

1. I hear 65Mph may be a stretch. I suppose that's fine, I may have more thrown that number out as a guesstimate. At the moment, the scoot will cruise around 30-35mph and max out somewhere around 40-45mph on a mild downhill. Maybe a more accurate depiction of my want is: I'm hoping to be able to bump that range up 10mph. Is that too ambitious?

2. It has a brand new complete clutch, complete variator, weights and belt from GBoost on it already. Should I buy a more diverse set of weights than just another 6 and 7-gram set (there is a 5-gram set in it now)? From what I've read, most rebuilds seem to settle somewhere in that range (some staggering the weights to achieve desired performance).

3. CF reeds were $9, I can shelf them for now.

4. Using stock airbox now. When I got it, I cleaned it and drilled a couple 1/4" holes on the back side to allow for a little more airflow. It seemed to run as is much better after I did that.

5. When you talk about "gearing" are you talking about something else besides the CVT? I assume the gearing in the transfer case on the rear wheel?

6. The tires are Michelin S1's now and they're in fairly decent shape. I'm 6' flat and 180lbs. If it's possible, I would like to explore changing out some shocks/struts to make it a softer ride. The springs on the front are pretty harsh (stock). Additionally, as long as it doesn't jeopardize safety, I have also thought about replacing the rear show with a slightly longer one to give it more room for travel.

Thanks again, everyone. I'll post some starter pictures today.

[aeroxbud]

The gears are in the cover behind the torque drive images.cmsnl.com/img/partslists/yamaha-yj50r-vino-2003-3-usa-clutch_bigyau2254b-3_34cf.gif

[Colter]

May 26, 2019 14:10:22 GMT -5 aeroxbud said:

The gears are in the cover behind the torque drive images.cmsnl.com/img/partslists/yamaha-yj50r-vino-2003-3-usa-clutch_bigyau2254b-3_34cf.gif

Ah, ok. 

Whats the general consensus on the need for this ATM around the group? Is this something I should do to obtain what I'm looking to do? 

[oldgeek]

May 26, 2019 15:29:16 GMT -5 Colter said:

May 26, 2019 14:10:22 GMT -5 aeroxbud said:

The gears are in the cover behind the torque drive images.cmsnl.com/img/partslists/yamaha-yj50r-vino-2003-3-usa-clutch_bigyau2254b-3_34cf.gif

Ah, ok. 

Whats the general consensus on the need for this ATM around the group? Is this something I should do to obtain what I'm looking to do? 

In my experience no. My vino would easily do 50+ when it was fresh with a 300lb payload. It had a next R pipe, a no name 70cc BBK and a rejetted stock carb. It got off the line plenty fast too. There is a little secret about the Vino motors. Yamaha used a special reed block, and angled the whole thing towards the transfers. They are also the only cases I know of that have factory trenching for better flow. There are plenty of pictures around here that show what I mean, I will look for some.

[aeroxbud]

It's something that you can always do later if you feel the need. Me personally I would wait and see. You just have to be aware to not over rev the engine.

[pinkscoot]

As you do this build be sure to do one thing at a time, get it running and move on. Too often people throw all of the parts on then come back and say it won't, start idle or run right. Take your time and get every step right before moving on. It may take a little time but it will be easier when you come back and ask for help, you'll know what the change was.

I haven't always listened to this advice and everything took twice as long and left me very frustrated.

[Colter]

Here's what I'm starting with:

I've already had all the fairings repainted; new badges and seat cover. All new handlebar controls and mirrors. I also put on the new exhaust the other night out of anxiety.. Of course, it ran horribly, but it was sooooo much quieter than the previous Technigas Silent Pro.

I'm going to pull the engine out of it this afternoon and prep it for the parts to arrive this week. Will post more pics.

Front
Left Side
Right Side
Handlebars
Rear