Yamaha PW70CNL, PW70CNM, PW70CNS Assembly Manual

2018
ASSEMBLY MANUAL
CROSS CONNECT
PW70CNL
PW70CNM
PW70CNS
LIT-15666-00-04
X1M-28107-13
FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha bicycle prior
to delivery to the customer. Since some external parts of the bicycle have been removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. No adjustment of the power
unit mechanism, which plays the most important part in riding, is necessary because it has been adjusted at
the factory before shipping. It should be noted that the assembled bicycle should be thoroughly cleaned,
checked, and adjusted prior to delivery to the customer.
IMPORTANT
7
The service specifications given in this assembly manual are based on the model as manufactured. Yamaha
Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes
in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future
editions of this manual where applicable.
The procedures below are described in the order that the procedures are carried out correctly and completely.
Failure to do so can result in poor performance and possible harm to the bicycle and/or rider.
Follow the instructions in the Dealer Warranty Handbook, Procedure Section.
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
the bicycle or other property.
TIP
A TIP provides key information to make procedures easier or clearer.
9
NOTICE
PW70CNL/PW70CNM/PW70CNS
ASSEMBLY MANUAL
©2018 by Yamaha Motor Corporation, U.S.A.
First edition, April 2018
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-15666-00-04
PARTS LOCATION
PARTS LOCATION
Body assembly
NOTICE
8 Do not use a cutter, scissors, or other sharp object to open the part boxes; otherwise, the included
parts could be damaged.
8 Wear suitable protective gear such as gloves when handling and opening the part boxes.
3
7
1
2
1. Part box 1
2. Front wheel
3. Front fender
9
–1–
INCLUDED PARTS
INCLUDED PARTS
The parts listed as follows are included*. Check the parts and their quantities before starting assembly.
No.
1
2
3
4
5
6
Part names
Front wheel
Front fender
Part box 1
Part box 2
Part box 3
Part box 4
Q’ty
1
1
1
1
1
1
Remarks
3 in part box 1
3 in part box 1
3 in part box 1
Part box 1 details
7
Saddle and seat post assembly
1
7
Part box 2 details
8
9
0
q
w
Front axle
Pedals
Bell
Front reflector
Owner’s manual
1
2
1
1
1
e
Button cell battery
1
Part box 3 details
r
Battery pack
1
Part box 4 details
t
Battery charger
1
9
* The form of the package is subject to change without notice.
–2–
1 each for left and right
w in owner’s manual pouch
Standard CR2032
INCLUDED PARTS
1
7
8
9
2
7
3
0
q
e
w
4
9
r
5
t
6
–3–
INSTALLING THE INCLUDED PARTS
INSTALLING THE INCLUDED
PARTS
WARNING
Tighten the bolts and nuts to the specified
torques. Failure to tighten the bolts and nuts to
the specified torques could prevent proper
operation of the bicycle and make it unsafe to
operate.
TIP
7
8 Charge the battery pack following the instructions in the owner’s manual before starting
installation.
8 The letters inside the parts list boxes in the
assembly procedures indicate the following:
A: Part in part box 1
B: Part in part box 2
C: Part in part box 3
1. Installing the front fender
Loosen the bolts a and lower the stay b until
90.
a
b
d
Secure the stay b to the portion c of the front
fender 1.
Adjust the installation position of the front fender
1 and tighten the bolts a and d to the specified torques.
9
Tightening torque 6 N·m (0.6 kgf·m, 4.4 lb·ft)
c
b
1
a
1
b
Front fender
1
1
Tightening torque 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
2. Installing the front wheel and fork end
Remove the spacer b from the front disc caliper a.
Give the removed spacer b to the customer,
explaining how it is used.
b
a
–4–
INSTALLING THE INCLUDED PARTS
Align the holes in the front wheel 1 with the
holes in the fork end and install the front wheel
1.
Install it in such a way that the disc rotor c does
not touch the disc pad.
Put the lever d of the front axle 2 down in the
direction in which the stamp “OPEN” is visible
and check that the collar e is open.
Install the front axle 2 to the fork end holes
from the left side of the bicycle.
a
TIP
1
2
1
Front wheel
Front axle
1
1
7
8 Even if the collar e of the front axle 2 is
inserted with the collar open, it will close when
pressed in.
8 When the collar e is closed, turn the nut f
approximately 1/8 turn counterclockwise while
keeping it pressed in; the collar will then open.
2
B
c
e
f
2
d
f
e
d
Determine the position in which the lever d is to
be fastened, lower it in the direction in which the
stamp “CLOSE” is visible, then fasten it.
d
–5–
9
Check that the collar e of the front axle 2 goes
through the hole in the right side of the fork end
and that the collar is actually open.
Turn the nut f while keeping it pressed to prevent the lever d from turning, and tighten it until
there is a little resistance.
INSTALLING THE INCLUDED PARTS
WARNING
8 Position the lever when it cannot touch
obstacles while the bicycle is moving. If not,
the lever could be unlocked unexpectedly,
causing the front wheel to come off, resulting in an accident with severe injury or
death.
