Yamaha X94 Series Service Manual Download

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SERVICE MANUAL

e-Bike SYSTEMS

X94 Series

Summary of Contents for X94 Series

Page 1: ...SERVICE MANUAL e Bike SYSTEMS X94 Series ...

Page 2: ...gs or items 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 hydrocar bon oil and synthetic ester oil MULTEMP AC N B New parts to be u...

Page 3: ... 2 For the illustrations and contents for disassembling the drive unit refer to the applicable pages according to the shape of the crank arm mount Mater Display 1 Battery Crank axle 2 Included crank parts Model type code Product code LED LCD Rear carrier Down tube Square type Spline type ISIS Sprocket Spacer Spider Nut lock X941 010 030 X942 010 X943 010 020 X944 010 020 X945 010 X946 010 020 ...

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Page 5: ...Index General Information GEN INFO 1 Electrical Components ELEC 2 Drive Unit Drive Unit 3 Service Data Service Data 4 ...

Page 6: ... 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 ba...

Page 7: ... 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...

Page 8: ...ke 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 depend ing on the model The actual Drive Unit may differ slightly from the picture shown a b c a b 1 2 4 3 5 È É Description 1 ...

Page 9: ...that 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 washing Keep away from fire Keep the workplace away from open fire Keep away from fire Proper tools When servicing the bicycle be sure to use the special tools intended for areas which require special...

Page 10: ...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 cleaning oil to clean Drive Unit parts after disassembly and blow parts clean with compressed air 4 Reassemble parts while checking any cor rections made to parts and referring to the data collected prio...

Page 11: ... 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 overheat ing 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 chargi...

Page 12: ...lel force to the inner race Oil Seal Installation 1 To install an oil seal direct the main lip towards the oil chamber the object of seal ing 2 Be sure to apply a thin even coat of grease to the sealing lip before installing the oil seal Main lip Oil Sub lip Spring Grease Circlip Installation 1 To install a circlip direct the chamfered side of the circlip inward 2 Install the circlip by aligning i...

Page 13: ...n apply 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 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 c...

Page 14: ...ntenance problems and mechanical breakage can be prevented by using the appropriate spe cialized tools Lithium soap based grease All purpose type grease with excellent water and heat resistance Three Bond No 1215 MULTEMP AC N Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil Digital circuit tester Device used for testing and measuring electrical components ...

Page 15: ...R Gy W G L Sb G B R Gy B R L Sb R SPEED SENSOR TO LIGHT DISPLAY UNIT LCD TYPE DISPLAY UNIT LED TYPE 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 MOTOR ASSEMBLY Encoder lead wire installation location Electrical component wiring diagram 2 ...

Page 16: ...attery capacity P 2 5 Error display 1 Depending on the model the battery capac ity indicator lamps are arranged horizontally or vertically as shown In the explanations in this manual the num bers 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 ...

Page 17: ...able errors of battery pack P 2 10 3 2 1 4 Off Fast flashing 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 func tion 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 3 2 1 4 Slow flashi...

Page 18: ...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 3 2 1 4 2 1 On Display of the total number of battery charging cycles Off On Slow flashing battery capacity indicator lamps on battery pack The...

Page 19: ...ttery 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 dur ing a malfunction and is not displayed in normal state The table below indicates the rel...

Page 20: ...1 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 lamp flashes indicating that it is charging Example of display on battery capacity display lamps on the battery pack while charging Fast flashing Off On Fast flashing Slow flashing ...

Page 21: ...f 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 charg ing In such case when checking the resid ual battery capacity not all of the four battery capacity indicator lamps on the bat tery pack may not turn on Cool down the battery pack for a while and c...

Page 22: ...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 batte...

Page 23: ...scharging 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 battery pack to the bicycle and ride it for a while 3 If the battery pack error occurs again perform the following Check the Drive Unit failure Replace the battery pack Charging over current during dis char...

