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3-9

Drive axle, Motor

Drive

Unit

Installation of the Bearing Housing

1. Apply Three Bond 1215B



to the following

parts:

• Housing complete

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

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 complete mating sur faces,
wipe the surfaces clean and then apply seal-
ant.

• Within 5 min. after applying the sealant, join

the left and right halves together.

sealant

2. Install the following part:

• Housing complete

4.5 Nm (0.45 kgf·m)

Содержание X0S Series

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 63: ......

Страница 64: ...EN...

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