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Yamaha X0S Series Service Manual

E-bike systems
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MY2017
SERVICE MANUAL
e-Bike SYSTEMS
X0S Series

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Summary of Contents for Yamaha X0S Series

  • Page 1 MY2017 SERVICE MANUAL e-Bike SYSTEMS X0S Series...
  • Page 2 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: Gen­ eral information, electrical components, Drive Unit, and service data.
  • Page 3 Index General Information INFO ELEC – Electrical Components ELEC Drive Unit Drive Unit SPEC Service Data Service Data...

  • Page 4: Table Of Contents

    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...
  • Page 5 CHAPTER 3 Drive Unit Drive axle, Motor ...................P3-1 Removal of the parts from the drive axle (drive axle with square-type end) ............P3-5 Removal of the parts from the drive axle (drive axle with spline-type end) .............P3-5 Removal of the Controller Assembly ............P3-5 Removal of the Torque sensor assembly and Drive axle ......P3-7 Installation of the Drive axle and Controller assembly ......P3-7 Installation of the Controller assembly ...........P3-7...

  • Page 6: Chapter 1 General Information

    Description INFO General Information Description È É 4. Battery charger 1. Drive Unit 5. Battery pack (The battery may differ 2. Speed sensor set depending on the model.) a) Magnet sensor spoke type È Rear carrier 400Wh b) Pick up É...

  • Page 7: Precautions Relating To Maintenance (1)

    Precautions relating to maintenance (1) 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.

  • Page 8: Replacement Parts

    Genuine parts circlips (split rings), lock washers, etc. with new parts. Be sure to use genuine new Yamaha parts and recommended parts for oils and greases, in­ cluding periodic replacement parts and repair parts. Do not use used parts because, even though...

  • Page 9: Handling The Battery Pack

    Precautions relating to maintenance (1) INFO Handling the Battery Pack 1. Use the dedicated battery charger for charging the battery pack. 2. The battery pack is a dedicated e­bike sys­ tem battery. If it is connected to a product other than the e­bike system, it will cause a fluid leakage, “overheating, or breakage.”...

  • Page 10: Servicing Precautions (2)

    Servicing Precautions (2) 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.

  • Page 11: Precautions Relating To Maintenance (3)

    Precautions relating to maintenance (3) INFO Precautions relating to maintenance (3) Handling of the torque sensor 1. Keep away from magnets. 7. Do not reuse damaged drive axles. Do not use magnetized screwdrivers or per­ The sensor shaft and the drive axle slide in a form maintenance near large sources of metal bearing.

  • Page 12: Specialized Tools And Equipment

    Specialized tools and equipment INFO Specialized tools and equipment The appropriate specialized tools must be used for inspection, adjustment, disassembly, and reas­ sembly. Maintenance problems and mechanical breakage can be prevented by using the appropriate spe­ cialized tools. Lithium soap based grease MULTEMP AC­N ...

  • Page 13: Chapter 2 Electrical Components

    – ELEC Electrical component wiring diagram Electrical Components Electrical component wiring diagram...

  • Page 14: Battery Pack

    – 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 Display item Display time Details Page pushed...
  • Page 15 – ELEC Battery pack 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 bat- tery capacity indicator button “ ” is pushed or connect the battery charger, see “Recover- able errors of battery pack or battery char- ger”.

  • Page 16: How To Check The Total Number Of Battery Charging Cycles

    – 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 but- ton “ ” 1 for 20 seconds. 2. The total number of battery charging cycles is indicated by the four battery capacity indi- cator lamps 2 on the battery pack.

  • Page 17: How To Check The Full Charge Capacity

    – ELEC Battery pack How to check the full charge capacity Check the * full charge capacity as fol lows: 1. Hold down the battery capacity indicator but- ton “ ” 1 for 30 seconds. 2. The * full charge capacity is indicated by the four battery capacity indicator lamps 2 on the battery pack.

  • Page 18: Charging

    – 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. 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...

  • Page 19: Display On Battery Capacity Indicator Lamps While Charging

    – ELEC Charging Display on battery capacity indicator lamps while charging Some phenomena such as the following may occur while charging the battery pack, depend- ing 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].

