Yamaha X94 Series Service manual

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Yamaha X94 Series Service manual | Manualzz

SERVICE MANUAL e-Bike SYSTEMS

X94 Series

1

2

3

4

How to Use This Manual

Searching for Manual Contents

1. Refer to the table on the following page to determine the applicable parts according to the model type code and product code.

2. This manual is divided into four parts: General information, electrical components,

Drive Unit, and service data.

3. The table of contents is provided at the beginning of the manual. Review the overall makeup of the manual and search for the chapters and sections you need.

Symbols

Important items in this manual are indicated by the following symbols:

The symbols indicate precautions pertaining to safety.

WARNING

Indicates that incorrect use could result in death or serious injury.

NOTICE

Indicates that incorrect use could cause property damage.

TIP

Symbols indicate the following meanings or items:

1 2

GEN

INFO

ELEC

– +

3

Drive

Unit

5 6

4

Service

Data

7

8

0

LS

A

Indicates methods are correct operation or main elements of inspection and maintenance.

9

B

.

T

R

.

1 General information section

2 Electrical Components section

3 Drive Unit section

4 Service data section

5 Special tools

6 Types of grease

7 Tightening torque

8 Standard values or limits of use

9 Standard values for resistance ( Ω), voltage (V), current (A)

0 Lithium-soap-based grease

A Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil (MULTEMP AC-

N ® )

B New parts to be used when replacing

Index

General Information

Electrical Components

Drive Unit

Service Data

GEN

INFO

– +

1

ELEC

2

Drive

Unit

3

Service

Data

4

CONTENTS

CHAPTER 1 General Information

Description ................................................................................................... P1-1

Precautions relating to maintenance (1).................................................... P1-2

Cleaning and Maintenance ................................................................... P1-2

Keep away from fire.............................................................................. P1-2

Proper tools .......................................................................................... P1-2

Replacement parts................................................................................ P1-3

Precautions for disassembly and reassembly ...................................... P1-3

Handling the Battery Pack .................................................................... P1-4

Servicing Precautions (2) ............................................................................ P1-5

Bearing Installation ............................................................................... P1-5

Oil Seal Installation ............................................................................... P1-5

Circlip Installation.................................................................................. P1-5

Precautions relating to maintenance (3).................................................... P1-6

Handling of the torque sensor............................................................... P1-6

Specialized tools and equipment ............................................................... P1-7

CHAPTER 2 Electrical Components

Electrical component wiring diagram ........................................................ P2-1

Battery pack ................................................................................................. P2-2

Battery pack display function ................................................................ P2-2

Error display.......................................................................................... P2-2

How to check the total number of battery charging cycles ................... P2-4

How to check the absolute battery capacity ......................................... P2-5

Charging ....................................................................................................... P2-6 e-Bike system dedicated battery charger ............................................. P2-6

Display on battery capacity indicator lamps while charging.................. P2-7

Diagnosis mode ........................................................................................... P2-8

Recoverable errors of battery pack or battery charger ......................... P2-8

Non-recoverable errors of battery pack .............................................. P2-11

Temperature protection function......................................................... P2-14

Over-discharge protection function..................................................... P2-15

Diagnosis function (LED type display unit)............................................. P2-17

Display unit’s display when there is an error ...................................... P2-17

Operating Procedures to Diagnosis Mode.......................................... P2-19

Diagnosis function (LCD type display unit) ............................................ P2-28

Display unit’s display when there is an error ...................................... P2-28

Operating Procedures to Diagnosis Mode.......................................... P2-30

Diagnosis function .............................................................................. P2-39

Speed sensor set ....................................................................................... P2-45

Speed sensor inspection .................................................................... P2-45

CHAPTER 3 Drive Unit

Drive axle, Motor (drive axle with square-type end) ................................. P3-1

Drive axle, Motor (drive axle with spline-type end [ISIS adapter]) .......... P3-5

Removal of the parts from the drive axle

(drive axle with square-type end).......................................................... P3-9

Removal of the parts from the drive axle

(drive axle with spline-type end) ........................................................... P3-9

Removal of the Controller Assembly .................................................... P3-9

Removal of the Torque sensor assembly and Drive axle. .................. P3-11

Installation of the Drive axle and Controller assembly........................ P3-11

Installation of the Controller assembly................................................ P3-11

Installation of the Bearing Housing ..................................................... P3-13

Installation of the Stator Cover ........................................................... P3-14

CHAPTER 4 Service Data

Tightening Torque ....................................................................................... P4-1

Other, general tightening torques ......................................................... P4-1

Lubricants, areas to apply sealant and specified types........................... P4-1

Cable, Wire, and Pipe routing diagram ...................................................... P4-2

Troubleshooting........................................................................................... P4-3

1

Description

1

Description

General Information

GEN

INFO

2 b a

3

È c

É a

4 b

5

1. Drive Unit

2. Speed sensor set a) Magnet sensor spoke type b) Pick up

3. È Display Unit (LED type)

É Display Unit (LCD type) a) Display (detachable) b) Display holder c) Switch

4. Battery charger

5. Battery pack (The battery may differ depending on the model.)

* The actual Drive Unit may differ slightly from the picture shown.

1-1

Keep away from fire!

Precautions relating to maintenance (1)

GEN

INFO

Precautions relating to maintenance (1)

Cleaning and Maintenance

NOTICE

When washing the bicycle, keep water away from the e-bike system.

Water which comes in direct contact with the e-bike system can get inside and reduce performance. Steam cleaning is particularly to be avoided.

1. Remove any mud or dust from the frame and Drive Unit to make sure that it does not get inside when performing service.

2. Use water or neutral cleanser to clean covers, and wipe off water using a soft cloth to prevent scratching. Avoid wiping with a dry cloth prior to washing.

Keep away from fire

Keep the workplace away from open fire.

1

Proper tools

When servicing the bicycle, be sure to use the special tools intended for areas which require special tools in order to prevent damage to parts. Also, work appropriate work should be done using appropriate tools and measuring devices. (Avoid using spanner wrenches. Use offset or box wrenches instead.)

1-2

Precautions relating to maintenance (1)

Genuine parts

GEN

INFO

Replacement parts

Replace gaskets (packing), O-rings, cotter pins, circlips (split rings), lock washers, etc.

with new parts.

Be sure to use genuine new Yamaha parts and recommended parts for oils and greases, including periodic replacement parts and repair parts.

Do not use used parts because, even though these parts may appear to be the same, they may not be genuine parts, or there is the risk that their quality has changed due to previous use.

Precautions for disassembly and reassembly

1. Inspect and measure parts as needed during disassembly. Keep good records which you can refer to when reassembling parts.

2. Organize parts by sections so that you do not mix them up or lose them.

3. Use cleaning oil to clean Drive Unit parts after disassembly and blow parts clean with compressed air.

4. Reassemble parts while checking any corrections made to parts and referring to the data collected prior to disassembly.

5. While reassembling parts make sure that each part is clean and free of foreign material.

6. Perform reassembly while checking the actions to be performed for each section.

7. Apply oil to sliding parts.

8. Tighten all nuts and bolts to their specified torque.

9. Maintain good communications when the work is done by 2 service personnel.

1-3

Precautions relating to maintenance (1)

GEN

INFO

Handling the Battery Pack

1. Use the dedicated battery charger for charging the battery pack.

2. The battery pack is a dedicated e-bike system battery. If it is connected to a product other than the e-bike system, it will cause a fluid leakage, “overheating, or breakage.”

3. Be sure to charge the e-bike system before operating it for the first time or after it has been unused for a long period of time.

4. Do not expose the battery pack to fresh water or seawater. It can cause the battery pack to overheat or rust.

5. Do not disassemble or modify the battery pack. It can cause a fluid leakage, overheating, or breakage. To replace the battery pack, replace the entire assembly.

6. If charging is not completed even after the specified charging time has elapsed, stop charging. If charging is continued, it can cause a fluid leakage, overheating, or breakage.

7. The battery pack should be sorted for environmental-friendly recycling. Do not dispose of the battery pack as household waste.

1-4

Servicing Precautions (2)

GEN

INFO

Servicing Precautions (2)

Bearing Installation

1. When installing a bearing, the surface with the manufacturer’s mark and the size code should face outward.

2. When striking a bearing into the case, apply a parallel force to the outer race.

3. When striking a bearing onto an axle, apply a parallel force to the inner race.

Main lip

Oil

Sub lip

Spring

Circlip

Gear

Chamfer

Grease

Oil Seal Installation

1. To install an oil seal, direct the main lip towards the oil chamber (the object of sealing).

2. Be sure to apply a thin, even coat of grease to the sealing lip before installing the oil seal.

Circlip

Circlip Installation

1. To install a circlip, direct the chamfered side of the circlip inward.

2. Install the circlip by aligning its opening with the center of the spline.

3. Do not expand the circlip more than necessary.

Axle

1-5

Precautions relating to maintenance (3)

GEN

INFO

Precautions relating to maintenance (3)

Handling of the torque sensor

1. Keep away from magnets.

Do not use magnetized screwdrivers or perform maintenance near large sources of electric power.

