Yamaha X0S Series Service Manual Download Page 5 | Manualshive

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Yamaha X0S Series Service Manual Download 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
Installation of the Bearing Housing ........................................................P3-9
Installation of the Stator Cover .............................................................P3-10

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

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Summary of Contents for X0S Series

Page 1: ...SERVICE MANUAL e Bike SYSTEMS X0S Series MY2017...

Page 2: ...NING Indicates that incorrect use could result in death or serious injury NOTICE Indicates that incorrect use could cause property damage TIP Indicates methods are correct operation or main elements o...

Page 3: ...Index General Information GEN INFO 1 Electrical Components ELEC ELEC 2 Drive Unit Drive Unit 3 Service Data SPEC Service Data 4...

Page 4: ...cal 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 full charge cap...

Page 5: ...val 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 Installation of the Bearing Housing P3 9...

Page 6: ...Display Unit a Display detachable b Display holder c Switch 4 Battery charger 5 Battery pack The battery may differ depending on the model Rear carrier 400Wh Rear carrier 500Wh 1 General Information D...

Page 7: ...hat it does not get inside when performing service 2 Use water or neutral cleanser to clean cov ers and wipe off water using a soft cloth to prevent scratching Avoid wiping with a dry cloth prior to w...

Page 8: ...pect and measure parts as needed dur ing 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 cle...

Page 9: ...een unused for a long period of time 4 Do not expose the battery pack to fresh wa ter or seawater It can cause the battery pack to overheat or rust 5 Do not disassemble or modify the battery pack It c...

Page 10: ...el force to the inner race Oil Seal Installation 1 To install an oil seal direct the main lip to wards the oil chamber the object of seal ing 2 Be sure to apply a thin even coat of grease to the seali...

Page 11: ...pply excessive force to the sensor shaft and result in volt age changes 4 Do not pull leads Do not pull forcefully on the small circuit board leads which connect the torque sen sor body to the torque...

Page 12: ...made from synthetic hydrocarbon oil and synthetic ester oil Digital circuit tester Device used for testing and measuring electrical components Specialized tools and equipment The appropriate specializ...

Page 13: ...Y B R Gy W G L Sb G B R Gy B R L Sb R SPEED SENSOR TO LIGHT DISPLAY UNIT WIRE LEAD 1 WIRE LEAD 3 WIRE LEAD 5 WIRE LEAD 4 Y Y L W R B W L TO MOTOR ENCODER CONTROLLER ASSEMBLY TORQUE SENSOR ASSEMBLY MO...

Page 14: ...5 seconds See How to check the total number of battery charging cycles P 2 4 30 seconds Full charge capacity 5 seconds See How to check the full charge capacity P 2 5 Error display 1 Depending on the...

Page 15: ...1 and 4 are fast flash simultaneously when the bat tery capacity indicator button is pushed or connect the battery charger see Non re coverable errors of battery pack P 2 11 3 2 1 4 Off Fast flashing...

Page 16: ...conds 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 ch...

Page 17: ...arge capacity Full charge capacity is not the relative speci fied electric power capacity that the battery pack has at any given point but the actual electric capacity that the battery pack itself can...

Page 18: ...4 3 2 1 4 3 2 1 4 3 2 1 4 Charging time Preliminary charging When starting charge from a discharged state Slow flashing Charging complete Fully charged state The lamp above the currently illuminating...

Page 19: ...you start charging properly if the battery pack exceeds the specified temper ature range while charging the charging process is aborted to protect the battery pack This may result in insufficient cha...

Page 20: ...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 but ton 1 for 10 second...

Page 21: ...ring discharging 1 Connect the battery pack to the dedicated battery charger for the e Bike system and charge it for a while 2 The battery pack returns to the normal state after the step 1 install the...

Page 22: ...eturn to the normal state after the battery pack is installed to the bicycle and the bicycle is ridden for a while 3 2 1 4 Charging over current during charging 3 2 1 4 Not turn on Zero charg i ng cur...

Page 23: ...ery 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 indica tor lamps 1 and 4...

Page 24: ...n 1 and 4 flash rapidly Hold down the residual battery capacity indicator button for 10 sec o nds 3 2 1 4 FET failure Replace the battery pack 3 2 1 4 AFE fault 3 2 1 4 High tem perature exposure 3 2...

Page 25: ...play unit turn on for 4 seconds and then the power turns off auto matically If the motor is rotating while running the power assist becomes weak and finally stops it The battery pack stops discharging...

Page 26: ...rature 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 indi cator lamps 1 2...

Page 27: ...or 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 malfunction of the battery pack Firs...

Page 28: ...ed state This is the battery pack s over discharged state The battery pack is in the Non recoverable error This is the Preliminary charging Initial charging state This is normal If the battery pack be...

Page 29: ...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 How communication errors are display...

Page 30: ...ayed The HIGH STD or ECO assist mode indi cator 1 are displayed with a slow flash 0 5 second The function display part 2 are displayed with when you select as follwing functions Average bicycle speed...

Page 31: ...ll 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 Approx imately 10 seconds Con...

Page 32: ...ist 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 rap idly 0 2 second For more information about the drive unit dia...

Page 33: ...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 Wh...

Page 34: ...unit func tion check Fast flashing List of Drive Unit Diagnosis Mode Display Methods Inspection items Diagno sis mode display Press operating button Diagnosis data display Press operating button 1 Tor...

