Yamaha X0S Series User manual

SERVICE MANUAL
e-Bike SYSTEMS
X0S Series
MY2017

How to UseThis 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.
3. The table of contents is provided at the
beginning of the manual. Review the overall
makeup of the manual and search for the
chapters and sections you need.
1
2
3
4
Symbols
Important items in this manual are indicated by the following symbols:
The symbols indicate precautions pertaining to safety.
WARNING
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 of inspection
and maintenance.
Symbols indicate the following meanings or items:
1 2
3 4
5 6 7
T
R
.
.
8 9 0
A B C
1General information section
2Electrical Components section
3Drive Unit section
4Service data section
5Special tools
6Types of grease
7Tightening torque
8Standard values or limits of use
9Standard values for resistance (Ω), voltage (V),
current (A)
0Lithium-soap-based grease
ALithium grease made from synthetic hydrocarbon
oil and synthetic ester oil (MULTEMP AC-N)
BNew parts to be used when replacing
CApply locking agent (LOCTITE).
GEN
INFO ELEC
–+
Drive
Unit
Unit
Service
Data
LS
LT

Index
General Information GEN
INFO 1
Electrical Components
–+
ELEC
ELEC 2
Drive Unit Drive
Unit 3
Service Data
SPEC
Service
Data 4

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
Precautions relating to maintenance (3) .....................................................P1-6
Handling of the torque sensor ................................................................P1-6
Specialized tools and equipment ................................................................P1-7
CHAPTER 2 Electrical Components
Electrical 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 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 battery pack................................................P2-11
Temperature protection function ..........................................................P2-14
Over-discharge protection function......................................................P2-15
Diagnosis function .....................................................................................P2-17
Display unit’s display when there is an error.........................................P2-17
Operating Procedures to Diagnosis Mode ...........................................P2-19
Diagnosis function ...............................................................................P2-28
Speed sensor set ........................................................................................P2-34
Speed sensor inspection .....................................................................P2-34

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

1-1
Description
GEN
INFO
1. Drive Unit
2. Speed sensor set
a) Magnet sensor spoke type
b) Pick up
3. Display Unit
a) Display (detachable)
b) Display holder
c) Switch
4. Battery charger
5. Battery pack (The battery may differ
depending on the model.)
ÈRear carrier 400Wh
ÉRear carrier 500Wh
1
General Information
Description
12
4
3
5
a
b
c
a
bÈ
É
* The actual Drive Unit may differ slightly from the picture shown.

1-2
Precautions relating to maintenance (1)
GEN
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. Steam cleaning is particularly
to be avoided.
1. Remove any mud or dust from the frame and
Drive Unit to make sure 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 tools in order to prevent damage to
parts. Also, work appropriate work should be
done using appropriate tools and measuring
devices. (Avoid using spanner wrenches. Use
offset or box wrenches instead.)
1

1-3
Precautions relating to maintenance (1)
GEN
INFO
Replacement parts
Replace gaskets (packing), O-rings, cotter pins,
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
these parts may appear to be the same, they
may not be genuine parts, or there is the risk
that their quality has changed due to previous
use.
Genuine
parts
Precautions for disassembly and
reassembly
1. Inspect 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 prior to disassembly.
5. While reassembling parts make sure that
each part is clean and free of foreign mate-
rial.
6. Perform reassembly while checking the
actions to be performed for each section.
7. Apply oil to sliding parts.
8. Tighten all nuts and bolts to their specified
torque.
9. Maintain good communications when the
work is done by 2 service personnel.

1-4
Precautions relating to maintenance (1)
GEN
INFO
Handling the Battery Pack
1. Use the dedicated battery charger for
charging the battery pack.
2. The battery pack is a dedicated e-bike sys-
tem battery. If it is connected to a product
other than the e-bike system, it will cause a
fluid leakage, “overheating, or breakage.”
3. Be sure to charge the e-bike system before
operating it for the first time or after it has
been 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 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
charging. If charging is continued, it can
cause a fluid leakage, overheating, or break-
age.
7. The battery pack should be sorted for envi-
ronmental-friendly recycling. Do not dispose
of the battery pack as household waste.