7. Do not reuse damaged drive axles.

The sensor shaft and the drive axle slide in a metal bearing. It will be difficult to install the one-way clutch and the sensor shaft if there are scratches on the surface of the drive axle.

2. Avoid strong mechanical impact.

Torque sensors which have been dropped or which have been removed through the use of a hammer or the like cannot be used because the torque sensor reference voltage can change significantly due to variations in the internal magnetic circuits.

8. Do not disassemble the torque sensor.

Do not disassemble the interior of the sensor because the torque sensor cannot be readjusted. Torque sensors that have been disassembled cannot be used.

3. Do not crush or press in the axial direction.

Any deformation of the torque sensor case by crushing can result in changes in the torque sensor reference voltage. Torque sensor reference voltage changes can also be caused by the application of a force of over 2 kgf on the sensor shaft while the case is clamped in place.

The installation of a one-way clutch having a tightly-fitted spline can apply excessive force to the sensor shaft and result in voltage changes.

4. Do not pull leads.

Do not pull forcefully on the small circuit board leads which connect the torque sensor body to the torque sensor. It can change the torque sensor reference voltage.

5. Do not allow water to come in contact with the Drive Unit.

Any rust on the sensor shaft or the main axle can cause output fluctuations or can reduce the strength of the parts. Do not perform servicing on the sensor in wet locations.

6. Organic solvents

Do not apply gasoline or solvent-based lubricants (consumer spray-type lubricants) to the sensor shaft or the circuit board. It can reduce the unit’s ability to prevent short-circuits.

1-6

Specialized tools and equipment

GEN

INFO

Specialized tools and equipment

The appropriate specialized tools must be used for inspection, adjustment, disassembly, and reassembly.

Maintenance problems and mechanical breakage can be prevented by using the appropriate specialized tools.

Lithium soap based grease MULTEMP AC-N

®

All-purpose type grease with excellent water and heat resistance

Three Bond No.1215

®

Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil

Digital circuit tester

Device used for testing and measuring electrical components

1-7

Electrical component wiring diagram

Electrical Components

Electrical component wiring diagram

ELEC

– +

2

Encoder lead wire installation location

2-1

2

ELEC

– +

Battery pack

Battery pack

Battery pack display function

By holding down the battery capacity indicator button “ ” on the battery pack, the following items can be checked.

Length of time that the button is pushed

Display item Display time Details Page

When pushed

Normal state:

Residual battery capacity

Error detected:

Error display

5 seconds

5 seconds

See the owner’s manual.

P. 2-2

20 seconds

30 seconds

Total number of battery charging cycle

Absolute battery capacity

5 seconds

5 seconds

See “Error display”.

See “How to check the total number of battery charging cycle”.

See “How to check the absolute battery capacity”.

P. 2-4

P. 2-5

4

3

2

1

4

3

2

1

4 3 2 1 or

4

3

2

1

4

3

2

1

4

3

2

1

Error display

1. Depending on the model, the battery capacity indicator lamps are arranged horizontally or vertically as shown.

In the explanations in this manual, the numbers used for the battery capacity indicator lamps are 4, 3, 2, and 1 from left to right or from top to bottom.

Although the illustrations in this manual show only the vertical-type battery capacity indicator, the operation of the lamps is the same for both types of battery capacity indicators.

2. If the battery capacity indicator lamps [1]/[3] and [2]/[4] turn on alternately, or the lamps

[1]/[2] and [3]/[4] turn on alternately when the battery capacity indicator button “ ” is pushed or connect the battery charger, see

“Recoverable errors of battery pack or battery charger”.

(P. 2-8)

Off On

2-2

Off

4

3

2

1

Fast flashing

4

3

2

1

Slow flashing

ELEC

– +

Battery pack

3. If the battery capacity indicator lamps [1] and [4] are fast flash simultaneously when the battery capacity indicator button “ ” is pushed or connect the battery charger, see

“Non-recoverable errors of battery pack”. (P.

2-10)

4. If all four battery capacity indicator lamps flash slowly at the same time when the bat- tery capacity indicator button “ ” is

pushed, see “Temperature protection function”. (P. 2-14)

If all four battery capacity indicator lamps flash slowly at the same time when con-

nect the battery charger, see “Charging on stand-by mode”. (P. 2-7)

2-3

On

4

3

2

1

2

1

ELEC

– +

Battery pack

How to check the total number of battery charging cycles

Check the total number of battery charging cycles as follows:

1. Hold down the battery capacity indicator button “ ” 1 for 20 seconds.

2. The total number of battery charging cycles is indicated by the four battery capacity indicator lamps 2 on the battery pack.

TIP

While holding down the battery capacity indicator button “ ” for 20 seconds, the lamps will display the currently applicable condition

(residual battery capacity, * error diagnosis), for five seconds for each condition.

*The error diagnosis are displayed only for a malfunction, and is not displayed in normal state.

The table below indicates the relationship between the total number of battery charging cycles and the battery capacity indicator lamps.

Display of the total number of battery charging cycles battery capacity indicator lamps on battery pack

The total number of battery charging cycles battery capacity indicator lamps on battery pack

4

3

2

1

0 to 100 times

4

3

2

1

The total number of battery charging cycles

401 to 500 times

4

3

2

1

101 to 200 times

2

1

4

3

501 to 600 times

4

3

2

1

4

3

2

1

201 to 300 times

301 to 400 times

4

3

2

1

4

3

2

1

601 to 700 times

701 times or more

Off

2-4

On

4

3

2

1

2

1

ELEC

– +

Battery pack

How to check the absolute battery capacity

Check the *

1

absolute battery capacity as follows:

1. Hold down the battery capacity indicator button “ ” 1 for 30 seconds.

2. The *

1

absolute battery capacity is indicated by the four battery capacity indicator lamps

2 on the battery pack.

TIP

While holding down the battery capacity indicator button “ ” for 30 seconds, the lamps will display the currently applicable conditions

(residual battery capacity, *

2

error diagnosis,

Total number of battery charging cycles), for five seconds for each condition.

*

1

Absolute battery capacity:

Absolute battery capacity is not the relative specified electric power capacity that the battery pack has at any given point, but the actual electric capacity that the battery pack itself can store. The capacity at the time of shipment is considered 100%.

*

2

The error diagnosis are displayed only during a malfunction, and is not displayed in normal state.

The table below indicates the relationship between the absolute battery capacity and the battery capacity indicator lamps.

Display of the absolute battery capacity battery capacity indicator lamps on battery pack

Absolute battery capacity (%)

4

3

2

1

0 to 24%

4

3

2

1

Off On

25 to 49%

2-5

battery capacity indicator lamps on battery pack

4

3

2

1

Absolute battery capacity (%)

50 to 74%

4

3

2

1

75 to 100%

ELEC

– +

Charging

Charging

e-Bike system dedicated battery charger

This battery charger 1 is a dedicated battery charger for the e-Bike system’s battery pack.

1

Example of display on battery capacity display lamps on the battery pack while charging

Preliminary charging

When starting charge from a discharged state

Fast flashing

4

3

2

1

Charging time

Slow flashing

Charging complete

(Fully-charged state)

4

3

2

1

4

3

2

1

2

1

4

3

4

3

2

1

4

3

2

1

The lamp above the currently illuminating lamp flashes, indicating that it is charging.

On

Fast flashing

Slow flashing

Off

2-6

4

3

2

1

Slow flashing

Off

4

3

2

1

Fast flashing

2-7

ELEC

– +

Charging

Display on battery capacity indicator lamps while charging

Some phenomena such as the following may occur while charging the battery pack, depending on the battery pack’s state; however, these are not malfunctions.

1. Charging on stand-by

Display on the battery capacity indicator lamps on the battery pack: [All four lamps flashing slowly at the same time].

When the battery pack’s internal temperature goes out of operating range, the battery pack changes to the “Charging on stand-by” state automatically.

TIP

• Once the temperature inside the battery pack becomes suitable for charging, the charging starts automatically.

(In such case, the charging time becomes longer by the time during which all four battery capacity indicator lamps on the battery pack were flashing simultaneously.)

As much as possible, charge at an optimal room temperature, approximately 15 to

25°C.

• Even if you start charging properly, if the battery pack exceeds the specified temperature range while charging, the charging process is aborted to protect the battery pack. This may result in insufficient charging. In such case, when checking the residual battery capacity, not all of the four battery capacity indicator lamps on the battery pack may not turn on. Cool down the battery pack for a while, and charge again, preferably in a cool place.