8 Fasten the lever d at position where the tip
does not touch other parts when the lever
d is lowered.
8 Fasten the lever d facing backward from
the direction of travel in such a way that it
cannot easily touch obstacles that might be
encountered while riding.
7
TIP
If the lever d of the front axle 2 is too hard and
cannot be lowered, or if it is too loose and cannot
be lowered for it to be locked, turn the nut f again
to loosen or tighten it, adjusting so that it can be
fastened securely.
Tightening torque 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
3. Installing the handlebar stem
Position the handlebar stem a in a straight line
with the front wheel.
Tighten the bolts b and c, in that order, to the
specified torques.
b
a
c
c
9
Tightening torque 6 N·m (0.6 kgf·m, 4.4 lb·ft)
4. Installing the handlebar
Install the handlebar a so that the knurled part
b is at the center of the handlebar holder c,
then tighten the 4 handlebar holder c bolts d
to the specified torque.
a d
b
NOTICE
c
The handlebar a should not touch the frame
when it is turned fully to the left or right.
d
Tightening torque 6 N·m (0.6 kgf·m, 4.4 lb·ft)
–6–
INSTALLING THE INCLUDED PARTS
TIP
Install the handlebar a so that the brake levers e
are at a 30 angle to the handlebar, as shown in the
illustration.
a
30°
e
TIP
d
8 Tighten bolts d evenly in stages, in the order
shown in the illustration.
8 Tighten in such a way that the gaps f above
and below the handlebar holder c are equal.
7
f
c
f
b
TIP
c
Install in such a way that the headlight points downward from horizontal and shines on the road
approximately 33 feet (10 meters) ahead.
a
Tightening torque 7 N·m (0.7 kgf·m, 5.2 lb·ft)
6. Installing the front reflector
Install the front reflector 1 in the position a
shown in the illustration, then tighten it together
with the stay 2 and screw 3.
a
1
2
3
3
1
2
Front reflector
Stay
Screw
1
1
1
B
B
B
TIP
Adjust so that the front reflector 1 faces straight
ahead, then tighten the screw.
–7–
9
5. Installing the headlight
Install the headlight a to the bracket b as
shown, then tighten the bolt c to the specified
torque.
INSTALLING THE INCLUDED PARTS
7. Installing the bell
Install the bell 1 in the position a shown, then
tighten it with the screw 2.
a
1
2
Bell
Screw
1
1
B
B
1
2
q
8. Routing the wires
6
7
WARNING
8
5
4
1
Be sure to route the wires as shown in the illustration. If not, they could interfere with handlebar operation which could cause loss of
control.
7
3
2
0
9
Confirm that hoses and wires are routed in
order starting from front to back
Front brake hose 1
Rear brake hose 2
Rear shift wire 3
Front shift wire 4
Headlight lead 5
Switch unit lead 6
Display unit lead 7
Clamp the front brake hose 1 and front shift
wire 4 with the wire clip 8 at the position
shown in the illustration.
Clamp the front shift wire 4 and headlight lead
5 with the plastic locking ties 9 at the position
shown in the illustration.
Clamp the rear brake hose 2, rear shift wire 3
and display unit lead 7 with the plastic locking
ties 0 at the position shown in the illustration.
Clamp the front shift wire 4 and switch unit lead
6 with the wire clip q at the position shown in
the illustration.
9
q6
8
5
4
1
9
7
3
2
0
–8–
INSTALLING THE INCLUDED PARTS
Check that the front brake hose 1, front shift
wire 4, headlight lead 5, wire clip 8, and plastic locking ties 9 are placed as shown in the
illustration.
5
1
4
8
9
7
3
2
8
1
Check that the front brake hose 1, rear brake
hose 2, rear shift wire 3, front shift wire 4,
display unit lead 7, wire clip 8, and plastic
locking ties 0 are placed as shown in the illustration.
7
0
9
4
Check that the rear brake hose 2, rear shift
wire 3, and speed sensor lead w are routed as
shown in the illustration.
3
2
w
–9–
INSTALLING THE INCLUDED PARTS
9. Tightening the seat pin
Insert the saddle and seat post 1, then tighten
the bolt a to the specified torque.
1
1
b
a
Saddle and seat post
1
A
WARNING
8 Insert the seat post far enough that the raise
limit b is not visible. If installed at a position at which the raise limit b is visible, the
seat post, clamp, or even frame may break,
which could cause the rider to lose control
and fall.
8 Always tighten fasteners to the correct
torque. Bolts that are too tight can stretch
and deform. Bolts that are too loose can
move and fatigue. Either mistake can lead
to a sudden failure of the bolt, causing the
rider to lose control and fall.
7
Tightening torque 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
NOTICE
Do not insert the seat post completely when
lowering the saddle. The bottom edge of the
seat post could touch parts inside the seat
pipe, breaking the seat post or the parts inside
the seat pipe. If the seat post is inserted fully,
lift it slightly then fasten it.