1-5
Servicing Precautions (2)
GEN
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. When striking a bearing onto an axle, apply a
parallel 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 sealing).
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 its opening with
the center of the spline.
3. Do not expand the circlip more than neces-
sary.
Gear
Circlip
Chamfer
Circlip
Axle

1-6
Precautions relating to maintenance (3)
GEN
INFO
Precautions relating to maintenance (3)
Handling of the torque sensor
1. Keep away from magnets.
Do not use magnetized screwdrivers or per-
form maintenance near large sources of
electric power.
2. Avoid strong mechanical impact.
Torque sensors which have been dropped or
which have been removed through the use
of a hammer or the like cannot be used be-
cause the torque sensor reference voltage
can change significantly due to variations in
the internal magnetic circuits.
3. Do not crush or press in the axial direction.
Any deformation of the torque sensor case
by crushing can result in changes in the
torque sensor reference voltage. Torque
sensor reference voltage changes can also
be caused by the application of a force of
over 2 kgf on the sensor shaft while the case
is clamped in place.
The installation of a one-way clutch having a
tightly-fitted spline can apply excessive force
to the sensor shaft and result in voltage
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 can reduce
the strength of the parts. Do not perform ser-
vicing on the sensor in wet locations.
6. Organic solvents
Do not apply gasoline or solvent-based lubri-
cants (consumer spray-type lubricants) to
the sensor shaft or the circuit board. It can
reduce the unit’s ability to prevent short-cir-
cuits.
7. Do not reuse damaged drive axles.
The sensor shaft and the drive axle slide in a
metal bearing. It will be difficult to install the
one-way clutch and the sensor shaft if there
are scratches on the surface of the drive
axle.
8. Do not disassemble the torque sensor.
Do not disassemble the interior of the sensor
because the torque sensor cannot be read-
justed.Torque sensors that have been disas-
sembled cannot be used.

1-7
Specialized tools and equipment
GEN
INFO
Lithium soap based grease
All-purpose type grease with excellent water and
heat resistance
Three Bond 1215B
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
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.

2-1
Electrical component wiring diagram ELEC
–+
Electrical Components
Electrical component wiring diagram
TO BATTERY WIRE LEAD 2
B
Or
P
W
R
Gy
Br
L
B
Y B
R
Gy
W
G
L
Sb
G
B
RGy
B
R
L
Sb
R
SPEED SENSOR
TO LIGHT
DISPLAY UNIT
WIRE LEAD 1
WIRE LEAD 3 WIRE LEAD 5 WIRE LEAD 4
Y
YLWRB
W
L
TO MOTOR ENCODER
CONTROLLER
ASSEMBLY
TORQUE SENSOR
ASSEMBLY
MOTOR ASSEMBLY
Encoder lead wire installation location
2
B = Black Br = Brown G = Green Gy = Gray L = Blue Or = Orange P = Pink R = Red Sb = Sky blue W = White Y = Yellow

2-2
Battery pack ELEC
–+
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
pushed
Display item Display time Details Page
When pushed
Normal state:
Residual battery
capacity
5 seconds See the owner’s
manual. –
Error detected:
Error display 5 seconds See “Error display”. P. 2-2
20 seconds Total number of
battery charging cycle 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 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 operation of the lamps is the
same for both types of battery capacity indi-
cators.
3
2
1
4
43214321
2

2-3
Battery pack ELEC
–+
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”. (P. 2-8)
or
3
2
1
4
3
2
1
4
3
2
1
4
3
2
1
4
Off On
3. If the battery capacity indicator lamps [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
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 connect
the battery charger, see “Display on battery
capacity indicator lamps while charging”.
(P. 2-7)
3
2
1
4
Slow flashing

2-4
Battery pack ELEC
–+
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 “ ” 1for 20 seconds.
2. The total number of battery charging cycles
is indicated by the four battery capacity indi-
cator lamps 2on the battery pack.
TIP
While holding down the battery capacity indi-
cator button “ ” for 20 seconds, the lamps will
display the currently applicable condition (resid-
ual battery capacity, * error diagnosis), for 5
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
42
1
On
Display of the total number of battery charging cycles
battery capacity indicator
lamps on battery pack
The total number of
battery charging cycles
battery capacity indicator
lamps on battery pack
The total number of
battery charging cycles
3
2
1
4
0 to 100 times
3
2
1
4
401 to 500 times
3
2
1
4
101 to 200 times
3
2
1
4
501 to 600 times
3
2
1
4
201 to 300 times
3
2
1
4
601 to 700 times
3
2
1
4
301 to 400 times
3
2
1
4
701 times or
more
Off On Slow flashing