Page 24: ...o the normal state after the battery pack is installed to the bicycle and the bicycle is ridden for a while Charging over current during charging Zero charg ing current 1 Disconnect the charging plug 2 Clean the charging connector and charging plug and dry them 3 Connect the charging plug to the charging connector 4 If the battery pack error occurs again replace the battery charger 3 2 1 4 3 2 1 4...

Page 25: ... 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 simulta neously 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 3 2 1 4 1 Off Fas...

Page 26: ...tion 1 and 4 flash rapidly Hold down the residual battery capacity indicator button for 10 sec onds FET failure Replace the battery pack AFE fault High tem perature exposure Battery pack failure FET temper ature fault Cells unbal anced Thermistor fault Over charg ing 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 ...

Page 27: ...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 lea...

Page 28: ...erature 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 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 charg ing 3 2 1 4 Slow f...

Page 29: ...ator 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...

Page 30: ...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 becomes the normal charging status the battery pack is normal All LED lamps goes out Replace the battery pack Over discharging of the battery pack 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 100 3 2 1 4 1...

Page 31: ...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 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 dis played on the function display 5 of the display unit When the functi...

Page 32: ...odes and corresponding power assist operations for more details Alternately flashes 5 2 3 4 6 1 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 usi...

Page 33: ... the lamps and segments will turn off and then the dis play 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 3 Press the assist mode ...

Page 34: ...it 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 diag nosis 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 swit...

Page 35: ...e 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 t...

Page 36: ... tion check Fast flashing List of Drive Unit Diagnosis Mode Display Methods Inspection items Diagnosis mode display Press operating button Diagnosis data display Press operating button 1 Torque sensor reference voltage Values are displayed from 0 0 to 5 0 V To 2 Motor current 2 Motor current Motor output current in HIGH mode is displayed as 00 to FL FULL output To 3 Error display 3 Error display T...

Page 37: ...ch 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 perform ing a torque sensor reference voltage adjust ment 1 Torque sensor reference voltage 1 2 2 Determining w...

Page 38: ...splayed good FL 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 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 i...

Page 39: ...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 perform ing repairs or replacing parts a 18 is displayed in the diagnosis mode dis play 1 of the display unit b Press the function select switch 2 of the display unit c All segments and all lamps of th...

Page 40: ...splayed when there are no errors 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 error codes are displayed on the display unit When there are no error codes When there is 1 error code When there are 2 error codes When there are 3 error codes Error code displays E1 along ...

Page 41: ...t decrease 2 and power assist increase 3 to switch 1 3 2 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 1 ...

Page 42: ...rence 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 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...

Page 43: ...ons are displayed The HIGH STD or ECO assist mode indi cator 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 dis play Average bicycle speed m...

Page 44: ...f 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 indica tors 2 have come on and then release the power switch 1 TIP Steps 1 and 2 must be performed within 30 seconds 3 Press the assist mode switch 3 or 4 to change the assist mo...

Page 45: ...s 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 rap idly 0 2 second For more information about the drive unit diag nosis 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 ...

Page 46: ... 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 senso...

Page 47: ... display unit func tion check Fast flashing List of Drive Unit Diagnosis Mode Display Methods Inspection items Diagno sismode display Press operating button Diagnosis data display Press operating button 1 Torque sensor reference voltage Values are displayed from 0 0 to 5 0 V To 2 Motor current 2 Motor current Motor output current in HIGH mode is displayed as 0 to 100 output To 3 Error display 3 Er...

Page 48: ...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 perform ing a torque sensor reference voltage adjust ment 1 Torque sensor reference voltage Determining whe...

Page 49: ...layed 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 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 i...

Page 50: ...rror 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 perform ing repairs or replacing parts 3 Error displays or a 18 is displayed in the diagnosis mode dis play 1 of the display unit b Press the function select switch s 2 of the display u...

Page 51: ...isplayed when there are no errors 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 error codes are displayed on the display unit When there are no error codes When there is 1 error code When there are 2 error codes When there are 3 error codes Error code displays E1 along...

Page 52: ...ode switch power assist decrease 2 and power assist increase 3 to switch 2 3 1 Fast flashing 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 ...