• Even if the room temperature is within the 0 to 45°C range, if attempting to charge the battery pack immediately after driving, or if the battery pack had been left in the sun during summer, the battery pack’s internal temperature may be outside the allowable temperature range for charging. If the room temperature is 30°C, it may take approximately 4 hours until the battery pack’s internal temperature is within the allowable temperature range for charging.

2. During pre-charging

Display on the battery capacity indicator lamps on the battery pack: [Battery capacity indicator lamps [1] flash rapidly].

4

3

2

1

4

3

2

1

Off On

4

3

2

Turn on alternately

1

1 or

2

Turn on alternately

1

4

3

ELEC

– +

Diagnosis mode

Diagnosis mode

Recoverable errors of battery pack or battery charger

If the battery pack or battery charger has the errors, the following procedure can be used to access the error diagnosis mode and confirm the details regarding the error of the battery pack or battery charger.

1. If there is an error when the battery capacity indicator button “ ” 1 on the battery pack is pushed or connect the battery charger, the battery capacity indicator lamps [1]/[3] and [2]/[4] turn on alternately, or the lamps

[1]/[2] and [3]/[4] turn on alternately.

When the battery capacity indicator lamps turn on alternately, the residual battery capacity is not displayed.

2. Hold down the battery capacity indicator button “ ” 1 for 10 seconds.

3. The lighting display of the battery capacity indicator lamps indicates the error of the battery pack or battery charger.

TIP

• If the battery pack or battery charger is operating normally, the battery capacity indicator lamps indicate the residual battery capacity.

• If there are multiple errors, only the latest error will be displayed.

• The error diagnosis mode can be accessed whether the battery charger is connected or disconnected.

2-8

2-9

Diagnosis mode

ELEC

– +

2-10

Diagnosis mode

ELEC

– +

Off

4

3

2

1

Fast flashing

1

ELEC

– +

Diagnosis mode

Non-recoverable errors of battery pack

If the battery pack has the errors, the following procedure can be used to access the error diagnosis mode and confirm the details regarding the error of the battery pack.

1. If there is a non-recoverable errors when the battery capacity indicator button “ ” 1 on the battery pack is pushed or connect the battery charger, the battery capacity indicator lamps [1] and [4] fast flash simultaneously.

2. Hold down the battery capacity indicator button “ ” 1 for 10 seconds.

3. The lighting display of the battery capacity indicator lamps indicates the error of the battery pack.

2-11

2-12

Diagnosis mode

ELEC

– +

A after

4 seconds

ELEC

– +

Diagnosis mode

When the battery pack signal lead wire becomes disconnected

Although the power to the display unit is turned on,

• All of the LED displays of the display unit

(LED type) turn on for 4 seconds, and then the power turns off automatically (LED) È

• All segments of the display unit (LCD type) unit turn on for 4 seconds, and then the power turns off automatically (LCD) É

If the motor is rotating (while running), the power assist becomes weak and finally stops it. The battery pack stops discharging after a short time.

Action:

Check the battery pack signal lead wire (gray) for a wire break or disconnection.

→ Replace the DC plug or power lead wire.

B after

4 seconds

2-13

4

3

2

1

Slow flashing

ELEC

– +

Diagnosis mode

Temperature protection function

If the battery pack’s internal temperature is -20°C or less or 80°C or higher while the battery pack is discharging (during the power assist), the temperature protection function of the battery pack operates and the battery pack stops discharging.

If the battery capacity indicator button “ ” is pushed at this time, the battery capacity indicator lamps [1], [2], [3], and [4] flash slowly at the same time.

TIP

The battery pack automatically recovers when the battery pack’s internal temperature returns to the allowable temperature range for charging.

2-14

Off

4

3

2

1

ELEC

– +

Diagnosis mode

Over-discharge protection function

If the battery pack becomes over-discharged, the over-discharge protection function of the battery pack operates.

If the battery capacity indicator button “ ” is pushed at this time, the battery capacity indicator lamps do not turn on.

The following procedure can be used to access the over-discharge protection function diagnostic mode and confirm the details regarding the malfunction of the battery pack.

*First connect the battery charger to the battery.

*Because the battery voltage is insufficient when the battery pack is over-discharged, the battery capacity indicator lamps will not turn on or flash if the battery pack is not connected to the battery charger.

2-15

2-16

Diagnosis mode

ELEC

– +

ELEC

– +

Diagnosis function (LED type display unit)

Diagnosis function (LED type display unit)

Display unit’s display when there is an error

Detects system malfunctions, changes assist operation, and displays the errors as well as performing error code recording.

Error displays are indicated by the display of

“Er” and an error code indicating the type of error. You can switch between “Er” and the error code display by pressing the function select switch “ ”.

When a malfunction which may reflect a abnormal operation is displayed, the malfunction is recorded to prevent recurrence of the condition, and thereafter the power assist will be immediately blocked after the power is turned on and the error will be displayed on the function display in display unit.

5 2

6

1

Slow flashing

4 3

Slow flashing

How communication errors are displayed

The 3 assist mode lamps 1, the “%” lamp 2, the “km” lamp 3, and the “km/h” lamp 4 will flash at the same time, and “Er” will be displayed on the function display 5 of the display unit.

When the function select switch “ ” 6 is pressed, error code “12” or “13” will be displayed.

TIP

• The error code is not stored.

• See “List of error codes and corresponding power assist operations” for more details.

• If there is a communication error, the power cannot be turned off using the “POWER” switch of the display unit. To turn the power off, remove the battery.

2-17

1

ELEC

– +

Diagnosis function (LED type display unit)

5 2

3

6

How Drive Unit malfunctions are displayed

The 3 assist mode lamps 1, the “%” lamp 2, the “km” lamp 3, and the “km/h” lamp 4 will flash alternately, and “Er” will be displayed on the function display 5 of the display unit.

When the function select switch “ ” 6 is pressed, error code “16” or higher will be displayed.

4

Alternately flashes

TIP

• Error codes are stored.

• See “List of error codes and corresponding power assist operations” for more details.

1

Slow flashing Slow flashing

How speed sensor malfunctions are displayed

The “HIGH”, “STD”, or “ECO” assist mode lamps 1 are displayed with a slow flash (0.5

seconds).

TIP

• Error codes are not stored.

• See “List of error codes and corresponding power assist operations” for more details.

• In assist off mode, displays of malfunctions cannot be made using the assist mode lamp.

2-18

Recovery method when there is a speed sensor malfunction

The display will return to normal when the speed sensor returns to normal condition.

3

4

ELEC

– +

2

Diagnosis function (LED type display unit)

1

Operating Procedures to Diagnosis Mode

This is the mode in which each type of diagnosis and the content of error codes which are stored when there is an error are displayed.

You can switch between speed sensor diagnosis mode, Drive Unit diagnosis mode, and error log check mode by using the display unit according to the following procedures.

1. Make sure that the power is turned off to the display unit.

Press the power switch “ ” 1 to turn on the power.

When the power is turned on, all lamps and segments of the display unit will illuminate.

After approximately 2 seconds, the lamps and segments will turn off, and then the display will return to normal.

2. Press the power switch “ ” 1 again, and continue pressing the switch until only the 3 assist mode lamps 2 are illuminated.

(Approximately 10 seconds)

Confirm that only the 3 assist mode lamps

2 are illuminated, and then release the power switch “ ” 1.

TIP

Steps 1 and 2 must be performed within 30 seconds.

2

3. Press the assist mode switch “ ” 3 or

“ ” 4 to change the assist mode.

When the assist mode is changed, one of the assist mode lamps 2 will illuminate.

You can select each diagnostic mode by changing the assist mode.

4. Press the light switch “ ” 5.

The “HIGH”, “STD”, or “ECO” assist mode lamp 2 will flash rapidly (0.2 second) to indicate each of the diagnostic modes.

TIP

If you pressed the wrong switch, turn off the power and perform steps 1–4 again.

2 5

2-19

1

2

Fast flashing

ELEC

– +

Diagnosis function (LED type display unit)

Speed Sensor Diagnosis Mode

Press the assist mode switch “ ” 1 until the

“HIGH” assist mode lamp is illuminated.

Press the light switch “ ”.

The “HIGH” assist mode lamp flashes rapidly

(0.2 second).

For more information about the speed sensor diagnosis mode, see “Speed sensor diagnosis mode display method”.

Drive Unit Diagnosis Mode

Press the assist mode switch “ ” 1

→ “

2 or “ ” 2

→ “

” 1 until the “STD” assist mode lamp is illuminated.

Press the light switch “ ”.

The “STD” assist mode lamp flashes rapidly

(0.2 second).

For more information about the drive unit diagnosis mode, see “Drive unit diagnosis mode display method”.

Error Log Check Mode

Press the assist mode switch “ ” 2 until the

“ECO” assist mode lamp is illuminated.

Press the light switch “ ”.

The “ECO” assist mode lamp flashes rapidly

(0.2 second).

For more information about the error log check mode, see “Error log check mode”.