Page 35: ...yed 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 Unt...

Page 36: ...isplayed good 100 is not displayed If the bicycle was ridden immediately before checking the motor current it is possible that the bat tery or the controller temperature control is working therefore w...

Page 37: ...nction check TIP When there is no malfunction the next 18 is displayed without the diagnosis mode 16 be ing displayed Perform a final check to make sure there is no error display in this mode when per...

Page 38: ...n there are no er rors When other error codes are stored the dis play will switch to the next error in 10 sec onds Fast flashing List of Error Log Check Mode Display Methods Number of error codes How...

Page 39: ...ower assist decrease 2 and power assist increase 3 to switch 1 2 3 Fast flashing 2 The diagnostic display pattern will stop all segment lights will turn on and off twice and the history will be delete...

Page 40: ...holder Power assist will stop after determine the error Error code does not record 0 Replace the display unit assem b ly Alternately flashes Encoder 16 Disconnected or red wire is short circuited Pow...

Page 41: ...ning with high con s tant voltage 25 Abnormal voltage detected during running others 26 Abnormal voltage detected during running at low speeds 27 Wiring failure between the coil and the circuit board...

Page 42: ...place the drive axle assem b ly 33 Short circuited or crank sen s or failure 1 Replace the crank sensor 2 Replace the encorder lead wire 3 Replace the drive axle assem b ly Motor 40 3 lead wires are d...

Page 43: ...tor is not operating 53 Over current is applied to the U phase of the motor Power assist will stop after determine the error Error code will record 2 1 Replace the controller assem b ly 2 Replace the...

Page 44: ...a ture is too low 20 C Power assist will stop after determine the error Error code will record 2 Replace the controller assembly 81 Detected circuit board temper a ture is too high 125 C including DC...

Page 45: ...ments will turn on during 4 seconds then automatically turn off 91 Can t receive data from bat t ery correctly Power assist will immediately stop after determine the error Also display unit will turn...

Page 46: ...net sensor c Check that the magnetic surface of the mag net sensor is facing the sensing point on the pickup d Install the magnet sensor to match the cen ter of the magnet sensor and the cutout point...

Page 47: ...0 75 Nm 0 075 kgf m T R 4 5 Nm 0 45 kgf m T R Order Job Part Q ty Remarks Removal of the Drive axle Motor Follow the work procedures for removal Drive Unit assembly 1 Lock nut 1 Left hand screw 2 Spro...

Page 48: ...5 kgf m T R Order Job Part Q ty Remarks 10 Plate washer 1 11 Oil seal 1 12 Clutch boss assembly 1 13 One way outer boss 1 14 Driven gear assembly 1 15 Gear cover 1 16 Heat dissipating sheet 1 17 Heat...

Page 49: ...Nm 0 45 kgf m T R Order Job Part Q ty Remarks 22 Wire lead 5 couplers 1 Disconnect 23 Controller assembly 1 NOTICE Do not touch the circuit board with greasy or dirty fingers Do not drop the circuit...

Page 50: ...T R 1 3 Nm 0 13 kgf m T R 0 75 Nm 0 075 kgf m T R 4 5 Nm 0 45 kgf m T R Order Job Part Q ty Remarks 31 Torque sensor assembly 1 32 Drive axle 1 Both end shapes of the drive axle is different by the sp...

Page 51: ...e the following parts Screw Adapter Locknut Left hand screw Spider Flanged bolt Removal of the Controller Assembly 1 Separate the housing complete from the mo tor complete TIP Separator ribs a are pro...

Page 52: ...2 4 Remove the following parts Heat dissipating sheet 1 Tapping screw 2 2 1 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...

Page 53: ...or assembly 2 Holder 3 Tapping screw 4 T R 0 75 Nm 0 075 kgf m 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...

Page 54: ...assembly is disas sembled 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 1 New 3...

Page 55: ...ne Three Bond 1215B TIP Before applying the sealant thoroughly clean all the mating surface of housing com plete and motor complete If there is any oil or grease on the housing complete or motor compl...

Page 56: ...cated by dark line Three Bond 1215B TIP Before applying the sealant thoroughly clean all the mating surface of stator cover and mo tor complete Within 5 min after applying the sealant join the left an...

Page 57: ...0 8 kgf m M8 12 mm P1 25 12 to 19 Nm 1 2 to 1 9 kgf m Lubricants areas to apply sealant and specified types Where to apply Types of oils grease and sealants All oil seal lips Lithium grease made from...

Page 58: ...re 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 Torque sensor positioner Apply the heat...

Page 59: ...ng Is the battery pack securely locked Check the battery pack lock Check if the battery pack is securely locked Inspect the battery pack ter minals and wiring for loose connection The cruising distanc...

Page 60: ...codes and corresponding power assist operations One of the assist mode lamps in the display unit 1 is flashing Speed sensor set See Chapter 2 How speed sensor malfunctions are displayed A state persis...

Page 61: ...ry pack for 10 seconds See Chapter 2 Recoverable errors of battery pack or battery charger See Chapter 2 List of battery pack battery charger diagnosis items Replace the parts according to List of bat...

Page 62: ...Yamaha X0S Series Service Manual MY2017 1st edition Published April 2016 Unauthorized reproduction prohibited Published by Yamaha Motor Co Ltd...

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