Page 53: ...om the holder Power assist will stop after determine the error Error code does not record 0 Replace the display unit assem bly Encoder 16 Disconnected or red wire is short circuited Power assist will immediately stop after determine the error Error code will record 1 1 Check the encoder connector 2 Replace the encoder lead wire 3 Replace the motor assembly 17 Black wire is short circuited Torque S...

Page 54: ...Wiring failure between the coil and the circuit board wire chattering nearly discon nected Replace the torque sensor assembly 28 Wiring failure between the coil and the circuit board wire chattering nearly discon nected 29 Abnormal no load voltage 1 Perform the torque sensor ref erence voltage adjustment 2 Replace the torque sensor assembly 30 Abnormal voltage detected during running with high con...

Page 55: ...he drive axle assem bly Motor 40 3 lead wires are disconnected Power assist will immediately stop after determine the error Error code will record 1 1 Replace the controller assem bly 2 Replace the motor assembly 41 Yellow lead wire is discon nected U phase Power assist will stop after determine the error Error code will record Replace the controller assembly 42 Blue lead wire is discon nected V p...

Page 56: ... 1 Replace the controller assem bly 2 Replace the motor assembly 54 Over current is applied to the V phase of the motor 55 Over current is applied to the W phase of the motor 56 Abnormal DC current Power assist will immediately stop after determine the error Error code will record 1 60 Not within the 12V output range Power assist will immediately stop after determine the error Error code will reco...

Page 57: ...t board temper ature is too high 125 C including DC circuit 82 Sensor on the board is nearly detached Others 89 Detected circuit board temper ature is too high 90 C Power assist is normal Error code will record 0 1 Check the environment of usage 2 Replace the controller assem bly Display pattern Fault device Error codes Fault details Power assist behavior and error code record Restoration Max Leve...

Page 58: ...e data from bat tery correctly Power assist will immediately stop after determine the error Also display unit will turn off Error code will record 1 Check the battery communica tion connector 2 Replace the plug DC 3 Replace the controller assem bly 4 Replace the battery Level 0 If the system detects this error the power assist mode will be down or turns to off But when the system is restored to no...

Page 59: ...gnet 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 a of the pickup e Check that the center location of the magnet sensor 1 is within specification f Check that the gap 2 between the pickup and the magnet sensor is within specifica tion Center locatio...

Page 60: ...f m T R 4 5 Nm 0 45 kgf m T R The actual lead wire may differ with the variety of Drive Unit from the pictures shown 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 Sprocket 1 3 Spacer 1 4 Spider 1 for spider type only 5 Button head bolt 3 6 Cover assembly 1 7 Stator cover 1 8 Flanged bolt 6 9 Hou...

Page 61: ... m T R 4 5 Nm 0 45 kgf m T R The actual lead wire may differ with the variety of Drive Unit from the pictures shown 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 dissipating sheet 1 18 Tapping screw 5 19 Wire lead 1 couplers 2 Disconnect 20 Wire lead 3 coupl...

Page 62: ...075 kgf m T R 4 5 Nm 0 45 kgf m T R The actual lead wire may differ with the variety of Drive Unit from the pictures shown 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 board or subject it to impact 24 Wire lead 2 1 25 Wire lead 1 1 26 Wire lead 3 1 27 Wire lead 4 ...

Page 63: ... 40 Nm 4 0 kgf m 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 The actual lead wire may differ with the variety of Drive Unit from the pictures shown 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 specifications of Drive Unit 33 Motor complete 1 Reverse the removal process for installation ...

Page 64: ... 0 kgf m T R 1 3 Nm 0 13 kgf m T R 0 75 Nm 0 075 kgf m T R 25 5 Nm 2 55 kgf m T R 4 5 Nm 0 45 kgf m T R The actual lead wire may differ with the variety of Drive Unit from the pictures shown Order Job Part Q ty Remarks Removal of the Drive axle Motor Follow the work procedures for removal Drive Unit assembly 1 Screw 2 2 Adapter 2 3 Lock nut 1 Left hand screw 4 Spider 1 5 Button head bolt 3 6 Cover...