2-20

Fast flashing

Number of

Wheel

Rotations

1 rotation

12 rotations

13 rotations

ELEC

– +

Diagnosis function (LED type display unit)

Speed Sensor Diagnosis Mode Display

Method

To determine if the controller is correctly recognizing the speed sensor signal, rotate the wheel to which the speed sensor is connected and make sure that the number of rotations of the wheel indicated matches the actual number of rotations.

Rotation number display of the display unit

1

1. Go into speed sensor diagnosis mode.

See “Operating Procedures to Diagnosis

Mode.”

Confirm that the “HIGH” lamp of the assist mode lamps is flashing fast.

2. When you raise and rotate the wheel (with the speed sensor), the rotation number display 1 on the display unit will change.

Before rotating the wheel (with the speed sensor), “0” will be displayed on the rotation number display 1 of the display unit.

When you rotate the wheel (with the speed sensor) 1 time, “1” will be displayed on the rotation number display 1 of the display unit.

When you rotate the wheel (with the speed sensor) 12 times, “12” will be displayed on the rotation number display 1 of the display unit.

When you rotate the wheel (with the speed sensor) 13 times, the display of the rotation number display 1 of the display unit will return to “1”.

Thereafter, each time the wheel (with the speed sensor) is rotated, the number of rotation number display 1 on the display unit will be from “1” to “12”.

TIP

• You should at least rotate the wheel (with speed sensor) 3 times and make sure that “3” is displayed.

• If the speed sensor malfunctions, the number of rotations displayed on the display unit will increase before the wheel (with speed sensor) is rotated even once, or the number will not increase even when the wheel (with speed sensor) is rotated once (or there is a delay in the increase in the value).

2-21

Fast flashing

ELEC

– +

Diagnosis function (LED type display unit)

Drive Unit Diagnosis Mode Display Method

You can check the status of or malfunctions in the Drive Unit.

1. Go into Drive Unit diagnosis mode.

See “Operating Procedures to Diagnosis

Mode.”

Confirm that the “STD” of the assist mode lamps is flashing fast.

After the diagnosis mode indicator of the display unit has displayed “1” for up to 10 seconds, you can check the torque sensor reference voltage, motor current, error displays (“E2”, “E4”), and the display unit function check.

List of Drive Unit Diagnosis Mode Display Methods

Inspection items

Diagnosis mode display

Press operating button

Diagnosis data display

1) Torque sensor reference voltage

2) Motor current

Values are displayed from 0.0 to 5.0 (V)

Motor output current in “HIGH” mode is displayed as 00 to “FL (= FULL)”

(= % output).

Press operating button

To 2) Motor current

To 3) Error display

3) Error display

4) Display unit function check

There is no display when there are no errors.

When there is an error, either “E2” (motor) or “E4” (controller) are displayed.

or

All segments and lamps are illuminated.

(Segments and lamps that are not illuminated indicate a malfunction.)

To 4) Display unit function check

Power goes off

2-22

2

Diagnosis function (LED type display unit)

ELEC

– +

1

2

* Determining whether or not the torque sensor is good

0.2 to 1.1 V = normal

If the torque sensor is outside of this range

→ Implement the torque sensor reference voltage adjustment function.

If the torque sensor remains outside of its normal range after torque sensor reference voltage adjustment

→ Torque sensor malfunction (replace)

1) Torque sensor reference voltage

1. Torque sensor reference voltage display a. “10” is displayed in the diagnosis mode display 1 of the display unit.

b. Press the function select switch “ ” of the display unit.

c. Displayed in units of 0.1 V from 0.0 to 5.0 V in the diagnosis data display 2 of the display unit.

d. The torque sensor is normal if the display voltage is 0.2 to 1.1 V.

Perform a torque sensor reference voltage adjustment if values outside of this range are displayed.

e. Press the light switch “ ” of the display unit.

f. Proceed to 2) Motor current.

2. Torque sensor reference voltage adjustment function

Turn the power on to the display unit and let it stand.

Guideline: Until the power to the display unit is turned off automatically

(about 5 min.).

TIP

Do not place feet on the pedals while performing a torque sensor reference voltage adjustment.

2-23

2

Diagnosis function (LED type display unit)

ELEC

– +

1

2

2) Motor current a. “14” is displayed in the diagnosis mode display 1 of the display unit.

b. Press the function select switch “ ” button of the display unit.

c. The diagnosis data display 2 of the display unit displays the motor output current (%) from “00” to “FL (= FULL)”.

d. Confirm that the diagnosis data display 2 of the display unit displays “FL” when applying the rear brake and strongly pressing on the pedals.

• “FL” is displayed: good

• “FL” is not displayed: If the bicycle was ridden immediately before checking the motor current, it is possible that the battery or the controller temperature control is working; therefore, wait until the bicycle cools down. If the bicycle was not ridden immediately before checking the motor current, recheck using a battery that is operating properly.

• “FL” is not displayed: The battery response is weak in winter (low temperatures), so use a battery that has been stored in a heated room.

• “FL” is not displayed: Replace the controller assembly.

e. Press the light switch “ ” of the display unit.

f. Proceed to 3) Error displays.

2-24

2

On

Diagnosis function (LED type display unit)

ELEC

– + or

1

2

3) Error displays a. “16” is displayed in the diagnosis mode display 1 of the display unit.

b. Press the function select switch “ ” of the display unit.

c. When there is a malfunction, “E2” (motor) or

“E4” (controller) will be displayed on the diagnosis data display 2 of the display unit.

TIP

Check the error code if “E2” or “E4” are displayed.

d. Press the light switch “ ” of the display unit.

e. Proceed to 4) Display unit function check.

TIP

Check the error code if E2 or E4 are displayed.

• When there is no malfunction the next “18” is displayed without the diagnosis mode “16” being displayed.

• Perform a final check to make sure there is no error display in this mode when performing repairs or replacing parts.

1

2

4) Display unit function check a. “18” is displayed in the diagnosis mode display 1 of the display unit.

b. Press the function select switch “ ” 2 of the display unit.

c. All segments and all lamps of the display unit will illuminate.

d. Replace the display unit if there are segments or lamps which are not illuminated.

e. Press the light switch “ ” 3 of the display unit.

f. The power to the display unit is turned off.

3

On

2-25

Fast flashing

ELEC

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Diagnosis function (LED type display unit)

Error Log Check Mode Display Method

The three most recent types of error codes which are stored when there is an error are stored and these are displayed in order from the most recent every 10 seconds.

1. Go into error log check mode.

See “Operating Procedures to Diagnosis

Mode.”

Confirm that the “ECO” lamp of the assist mode lamps is flashing fast.

The display unit displays the three most recent error codes in the order stored as

“E1” to “E3”. To display the error codes, press the function select switch “ ” of the display unit.

“0” will be displayed when there are no errors.

When other error codes are stored, the display will switch to the next error in 10 seconds.

List of Error Log Check Mode Display Methods

Number of error codes

How error codes are displayed on the display unit

When there are no error codes

When there is 1 error code

Error code displays

When there are 2 error codes

Error code displays

([E1] along with the error code are displayed for 10 seconds)

When there are 3 error codes

Error code displays

([E1] along with the error code are displayed for 10 seconds)

([E2] along with the error code are displayed for 10 seconds)

Error code displays displays

([E2] along with the error code are displayed for 10 seconds)

Error code

Error code displays

([E3] along with the error code are displayed for 10 seconds)

2-26

3

2

ELEC

– +

Diagnosis function (LED type display unit)

How to delete the malfunction history

1. While pressing the light switch “ ” 1 during the error code display, press the assist mode switch power assist decrease 2 and power assist increase 3 to switch.

1

1

2. The diagnostic display pattern will stop, all lamps will turn on and off twice (“8.8.” will be shown in the error code display 1 of the display unit), and the history will be deleted.

The power to the display unit will be turned off at this time.

TIP

Be sure to clear the diagnosis history after replacing the motor or other parts.

Repeats 2 times

2-27

ELEC

– +

Diagnosis function (LCD type display unit)

Diagnosis function (LCD type display unit)

Display unit’s display when there is an error

Detects system malfunctions, changes assist operation, and displays the errors as well as performing error code recording.

Error displays are indicated by the display of

“Er” and an error code indicating the type of error. You can switch between “Er” and the error code display by pressing the function select switch “s”.

When a malfunction which may reflect a serious abnormal operation is displayed, the malfunction is recorded to prevent recurrence of the condition, and thereafter the power assist will be immediately blocked after the power is turned on and the error will be displayed on the speedometer section in display unit.

Slow flashing

4

3

1

2

How communication errors are displayed

All segments of the assist mode indicator 1 and battery capacity indicator 2 will flash at the same time, and “Er” will be displayed on the speedometer section 3 of display unit.

When the function select switch “s” 4 is pressed, error code “12”, “13” or “15” will be displayed.

TIP

• The error code is not stored.