  • Page 20: Diagnosis Mode

    – 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 Turn on access the error diagnosis mode and confirm alternately the details regarding the error of the battery pack or battery charger.
  • Page 21 – ELEC Diagnosis mode...
  • Page 22 – ELEC Diagnosis mode 2-10...

  • Page 23: Non-Recoverable Errors Of Battery Pack

    – 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 di- agnosis mode and confirm the details regarding the error of the battery pack. 1.
  • Page 24 – ELEC Diagnosis mode 2-12...
  • Page 25 – ELEC Diagnosis mode When the battery pack signal lead wire becomes disconnected Although the power to the display unit is turned on, all segments of the display unit turn on for 4 seconds, and then the power turns off auto- matically.

  • Page 26: Temperature Protection Function

    – 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 tem- perature protection function of the battery pack operates and the battery pack stops discharging.

  • Page 27: Over-Discharge Protection Function

    – 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 indi cator lamps do not turn on. The following procedure can be used to access the over-discharge protection function diagnos- tic mode and confirm the details regarding the...
  • Page 28 – ELEC Diagnosis mode 2-16...

  • Page 29: Diagnosis Function

    – ELEC Diagnosis function Diagnosis function 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 er- ror.
  • Page 30 – ELEC Diagnosis function How Drive Unit malfunctions are displayed All segments of the assist mode indicator 1 and all segments of the battery capacity indi- cator 2 will flash alternately, and “Er” will be displayed on the speedometer section 3 of the display unit.

  • Page 31: Operating Procedures To Diagnosis Mode

    – ELEC Diagnosis function Operating Procedures to Diagnosis Mode This is the mode in which each type of diagno- sis and the content of error codes which are stored when there is an error are displayed. You can switch between speed sensor diagno sis mode, Drive Unit diagnosis mode, and error log check mode by using the display unit according to the following procedures.
  • Page 32 – ELEC Diagnosis function 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 rap- idly (0.2 second). For more information about the speed sensor diagnosis mode, see “Speed Sensor Diagnosis Mode Display Method”.
  • Page 33 – ELEC Diagnosis function Speed Sensor Diagnosis Mode Display Method To determine if the controller is correctly rec- ognizing 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 num ber of rotations.

  • Page 34: Diagnosis Function

    – ELEC Diagnosis function 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 flash- ing “STD”...
  • Page 35 – ELEC Diagnosis function 1) Torque sensor reference voltage 1. Torque sensor reference voltage display a. “10” is displayed in the diagnosis mode dis- play 1 of the display unit. b. Press the function select switch “s” of the display unit. c.
  • Page 36 – ELEC Diagnosis function 2) Motor current a. “14” is displayed in the diagnosis mode dis- play 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”...
  • Page 37 – ELEC Diagnosis function 3) Error displays a. “16” is displayed in the diagnosis mode dis- play 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”...
  • Page 38 – ELEC Diagnosis function 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.
  • Page 39 – ELEC Diagnosis function How to delete the malfunction history 1. While pressing the light switch “ ” 1 dur- ing the error code display, press the assist mode switch power assist decrease 2 and power assist increase 3 to switch. Fast flashing 2.
  • Page 40 – ELEC Diagnosis function 2-28...
  • Page 41 – ELEC Diagnosis function 2-29...
  • Page 42 – ELEC Diagnosis function 2-30...
  • Page 43 – ELEC Diagnosis function 2-31...
  • Page 44 – ELEC Diagnosis function 2-32...
  • Page 45 – ELEC Diagnosis function 2-33...

  • Page 46: Speed Sensor Set

    – ELEC Speed sensor set Speed sensor set Speed sensor inspection 1. Pickup • Check that the pickup is installed at the spec- ified location on the bike. • Check that the pickup is not damaged. 2. Magnet sensor Magnet sensor a.