Page 65: ... T R 4 5 Nm 0 45 kgf m T R 25 5 Nm 2 55 kgf m T R The actual lead wire may differ with the variety of Drive Unit from the pictures shown 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 dissipating sheet 1 18 Tapping screw 5 19 Wire lead 1 couplers 2 Disconnect...

Page 66: ...kgf m T R 4 5 Nm 0 45 kgf m T R 25 5 Nm 2 55 kgf m T R The actual lead wire may differ with the variety of Drive Unit from the pictures shown 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 board or subject it to impact 24 Wire lead 2 1 25 Wire lead 1 1 26 Wire lead ...

Page 67: ... Nm 4 0 kgf m T R 1 7 Nm 0 17 kgf m T R 0 75 Nm 0 075 kgf m T R 4 5 Nm 0 45 kgf m T R 25 5 Nm 2 55 kgf m T R The actual lead wire may differ with the variety of Drive Unit from the pictures shown 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 specifications of Drive Unit 33 Motor complete 1 Reverse the removal process f...

Page 68: ...ove the following parts Screw Adapter Locknut Left hand screw Spider Flanged bolt 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 sur faces of the housing complete and the motor complete with screwdrivers or other tools Take care...

Page 69: ...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 2 4 3 1 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 1...

Page 70: ...assembly 2 Holder 3 Tapping screw 4 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 2 4 3 1 T R 0 75 Nm 0 075 kgf m 1 3 5 b a 2 4 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...

Page 71: ...n 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 1 New 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 pro jections a of the gear cover...

Page 72: ...ne TIP 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 complete mating sur faces wipe the surfaces clean and then apply sealant Within 5 min after applying the sealant join the left and right halves together Three Bond 1215 sealant 1 2 Install the following part Housing co...

Page 73: ...ng surface of stator cover and motor complete Within 5 min after applying the sealant join the left and right halves together Three Bond 1215 sealant 1 2 Install the following part Damper rubber 1 Stator cover 2 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...

Page 74: ...M8 12 mm P1 25 12 to 19 Nm 1 2 to 1 9 kgf m Where to apply Types of oils grease and sealants All oil seal lips Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil MULTEMP AC N Pawl kicks Lithium grease made from synthetic hydrocarbon oil and synthetic ester oil MULTEMP AC N Drive axle O rings Lithium soap based grease Interior of torque sensor bushing Lithium grease made fro...

Page 75: ...rs 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 dissipat ing sheet should not be stretched beyond 10 of its original dimen sions Ê Route the encoder lead wires through the outer side of holder projections as shown in the draw ing The actual lead wire may differ with the variety...

Page 76: ...k if the battery pack is securely locked Inspect the battery pack ter minals and wiring for loose connection The cruising distance is short Has the battery pack been sufficiently charged Charge until full Is it being used in a low tem perature environment Check the ambient tempera ture This will be restored when the ambient temperature warms up Is the battery pack degrad ing Check the battery pack...

Page 77: ...f error codes and corre sponding power assist opera tions All segments of the assist mode display and battery capacity indicator are flash ing alternately and Er is displaying on the speedome ter section of the LCD type display unit One of the assist mode lamps in the display unit 1 is flashing Speed sensor set See Chapter 2 How speed sensor malfunctions are dis played A state persists where the s...

Page 78: ...mediately after driving or when the battery pack tem perature was high Recharge the battery in a location where the tempera ture is suitable for charging 0 to 45 C All four residual residual bat tery capacity display lamp on the battery pack are slow flashing simultaneously while charging the battery pack This is not a malfunction On standby for charging The charging will start once the internal t...

Page 79: ...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 Clean the charging connector and charging plug and dry them Abnormal sound is produced from the Drive Unit assembly Assist driving Abnormal sound is produced during assist drivin...

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Page 81: ...Yamaha X94 Series Service Manual 7th edition Published October 2014 Unauthorized reproduction prohibited Published by Yamaha Motor Co Ltd ...

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