• See “List of error codes and corresponding power assist operations” for more details.

• If there is a communication error, the power cannot be turned off using the “POWER” switch of the display unit. To turn the power off, remove the battery.

2-28

4

ELEC

– +

Diagnosis function (LCD type display unit)

1

Alternately flashes

3

How Drive Unit malfunctions are displayed

All segments of the assist mode indicator 1 and all segments of the battery capacity indicator 2 will flash alternately, and “Er” will be displayed on the speedometer section 3 of the display unit. When the function select switch “s” 4 is pressed, error code “16” or higher will be displayed.

TIP

• Error codes are stored.

• See “List of error codes and corresponding power assist operations” for more details.

2

Slow flashing

1

2

2-29

How speed sensor malfunctions are displayed

The “HIGH”, “STD”, or “ECO” assist mode indicator 1 are displayed with a slow flash (0.5

seconds).

The function display part 2 are displayed with

“----” when you select as follwing functions.

• Average bicycle speed

• Maximum bicycle speed

• Trip meter

• Odometer

TIP

• Error codes are not stored.

• In assist off mode, displays of malfunctions cannot be made using the assist mode display.

• Average bicycle speed, maximum bicycle speed, tripmeter, and odometer are not updated when speed sensor malfunction is occurred.

• See “List of error codes and corresponding power assist operations” for more details.

Recovery method when there is a speed sensor malfunction

The display will return to normal when the speed sensor returns to normal condition.

3

4

1

1

ELEC

– +

Diagnosis function (LCD type display unit)

2

Operating Procedures to Diagnosis Mode

This is the mode in which each type of diagnosis and the content of error codes which are stored when there is an error are displayed.

You can switch between speed sensor diagnosis mode, Drive Unit diagnosis mode, and error log check mode by using the display unit according to the following procedures.

1. Make sure that the power is turned off to the display unit.

Press the power switch “ ” 1 to turn on the power.

When the power is turned on, all segments of the display unit will come on.

After approximately 2 seconds, the segments will turn off, and then the display will return to normal.

2. Press the power switch “ ” 1 again, and continue pressing the switch until only the 3 assist mode indicators 2 come on.

(Approximately 10 seconds)

Confirm that only the 3 assist mode indicators 2 have come on, and then release the power switch “ ” 1.

TIP

Steps 1 and 2 must be performed within 30 seconds.

5

3. Press the assist mode switch “ ” 3 or

“ ” 4 to change the assist mode.

When the assist mode is changed, one of the assist mode indicators 2 will come on.

You can select each diagnostic mode by changing the assist mode.

4. Press the light switch “ ” 5.

The “HIGH”, “STD”, or “ECO” assist mode indicator 2 will flash rapidly (0.2 second) to indicate each of the diagnostic modes.

TIP

Steps 2-4 must be performed within 30 seconds.

If you pressed the wrong switch, turn off the power and perform steps 1–4 again.

2-30

1

2

1

2

1

2

Fast flashing

3

ELEC

– +

Diagnosis function (LCD type display unit)

Speed Sensor Diagnosis Mode

Press the assist mode switch “ ” 1 until the

“HIGH” assist mode indicator comes on.

Press the light switch “ ” 3.

The “HIGH” assist mode indicator flashes rapidly (0.2 second).

For more information about the speed sensor diagnosis mode, see “Speed sensor diagnosis mode display method”.

3

3

Drive Unit Diagnosis Mode

Press the assist mode switch “ ” 1

→ “

2 or “ ” 2

→ “

” 1 until the “STD” assist mode indicator comes on.

Press the light switch “ ” 3.

The “STD” assist mode indicator flashes rapidly (0.2 second).

For more information about the drive unit diagnosis mode, see “Drive unit diagnosis mode display method”.

Error Log Check Mode

Press the assist mode switch “ ” 2 until the

“ECO” assist mode indicator comes on.

Press the light switch “ ” 3.

The “ECO” assist mode indicator flashes rapidly (0.2 second).

For more information about the error log check mode, see “Error log check mode”.

2-31

Fast flashing

ELEC

– +

Diagnosis function (LCD type display unit)

Speed Sensor Diagnosis Mode Display

Method

To determine if the controller is correctly recognizing the speed sensor signal, rotate the wheel to which the speed sensor is connected and make sure that the number of rotations of the wheel indicated matches the actual number of rotations.

1. Go into speed sensor diagnosis mode.

See “Operating Procedures to Diagnosis

Mode.”

Confirm that the assist mode display is flashing “HIGH” rapidly (0.2 seconds).

Number of

Wheel

Rotations

Rotation number display of the display unit

1 rotation

12 rotations

13 rotations

2. When you raise and rotate the wheel (with the speed sensor), the rotation number display 1 on the display unit will change.

Before rotating the wheel (with the speed sensor), “0” will be displayed on the rotation number display 1 of the display unit.

When you rotate the wheel (with the speed sensor) 1 time, “1” will be displayed on the rotation number display 1 of the display unit.

When you rotate the wheel (with the speed sensor) 12 times, “12” will be displayed on the rotation number display 1 of the display unit.

When you rotate the wheel (with the speed sensor) 13 times, the display of the rotation number display 1 of the display unit will return to “1”.

Thereafter, each time the wheel (with the speed sensor) is rotated, the number of rotations display 1 on the display unit will be from “1” to “12”.

TIP

• You should at least rotate the wheel (with the speed sensor) 3 times and make sure that “3” is displayed.

• If the speed sensor malfunctions, the number of rotations displayed on the display unit will increase before the wheel (with the speed sensor) is rotated even once, or the number will not increase even when the wheel (with the speed sensor) is rotated once (or there is a delay in the increase in the value).

2-32

Fast flashing

ELEC

– +

Diagnosis function (LCD type display unit)

Drive Unit Diagnosis Mode Display Method

You can check the status of or malfunctions in the Drive Unit.

1. Go into Drive Unit in diagnosis mode.

See “Operating Procedures to Diagnosis

Mode.”

Confirm that the assist mode display is flashing “STD” fast (0.2 seconds).

After the diagnosis mode indicator of the display unit has displayed “1” for up to 10 seconds, you can check the torque sensor reference voltage, motor current, error displays (“E2”, “E4”), and the display unit function check.

List of Drive Unit Diagnosis Mode Display Methods

Inspection items

Diagnosis mode display

Press operating button

Diagnosis data display

1) Torque sensor reference voltage

2) Motor current

Values are displayed from 0.0 to 5.0 (V)

Motor output current in “HIGH” mode is displayed as 0 to 100 (= % output).

Press operating button

To 2) Motor current

To 3) Error display

3) Error display

4) Display unit function check

There is no display when there are no errors.

When there is an error, either “E2”

(motor) or “E4” (controller) are displayed.

or

All segments are illuminated

(segments that are not illuminated indicate a malfunction.)

To 4) Display unit function check

Power goes off

2-33

Diagnosis function (LCD type display unit)

ELEC

– +

* Determining whether or not the torque sensor is good

0.2 to 1.1 V = normal

If the torque sensor is outside of this range

→Implement the torque sensor reference voltage adjustment function.

If the torque sensor remains outside of its normal range after torque sensor reference voltage adjustment

→Torque sensor malfunction (replace)

1) Torque sensor reference voltage

1. Torque sensor reference voltage display a. “10” is displayed in the diagnosis mode display 1 of the display unit.

b. Press the function select switch “s” of the display unit.

c. Displayed in units of 0.1 V from 0.0 to 5.0 V in the diagnosis data display 2 of the display unit.

d. The torque sensor is normal if the display voltage is 0.2 to 1.1 V.

Perform a torque sensor reference voltage adjustment if values outside of this range are displayed.

e. Press the light switch “ ” of the display unit.

f. Proceed to 2) Motor current.

2. Torque sensor reference voltage adjustment function

Turn the power on to the display unit and let it stand.

Guideline: Until the power to the display unit is turned off automatically

(about 5 min.).

TIP

Do not place feet on the pedals while performing a torque sensor reference voltage adjustment.

2-34

Diagnosis function (LCD type display unit)

ELEC

– +

2) Motor current a. “14” is displayed in the diagnosis mode display 1 of the display unit.

b. Press the function select switch “s” of the display unit.

c. The diagnosis data display 2 of the display unit displays the motor output current (%) from “0” to “100”.

d. Confirm that the diagnosis data display 2 of the display unit displays “100” when applying the rear brake and strongly pressing on the pedals.

• “100” is displayed: good

• “100” is not displayed: If the bicycle was ridden immediately before checking the motor current, it is possible that the battery or the controller temperature control is working; therefore, wait until the bicycle cools down. If the bicycle was not ridden immediately before checking the motor current, recheck using a battery that is operating properly.

• “100” is not displayed: The battery response is weak in winter (low temperatures), so use a battery that has been stored in a heated room.