2-5
Battery pack ELEC
–+
How to check the full charge capacity
Check the *1full charge capacity as follows:
1. Hold down the battery capacity indicator but-
ton “ ” 1for 30 seconds.
2. The *1full charge capacity is indicated by the
four battery capacity indicator lamps 2on
the battery pack.
TIP
While holding down the battery capacity indi-
cator button “ ” for 30 seconds, the lamps will
display the currently applicable conditions (re-
sidual battery capacity, *2error diagnosis, Total
number of battery charging cycles), for 5 sec-
onds for each condition.
*1Full charge 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 store. The capacity at the time of ship-
ment is considered 100%.
*2
The error diagnosis are displayed only during
a malfunction, and is not displayed in normal
state.
The table below indicates the relationship
between the full charge capacity and the battery
capacity indicator lamps.
3
2
1
42
1
On
Display of the full charge capacity
Battery capacity indicator
lamps on battery pack
Full charge
capacity (%)
Battery capacity indicator
lamps on battery pack
Full charge
capacity (%)
3
2
1
4
0 to 24%
3
2
1
4
50 to 74%
3
2
1
4
25 to 49%
3
2
1
4
75 to 100%
Off On

2-6
Charging ELEC
–+
Charging
e-Bike system dedicated battery charger
This battery charger 1is a dedicated battery
charger for the e-Bike system’s battery pack.
1
3
2
1
4
3
2
1
4
3
2
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

2-7
Charging ELEC
–+
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].
When the battery pack’s internal tempera-
ture goes out of operating range, the battery
pack changes to the “Charging on stand-by”
state automatically.
TIP
• Once the temperature inside the battery
pack becomes suitable for charging, the
charging starts automatically.
(In such case, the charging time becomes
longer by the time during which all four bat-
tery capacity indicator lamps on the battery
pack were flashing simultaneously.)
As much as possible, charge at an optimal
room temperature, approximately 15 to 25°C.
• Even if 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 charging.
In such case, when checking the residual
battery capacity, not all of the four battery
capacity indicator lamps on the battery pack
may not turn on. Cool down the battery pack
for a while, and charge again, preferably in a
cool place.
• Even if the room temperature is within the 0
to 45°C range, if attempting to charge the
battery pack immediately after driving, or if
the battery pack had been left in the sun
during summer, the battery pack’s internal
temperature may be outside the allowable
temperature range for charging. If the room
temperature is 30°C, it may take approxi-
mately 4 hours until the battery pack’s inter-
nal temperature is within the allowable tem-
perature range for charging.
2. During pre-charging
Display on the battery capacity indicator
lamps on the battery pack: [Battery capacity
indicator lamps [1] flash rapidly].
3
2
1
4
Slow flashing
3
2
1
4
Off Fast flashing

2-8
Diagnosis mode ELEC
–+
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
access the error diagnosis mode and confirm
the details regarding the error of the battery
pack or battery charger.
1. If there is an error when the battery capacity
indicator button “ ” 1on the battery pack is
pushed or connect the battery charger, 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 battery capacity indicator lamps
turn on alternately, the residual battery
capacity is not displayed.
2. Hold down the battery capacity indicator but-
ton “ ” 1for 10 seconds.
3. The lighting display of the battery capacity
indicator lamps indicates the error of the bat-
tery pack or battery charger.
TIP
• If the battery pack or battery charger is oper-
ating normally, the battery capacity indicator
lamps indicate the residual battery capacity.
• If there are multiple errors, only the latest er-
ror will be displayed.
• The error diagnosis mode can be accessed
whether the battery charger is connected or
disconnected.
or
Turn on
alternately
Turn on
alternately
3
2
1
4
3
2
1
4
3
2
1
4
3
2
1
4
1
Off On