10. Installing the pedals
Install the pedal 1 to the crank a, then tighten
to the specified torque.
9
1
Pedals (left and right)
a
1
1
each
B
TIP
8 Right screw for the right pedal
8 Left screw for the left pedal
Tightening torque 40 N·m (4.0 kgf·m, 30 lb·ft)
11. Installing the battery pack
Check that the battery pack 1 is fully charged
according to owner’s manual procedures, then
install the battery pack 1.
1
1
– 10 –
Battery pack
1
C
INSTALLING THE INCLUDED PARTS
b
12. Installing the display unit’s button cell battery
Loosen the bolts a and remove the display unit
b from the bracket c.
c
a
Tightening torque 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
e
Turn the button cell battery cover d on the back
of the display unit b in direction e, remove it,
then install the button cell battery 1.
Mount the button cell battery cover d, then turn
it in direction f until it locks.
f
d
1
g
b
Button cell battery
1
B
7
1
NOTICE
8 Install the button cell battery with the plus
(+) mark facing upward.
8 Check that the O-ring g is properly
installed.
After installing the button cell battery, install the
display unit onto the bracket following the
removal procedure in reverse order.
Peel off the protective film after installing.
c
d
b
a
D. The hours value increases when the “ ▲ ” assist
mode switch f is pressed while the “Hour” section of the clock e is flashing.
The hours value decreases when the “▼” assist
mode switch d is pressed.
Press the function select switch b to set the
hours.
e
f
d
b
– 11 –
9
13. Adjusting the display unit’s time
A. Press the power switch a to turn on the power.
B. Press and hold the function select switch b (2
seconds or longer) until the function display c
switches to the main menu display.
C. Press the “ ▼ ” assist mode switch d, display
“TIME ADJ” on the main menu display, then
press the function select switch b to set.
INSTALLING THE INCLUDED PARTS
E. The minutes value increases when the “ ▲ ”
assist mode switch f is pressed while the “Minute” section of the clock e is flashing.
The minutes value decreases when the “ ▼ ”
assist mode switch d is pressed.
Press the function select switch b to set the
minutes.
F. The time is set and the mode returns to the normal mode.
e
f
d
b
a
TIP
If you make a mistake adjusting the time, start over
from step B.
G. Press the power switch a to complete adjustment of the time.
7
14. Checking the operation of the speed sensor
A. Press the power switch a to turn on the power.
B. Long-press the power switch a (approximately
10 seconds) within 30 seconds after turning on
the power, check that the display switches to the
diagnosis function selection screen b, then
release the power switch a.
C. Press the “ ▼ ” assist mode switch c, display
“SPEED SNSR” on the diagnosis function
selection screen b, then press the function
select switch d to set.
b
c
d
a
D. Check that the speedometer e is displayed and
that the speed sensor checking mode has been
set.
E. The number displayed on the speedometer e
counts up when the rear wheel is lifted off the
ground and turned.
The number increases by 1 for 1 turn. Check
that the position of the wheel at which the display counts up is stable.
F. After checking the operation, press the power
switch a to quit.
9
e
a
TIP
Turn the rear wheel at least 3 revolutions and check
that the display reads “3”.
15. Adjusting the opening of the front and rear
brake levers
Before adjusting the opening of the brake
levers, grip the brake levers approximately 10
times to pump them.
Turn the adjusting screw 1 to adjust the opening of the tip of the brake lever a from the tip of
the grip.
1
a
c b
b direction
c direction
– 12 –
Opening gets larger.
Opening gets smaller.
INSTALLING THE INCLUDED PARTS
NOTICE
After adjusting the brake lever opening, check
that the rotation of the front and rear wheels is
not heavy.
TIP
Adjust to a position at which it is easy for the customer to operate the front and rear brake levers and
within the range of play of the brake levers.
7
9
– 13 –
PREDELIVERY INSPECTION
PREDELIVERY INSPECTION
WARNING
8 Handlebar orientation, height, angle, and tightening
8 Saddle orientation, height, angle, and tightening
* Check that the saddle is firmly fastened.
8 Various fittings adjusted to the customer’s riding posture
* Including brake lever angle, fork suspension air pressure, etc.
8 Inspection of the wheels, hubs, and spokes
8 Tightening of the pedals
8 Tightening of the screws of each part
8 Brake performance
8 Shift changing operation
8 Looseness of the chain
8 Bell sound
8 Battery pack locking operation
* Check that the battery pack locks securely.
8 Check of battery pack and battery charger operation
8 Operation of the meter, switches, and drive unit
8 Light, brightness, and angle of the headlight
* Check that the headlight shines on the road approximately 33 ft. (10 m) ahead.
8 Installation state of the reflectors
8 Maximum tire air pressure
Front tire: 515 kPa (5.1 kgf/cm2, 75 psi)
Rear tire: 515 kPa (5.1 kgf/cm2, 75 psi)
9
7
After completing the installation, inspect the items as follows and check that there are no problems
before delivering the bicycle. Adjust controls and saddle height to the customer’s satisfaction
according to this manual.
– 14 –

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