• “100” is not displayed: Replace the controller assembly. e. Press the light switch “ ” of the display unit.

f. Proceed to 3) Error displays.

2-35

4

2

Diagnosis function (LCD type display unit)

ELEC

– + or

3) Error displays a. “16” is displayed in the diagnosis mode display 1 of the display unit. b. Press the function select switch “s” of the display unit.

c. When there is a malfunction, “E2” (motor) or

“E4” (controller) will be displayed on the diagnosis data display 2 of the display unit.

TIP

Check the error code if “E2” or “E4” are displayed.

d. Press the light switch “ ” of the display unit.

e. Proceed to 4) Display unit function check.

TIP

Check the error code if E2 or E4 are displayed.

• When there is no malfunction the next “18” is displayed without the diagnosis mode “16” being displayed.

• Perform a final check to make sure there is no error display in this mode when performing repairs or replacing parts.

3

4) Display unit function check a. “18” is displayed in the diagnosis mode display 1 of the display unit. b. Press the function select switch “s” 2 of the display unit.

c. All segments of the display unit 3 will illuminate.

d. Replace the display unit if there are segments which are not illuminated.

e. Press the light switch “ ” 4 of the display unit.

f. The power to the display unit is turned off.

2-36

Fast flashing

ELEC

– +

Diagnosis function (LCD type display unit)

Error Log Check Mode Display Method

The three most recent types of error codes which are stored when there is an error are stored and these are displayed in order from the most recent every 10 seconds.

1. Go into error log check mode.

See “Operating Procedures to Diagnosis

Mode.”

Confirm that the assist mode display is flashing “ECO” fast (0.2 seconds).

The display unit displays the three most recent error codes in the order stored as

“E1” to “E3”. To display the error codes, press the function select switch “ ” of the display unit.

“0” will be displayed when there are no errors.

When other error codes are stored, the display will switch to the next error in 10 seconds.

List of Error Log Check Mode Display Methods

Number of error codes

How error codes are displayed on the display unit

When there are no error codes

When there is 1 error code

Error code displays

When there are 2 error codes

When there are 3 error codes displayed for 10 seconds)

Error code displays

([E1] along with the error code are displayed for 10 seconds)

Error code displays

([E1] along with the error code are

Error code displays

([E2] along with the error code are displayed for 10 seconds)

Error code displays

([E2] along with the error code are displayed for 10 seconds) code displays

([E3] along with the error code are displayed for 10 seconds)

Error

2-37

3

2

Fast flashing

ELEC

– +

Diagnosis function (LCD type display unit)

1

How to delete the malfunction history

1. While pressing the light switch “ ” 1 during the error code display, press the assist mode switch power assist decrease 2 and power assist increase 3 to switch.

2. The diagnostic display pattern will stop, all segment lights will turn on and off twice, and the history will be deleted.

The power to the display unit will be turned off at this time.

TIP

Be sure to clear the diagnosis history after replacing the motor or other parts.

Repeats 2 times

2-38

Diagnosis function (LCD type display unit)

ELEC

– +

2-39

Diagnosis function (LCD type display unit)

ELEC

– +

2-40

Diagnosis function (LCD type display unit)

ELEC

– +

2-41

Diagnosis function (LCD type display unit)

ELEC

– +

2-42

Diagnosis function (LCD type display unit)

ELEC

– +

2-43

Diagnosis function (LCD type display unit)

ELEC

– +

2-44

ELEC

– +

Speed sensor set

Speed sensor set

Speed sensor inspection

1. Pickup

• Check that the pickup is installed at the specified location on the bike.

• Check that the pickup is not damaged.

Magnet sensor

1

Pickup

1

2 a

2. Magnet sensor a. Check that the magnet sensor is not damaged.

b. Check that no metallic foreign material has adhered to the magnet sensor.

c. Check that the magnetic surface of the magnet sensor is facing the sensing point on the pickup.

d. Install the magnet sensor to match the center of the magnet sensor and the cutout point a of the pickup.

e. Check that the center location of the magnet sensor 1 is within specification.

Center location of the magnet

sensor 1

5 mm f. Check that the gap 2 between the pickup and the magnet sensor is within specification.

Gap (between the pickup and

magnet sensor) 2

10 mm or less

2-45

Drive axle, Motor (drive axle with square-type end)

Drive Unit

Drive axle, Motor (drive axle with square-type end)

Drive

Unit

T.R.

40 Nm (4.0 kgf

m)

1

8

T.R

4.5 Nm (0.45 kgf

m)

9

11 12

13

2

3

4

3

24

14

31

T.R.

1.3 Nm (0.13 kgf

m)

23

18

32

10

LS

33

15

New 16

New 17

20

21

22

19

29

25

26

27 28

T.R

30

0.75 Nm (0.075 kgf

m)

7

5

6

T.R

4.5 Nm (0.45 kgf

m)

D

FWD

Order

6

7

4

5

8

9

1

2

3

Job/Part

Removal of the Drive axle,

Motor

Drive Unit assembly

Lock nut

Sprocket

Spacer

Spider

Button head bolt

Cover assembly

Stator cover

Flanged bolt

Housing complete

Q’ty

1

1

1

1

1

1

Remarks

Follow the work procedures for removal.

Left-hand screw

1 for spider type only

3

6

* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.

3-1

Drive axle, Motor (drive axle with square-type end)

Drive

Unit

T.R.

40 Nm (4.0 kgf

m)

1

11 12

13

2

3

4

8

T.R

4.5 Nm (0.45 kgf

m)

9

24

14

31

T.R.

1.3 Nm (0.13 kgf

m)

23

18

32

10

LS

33

15

D

FWD

New 16

New 17

20 21

22

19

29

25

26

27 28

T.R

30

0.75 Nm (0.075 kgf

m)

7

5

6

T.R

4.5 Nm (0.45 kgf

m)

Order Job/Part

10 Plate washer

11 Oil seal

12 Clutch boss assembly

13 One-way outer boss

14 Driven gear assembly

15 Gear cover

16 Heat-dissipating sheet

17 Heat-dissipating sheet

18 Tapping screw

19 Wire lead 1 couplers

20 Wire lead 3 couplers

21 Wire lead 4 couplers

Q’ty

1

1

1

1

1

1

1

1

5

2

1

1

Disconnect.

Disconnect.

Disconnect.

Remarks

* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.

3-2

3

Drive axle, Motor (drive axle with square-type end)

Drive

Unit

T.R.

40 Nm (4.0 kgf

m)

1

11 12

13

2

3

4

8

T.R

4.5 Nm (0.45 kgf

m)

9

24

14

31

T.R.

1.3 Nm (0.13 kgf

m)

23

18

32

10

LS

33

15

New 16

New 17

20

21

22

19

29

25

26

27 28

T.R

30

0.75 Nm (0.075 kgf

m)

7

5

6

T.R

4.5 Nm (0.45 kgf

m)

D

FWD

Order

22

23

Job/Part

Wire lead 5 couplers

Controller assembly

Q’ty

1 Disconnect.

1

NOTICE

Remarks

• Do not touch the circuit board with greasy or dirty fingers.

• Do not drop the circuit board or subject it to impact.

24 Wire lead 2

25 Wire lead 1

26 Wire lead 3

27 Wire lead 4

28 Wire lead 5

29 Tapping screw

30 Holder

1

1

1

1

1

2

1

* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.

3-3

Drive axle, Motor (drive axle with square-type end)

Drive

Unit

T.R.

40 Nm (4.0 kgf

m)

1

11 12

13

2

3

4

8

T.R

4.5 Nm (0.45 kgf

m)

9

24

14

31

T.R.

1.3 Nm (0.13 kgf

m)

23

18

32

10

LS

33

15

New 16

New 17

20 21

22

19

29

25

26

27 28

T.R

30

0.75 Nm (0.075 kgf

m)

7

5

6

T.R

4.5 Nm (0.45 kgf

m)

D

FWD

Order Job/Part

31 Torque sensor assembly

32 Drive axle

33 Motor complete

Q’ty Remarks

1

1 Both end shapes of the drive axle is different by the specifications of Drive Unit.

1

Reverse the removal process for installation.

* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.

3-4

Drive axle, Motor (drive axle with spline-type end [ISIS])

Drive axle, Motor (drive axle with spline-type end [ISIS])

Drive

Unit

T.R.

25.5 Nm (2.55 kgf

m)

11 12

1

2

3

4

T.R

40 Nm (4.0 kgf

m)

8

T.R

4.5 Nm (0.45 kgf

m)

9

13

24

14

31

T.R.

1.3 Nm (0.13 kgf

m)

23

18

32

10

LS

33

15

2

1

New 16

New 17

20 21

22

19

29

25

26

27 28

T.R

30

0.75 Nm (0.075 kgf

m)

7

5

6

T.R

4.5 Nm (0.45 kgf

m)

D

FWD

Order

6

7

4

5

8

9

1

2

3

Job/Part

Removal of the Drive axle,

Motor

Drive Unit assembly

Screw

Adapter

Lock nut

Spider

Button head bolt

Cover assembly

Stator cover

Flanged bolt

Housing complete

Q’ty

2

2

Remarks

Follow the work procedures for removal.