  • Page 47: Chapter 3 Drive Unit

    Drive Drive axle, Motor Unit Drive Unit Drive axle, Motor 4.5 Nm (0.45 kgf 40 Nm (4.0 kgf • • 11 12 1.3 Nm (0.13 kgf • 4.5 Nm (0.45 kgf • 0.75 Nm (0.075 kgf 27 28 • Order Job/Part Q’ty Remarks...
  • Page 48 Drive Drive axle, Motor Unit 4.5 Nm (0.45 kgf 40 Nm (4.0 kgf • • 11 12 1.3 Nm (0.13 kgf • 4.5 Nm (0.45 kgf • 0.75 Nm (0.075 kgf 27 28 • Order Job/Part Q’ty Remarks Plate washer Oil seal Clutch boss assembly One-way outer boss...
  • Page 49 Drive Drive axle, Motor Unit 4.5 Nm (0.45 kgf 40 Nm (4.0 kgf • • 11 12 1.3 Nm (0.13 kgf • 4.5 Nm (0.45 kgf • 0.75 Nm (0.075 kgf 27 28 • Order Job/Part Q’ty Remarks Wire lead 5 couplers Disconnect.
  • Page 50 Drive Drive axle, Motor Unit 4.5 Nm (0.45 kgf 40 Nm (4.0 kgf • • 11 12 1.3 Nm (0.13 kgf • 4.5 Nm (0.45 kgf • 0.75 Nm (0.075 kgf 27 28 • Order Job/Part Q’ty Remarks Torque sensor assembly Drive axle Both end shapes of the drive axle is different by the specifications of Drive Unit.

  • Page 51: Removal Of The Parts From The Drive Axle (Drive Axle With Square-Type End)

    Drive Drive axle, Motor 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.
  • Page 52 Drive Drive axle, Motor Unit 2. Remove the following parts: • Plate washer 1 • Clutch boss assembly 2 3. Remove the following parts: • One-way outer boss 1 • Driven gear assembly 2 • Gear cover 3 4. Remove the following parts: •...

  • Page 53: Removal Of The Torque Sensor Assembly And Drive Axle

    Drive Drive axle, Motor 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 as- sembly because it cannot be readjusted.
  • Page 54 Drive Drive axle, Motor Unit 2. Install the following part: • Heat-dissipating sheet 1 NOTICE 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 disas- sembled.

  • Page 55: Installation Of The Bearing Housing

    Drive Drive axle, Motor Unit Installation of the Bearing Housing 1. Apply Three Bond 1215B to the following  sealant parts: • Housing complete 1 Apply a continuous 2 to 3 mm thick coating as shown in the drawing (area indicated by dark line).

  • Page 56: Installation Of The Stator Cover

    Drive Drive axle, Motor Unit Installation of the Stator Cover 1. Apply Three Bond 1215B to the following  sealant parts: • Motor complete 1 Apply a continuous 2 to 3 mm thick coating as shown in the drawing (area indicated by dark line).

  • Page 57: Chapter 4 Service Data

    Tightening Torque/ Service Lubricants, areas to apply sealant and specified types Data Service Data Tightening Torque Unit: Nm kgf·m (in) Screw Tightening Tightening locations Q’ty Notes diameter torque Drive sprocket lock nut 40 (4.0) Left hand screw Stator cover installation 4.5 (0.45) Motor assembly and bearing housing 4.5 (0.45)

  • Page 58: Cable, Wire, And Pipe Routing Diagram

    Service Cable, Wire, and Pipe routing diagram Data Cable, Wire, and Pipe routing diagram 1 Wire lead 2 A Crank sensor Ê Route the encoder lead wires 2 Torque sensor plate through the outer side of holder 3 Wire lead 3 (Yellow) projections as shown in the draw- È...

  • Page 59: Troubleshooting

    Service Troubleshooting Data Troubleshooting Symptom Check point/method Possible cause/check Part replacement/action Check for appropriate air Is the air pressure in the tires Repair puncture, replace pressure. normal? tube. Check for punctures. Is the gear-shifting working Check the gear shifting Replace the gear shifting smoothly? sys tem.
  • Page 60 Service Troubleshooting Data Symptom Check point/method Possible cause/check Part replacement/action All segments of the assist mode display and battery capacity indicator are flash ing alternately, and “Er” is displaying on the speedome- ter section. Check the error log according to the display on the display Drive Unit assembly error.
  • Page 61 Service Troubleshooting Data Symptom Check point/method Possible cause/check Part replacement/action Charged the battery pack, but Was the charging started Recharge the battery in a the residual battery capacity immediately after driving, or location where the tempera- display lamp on the display when the battery pack ture is suitable for charging (0 unit does not show [FL].
  • Page 62 Yamaha X0S Series Service Manual MY2017 1st edition Published April 2016 Unauthorized reproduction prohibited Published by: Yamaha Motor Co., Ltd.
  • Page 64 (EN)

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