1 Left-hand screw

1

3

1

1

6

1

* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.

3-5

Drive axle, Motor (drive axle with spline-type end [ISIS])

Drive

Unit

T.R.

25.5 Nm (2.55 kgf

m)

12 13

1

2

3

4

T.R

40 Nm (4.0 kgf

m)

9

T.R

4.5 Nm (0.45 kgf

m)

10

14

25

15

32

T.R.

1.7 Nm (0.17 kgf

m)

24

19

33

11

D

FWD

LS

34

16

New 17

New 18

21

22

23

30

26

New 8

27

28 29

20

7

T.R

5

31

T.R

4.5 Nm (0.45 kgf

m)

0.75 Nm (0.075 kgf

m)

2

1

6

Order Job/Part

10 Plate washer

11 Oil seal

12 Clutch boss assembly

13 One-way outer boss

14 Driven gear assembly

15 Gear cover

16 Heat-dissipating sheet

17 Heat-dissipating sheet

18 Tapping screw

19 Wire lead 1 couplers

20 Wire lead 3 couplers

21 Wire lead 4 couplers

Q’ty

1

1

1

1

1

1

1

1

5

2 Disconnect.

1

1

Disconnect.

Disconnect.

Remarks

* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.

3-6

Drive axle, Motor (drive axle with spline-type end [ISIS])

Drive

Unit

T.R.

25.5 Nm (2.55 kgf

m)

12 13

1

2

3

4

T.R

40 Nm (4.0 kgf

m)

9

T.R

4.5 Nm (0.45 kgf

m)

10

14

25

15

32

T.R.

1.7 Nm (0.17 kgf

m)

24

19

33

11

D

FWD

LS

34

16

New 17

New 18

26

21

22

23

30

New 8

27

28 29

20

7

T.R

5

31

T.R

4.5 Nm (0.45 kgf

m)

0.75 Nm (0.075 kgf

m)

2

1

6

Order

22

23

Job/Part

Wire lead 5 couplers

Controller assembly

Q’ty

1 Disconnect.

1

NOTICE

Remarks

• Do not touch the circuit board with greasy or dirty fingers.

• Do not drop the circuit board or subject it to impact.

24 Wire lead 2

25 Wire lead 1

26 Wire lead 3

27 Wire lead 4

28 Wire lead 5

29 Tapping screw

30 Holder

1

1

1

1

1

2

1

* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.

3-7

Drive axle, Motor (drive axle with spline-type end [ISIS])

Drive

Unit

T.R.

25.5 Nm (2.55 kgf

m)

12 13

1

2

3

4

T.R

40 Nm (4.0 kgf

m)

9

T.R

4.5 Nm (0.45 kgf

m)

10

14

25

15

32

T.R.

1.7 Nm (0.17 kgf

m)

24

19

33

11

D

FWD

LS

34

16

New 17

New 18

21

22

23

30

26

New 8

27

28 29

20

7

T.R

5

31

T.R

4.5 Nm (0.45 kgf

m)

0.75 Nm (0.075 kgf

m)

2

1

6

Order Job/Part

31 Torque sensor assembly

32 Drive axle

33 Motor complete

Q’ty Remarks

1

1 Both end shapes of the drive axle is different by the specifications of Drive Unit.

1

Reverse the removal process for installation.

* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.

3-8

Drive axle, Motor

Drive

Unit

Removal of the parts from the drive axle

(drive axle with square-type end)

1. Remove the following parts:

• Locknut (Left-hand screw)

• Drive sprocket or spider

• Spacer (for sprocket only)

• Flanged bolt

Removal of the parts from the drive axle

(drive axle with spline-type end)

1. Remove the following parts:

• Screw

• Adapter

• Locknut (Left-hand screw)

• Spider

• Flanged bolt a a a

Removal of the Controller Assembly

1. Separate the housing complete from the motor complete.

TIP

Separator ribs a are provided in 3 locations for separating the housing complete.

NOTICE

• Take care not to scratch the mating surfaces of the housing complete and the motor complete with screwdrivers or other tools.

• Take care not to damage the boards of the controller assembly and the torque sensor assembly with tools.

3-9

2

1

3

2

1

Drive axle, Motor

Drive

Unit

2. Remove the following parts:

• Plate washer 1

• Clutch boss assembly 2

1

2

3. Remove the following parts:

• One-way outer boss 1

• Driven gear assembly 2

• Gear cover 3

4. Remove the following parts:

• Heat-dissipating sheet 1

• Tapping screw 2

1

2

4

3

5. Disconnect the following couplers:

• Wire lead 1 couplers 1

• Wire lead 3 coupler 2

• Wire lead 4 coupler 3

• Wire lead 5 coupler 4

1

3-10

6. Remove the following part:

• Controller assembly 1

NOTICE

Precautions

• Do not touch the board of the controller assembly with greasy or dirty fingers.

• Do not drop the board or subject it to impact.

4

3

2 b

5 a

3

1

2

4

1

Drive axle, Motor

Drive

Unit

Removal of the Torque sensor assembly and Drive axle.

1. Remove the following parts:

• Tapping screw 1

• Holder 2

• Torque sensor assembly 3

• Drive axle 4

NOTICE

Do not disassemble the torque sensor assembly because it cannot be readjusted.

Installation of the Drive axle and Controller assembly

1. Install the following parts:

• Drive axle 1

• Torque sensor assembly 2

• Holder 3

• Tapping screw 4

0.75 Nm ( 0.075 kgf·m)

T

R

TIP

TIP

When installing the drive axle, align the cut out parts a of the torque sensor assembly 2 with the projections b on the motor complete 5.

3-11

Installation of the Controller assembly

1. Install the following parts and connect the following couplers:

• Controller assembly

• Wire lead 5 coupler

• Wire lead 4 coupler

• Wire lead 3 coupler

• Wire lead 1 coupler

• Tapping screw

T

R

1.3 Nm ( 0.13 kgf·m)

NOTICE

TIP

The tapping screw of the controller assembly must be installed because it also serves as a ground.

ab ab

1

New

Drive axle, Motor

Drive

Unit

2. Install the following part:

• Heat-dissipating sheet 1

NOTICE

Precautions

Thermal protection may be compromised by an ill-fitting heat-dissipating sheet, so be sure to replace the heat-dissipating sheet with a new one when the assembly is disassembled.

TIP

TIP

• Put the heat-dissipating sheet to designated location of controller.

• The heat-dissipating sheet should not be stretched more than 10% beyond its original dimensions.

3. Install the following parts:

• Gear cover

• Driven gear assembly

• One-way outer boss

• Clutch boss assembly

• Plate washer

TIP

When installing the gear cover, align the projections a of the gear cover with the cut out parts b of the motor complete.

3-12

sealant

1

Drive axle, Motor

Drive

Unit

Installation of the Bearing Housing

1. Apply Three Bond 1215 ® to the following parts:

• Housing complete 1

Apply a continuous 2 to 3 mm thick coating as shown in the drawing (area indicated by dark line).

Three Bond 1215 ®

TIP

TIP

• Before applying the sealant, thoroughly clean all the mating surface of housing complete and motor complete.

• If there is any oil or grease on the housing complete or motor complete mating surfaces, wipe the surfaces clean and then apply sealant.

• Within 5 min. after applying the sealant, join the left and right halves together.

2. Install the following part:

• Housing complete

T

R

4.5 Nm (0.45 kgf·m)

3-13

2

2 sealant

1

1

New

Drive axle, Motor

Drive

Unit

Installation of the Stator Cover

1. Apply Three Bond 1215 ® to the following parts:

• Motor complete 1

Apply a continuous 2 to 3 mm thick coating as shown in the drawing (area indicated by dark line).

Three Bond 1215 ®

TIP

TIP

• Before applying the sealant, thoroughly clean all the mating surface of stator cover and motor complete.

• Within 5 min. after applying the sealant, join the left and right halves together.

2. Install the following part:

• Damper rubber 1

• Stator cover 2

T

R

4.5 Nm (0.45 kgf·m)

TIP

TIP

• When assembling the stator cover, hand tighten the three flanged bolts and then tighten them evenly.

• Install the Damper rubber 1 inside the stator cover.

• Be sure to replace the Damper rubber 1 with a new one when the assembly is disassembled.

3-14

4

Tightening Torque/

Lubricants, areas to apply sealant and specified types

Service Data

Tightening Torque

Tightening locations

Drive sprocket lock nut

Stator cover installation

Motor assembly and bearing housing

Circuit board installation

Holder installation

LCD type display holder

ISIS adapter installation

Screw diameter

M27

M5

M5

M3

M3

M3

M8

Service

Data

Unit: Nm kgf·m (in)

Q’ty

Tightening torque

Notes

6

5

1

3

40 (4.0)

4.5 (0.45)

Left hand screw

4.5 (0.45)

1.3 (0.13) Self-tapping screw

2 0.75 (0.075) Self-tapping screw

2 0.3 (0.03)

2 25.5 (2.55) Torx T30

Other, general tightening torques

The tightening torques of bolts and nuts other than those with tightening force for specified locations is determined by the screw diameter (width between two surfaces) and the pitch.

Width between surfaces

Screw diameter (width between two surfaces)

× pitch

Tightening torque

Pitch

Screw diameter

M4 (7 mm)

M5 (8 mm)

×

P0.7

×

P0.8

M6 (10 mm)

M8 (12 mm)

×

P1.0

×

P1.25

1.5 to 2.5 Nm

(0.15 to 0.25 kgf·m)

3 to 4.5 Nm

(0.3 to 0.45 kgf·m)

5 to 8 Nm

(0.5 to 0.8 kgf·m)

12 to 19 Nm

(1.2 to 1.9 kgf·m)

Lubricants, areas to apply sealant and specified types

Where to apply

All oil seal lips

Pawl kicks

Drive axle O-rings

Interior of torque sensor bushing

Spline of torque sensor

Interiors of the drive axle assembly and the one-way inner/outer bosses

All driven gear surfaces

Types of oils, grease, and sealants

Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil (MULTEMP AC-N ® )

Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil (MULTEMP AC-N ® )

Lithium-soap-based grease

Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil (MULTEMP AC-N ® )

Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil (MULTEMP AC-N ® )

Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil (MULTEMP AC-N ® )

Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil (MULTEMP AC-N ® )

Motor assembly’s surface which contact to the gromet of power lead wire.

Mating surfaces between motor assembly and bearing housing

Lithium-soap-based grease

Three Bond 1215 ®

4-1

Cable, Wire, and Pipe routing diagram

Service

Data

Cable, Wire, and Pipe routing diagram

1 Wire lead 2

2 Torque sensor plate

3 Wire lead 3 (Yellow)

4 Wire lead 4 (Blue)

5 Wire lead 5 (White)

6 Controller assembly

7 Heat-dissipating sheet

8 Wire lead 1

9 Wire lead 1 couplers 1

0 Wire lead 1 couplers 2

A Crank sensor

È Torque sensor positioner.

É Apply the heat-dissipating sheet so that it does not protrude from the heat sink plate. The heat-dissipating sheet should not be stretched beyond 10% of its original dimensions.

Ê Route the encoder lead wires through the outer side of holder projections as shown in the drawing.

È

1

6

A 8

2 9 Ê

3

5

4

0

*The actual lead wire may differ with the variety of Drive Unit from the pictures shown.

4-2

4

Troubleshooting

Service

Data

Troubleshooting

Symptom Check point/method Possible cause/check Part replacement/action

The pedal feels heavy.

The e-bike systems activates and cuts off during driving.

Is the air pressure in the tires normal?

Check for appropriate air pressure.

Check for punctures.

Is the gear-shifting working smoothly?

Is it being driven up a long slope in the summer, or carrying a heavy load?

Check the gear shifting system.

Repair puncture, replace tube.

Replace the gear shifting system.

This is due to the temperature rising in the battery pack or the Drive Unit assembly, and is not a malfunction.

The assist power is restored once the temperature of the battery pack or the Drive Unit assembly drops.

Is the ambient temperature low (around 10°C or below)?

Is the battery pack securely locked?

Check the ambient temperature.

Check the battery pack lock.

During the winter, store the battery pack indoors before use.

Check if the battery pack is securely locked.

Inspect the battery pack terminals and wiring for loose connection.

Has the battery pack been sufficiently charged?

Charge until full.

The cruising distance is short.

Is it being used in a low-temperature environment?

Is the battery pack degrading?

Check the ambient temperature.

Check the battery pack’s

Total number of battery charging cycles , actual capacity.

This will be restored when the ambient temperature warms up.

Replace the battery pack.

The 3 assist mode lamps, the

“%” lamp, the “Km” lamp, and the “km/h” lamp are flashing at the same time, and “Er” is displaying on the LED type display unit.

All segments of the assist mode display and battery capacity indicator are flashing at the same time, and “Er” is displaying on the speedometer section of the LCD type display unit.

Check the error according to the display on the display unit when the error occurred.

Communication error.

Check the “List of error codes

(See Chapter 2 “How communication errors are displayed”.) and corresponding power assist operations”.

Replace parts according to

“List of error codes and corresponding power assist operations”.

4-3

Troubleshooting

Service

Data

Symptom

The 3 assist mode lamps, the

“%” lamp, the “km” lamp, and the “km/h” lamp are flashing alternately, and “Er” is displaying on the LED type display unit.

Check point/method Possible cause/check Part replacement/action

Alternately flashes

All segments of the assist mode display and battery capacity indicator are flashing alternately, and “Er” is displaying on the speedometer section of the LCD type display unit.

Check the error log according to the display on the display unit when the error occurred.

Drive Unit assembly error.

Check “List of error codes

(See Chapter 2 “How Drive

Unit malfunctions are displayed”.) and corresponding power assist operations”.

Replace parts according to

“List of error codes and corresponding power assist operations”.

Alternately flashes

One of the assist mode lamps in the display unit 1 is flashing.

1 or

Speed sensor set

(See Chapter 2 “How speed sensor malfunctions are displayed”.)

A state persists where the speed sensor unit cannot detect the signal correctly.

Inspect the speed sensor set lead wires, pick up, and magnet sensor spoke type.

1

4-4

Troubleshooting

Service

Data

Symptom

Although the power to the display unit is turned on, all of the LED display of the LED type display unit turn on for 4 seconds, and then the power turns off automatically.

Check point/method Possible cause/check Part replacement/action after

4 seconds

Although the power to the display unit is turned on, all segments of the LCD type display unit turn on for 4 seconds, and then the power turns off automatically.

Battery pack signal lead wires

(See Chapter 2 “When the battery pack signal lead wire becomes disconnected”.)

Disconnection of signal lead wires in the battery pack.

Replace the lead wires for the DC plug or the power supply.

after

4 seconds

Charged the battery pack, but the residual battery capacity display lamp on the display unit does not show [FL].

Was the charging started immediately after driving, or when the battery pack temperature was high?

All four residual residual battery capacity display lamp on the battery pack are slow This is not a malfunction.

flashing simultaneously while charging the battery pack.

On standby for charging.

When pressing the battery capacity indicator button on the battery pack, all four battery capacity indicator lamps flash slowly at the same time.

This is not a malfunction.

Recharge the battery in a location where the temperature is suitable for charging (0 to 45°C).

The charging will start once the internal temperature of the battery pack is within the

0 to 45°C range.

See chapter 2 “Temperature protection function”.

The battery pack automatically recovers when the battery pack’s internal temperature returns to the allowable temperature for charging.

4-5

Troubleshooting

Service

Data

Symptom Check point/method Possible cause/check Part replacement/action

When pressing the battery capacity indicator button on the battery pack, lamps [1]/[3] and [2]/[4] or [1]/[2] and [3]/[4] turn on alternately.

Hold down the battery capacity indicator button on the bat(See Chapter 2 “Battery tery pack for 10 seconds.

(See Chapter 2 “Error diagnosis mode”.) pack/battery charger diagnosis items table”.)

The battery capacity indicator lamps [1] and [4] on the battery pack flash simultaneously.

Hold down the battery capacity indicator button on the battery pack for 10 seconds.

(See Chapter 2 “Battery

(See Chapter 2 “Battery pack protection function diagnosis pack/battery charger diagnosis items table”.) mode”.)

After disconnecting the charging plug on the battery charger from the battery pack, the battery capacity indicator lamps continue to light.

Charging connector on the battery pack.

Charging connector and charging plug are wet.

Assist driving

Replace the parts according to “Battery pack/battery charger diagnosis items table”.

Replace the battery pack.

Clean the charging connector and charging plug, and dry them.

Abnormal sound is produced during assist driving.

Check for sprocket wear or stretched chain

Abnormal sound is produced when the motor is operating.

Disassemble the Drive Unit.

Inspect the driven gear.

Replace the motor assembly.

Abnormal sound is produced from the Drive Unit assembly.

Turn the crank.

Turning the crank produces periodic abnormal sound.

Inspect the housing bearing.

Inspect the bearing.

Turn off the power for manual

Stepping on the pedal propedalling.

duces abnormal sound and vibration (clicking).

Check the joints.

If further tightening does not improve the problem, replace parts.

4-6

Yamaha X94 Series Service Manual

7th edition

Published October 2014

Unauthorized reproduction prohibited

Published by: Yamaha Motor Co., Ltd.

SERVICE MANUAL e-Bike SYSTEMS

X94 Series

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