Yamaha X94 Series User manual

SERVICE MANUAL
e-Bike SYSTEMS
X94 Series

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.
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:
Symbols indicate the following meanings or items:
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 hydrocar-
bon oil and synthetic ester oil (MULTEMP AC-
N®)
BNew parts to be used when replacing
The symbols indicate precautions pertaining to safety.
Indicates that incorrect use could result in death or serious injury.
Indicates that incorrect use could cause property damage.
Indicates methods are correct operation or main elements of inspection
and maintenance.
WARNING
NOTICE
TIP
12
34
567
89
0AB
GEN
INFO
ELEC
–+
Unit
Drive
Service
Data
T
R
.
.
LS

List of part types and included crank parts according to the model type code and product code *1: In the diagnosis section, refer to the applicable pages according to the type of meter display unit. *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 √√√ √√

Index
General Information GEN
INFO 1
Electrical Components ELEC 2
Drive Unit Drive
Unit 3
Service Data 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 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 battery pack .............................................. P2-11
Temperature protection function......................................................... P2-14
Over-discharge protection function..................................................... P2-15
Diagnosis function (LED type display unit)............................................. P2-17
Display unit’s display when there is an error ...................................... P2-17
Operating Procedures to Diagnosis Mode.......................................... P2-19
Diagnosis function (LCD type display unit) ............................................ P2-28
Display unit’s display when there is an error ...................................... P2-28
Operating Procedures to Diagnosis Mode.......................................... P2-30

Diagnosis function .............................................................................. P2-39
Speed sensor set ....................................................................................... P2-45
Speed sensor inspection .................................................................... P2-45
CHAPTER 3 Drive Unit
Drive axle, Motor (drive axle with square-type end) ................................. P3-1
Drive axle, Motor (drive axle with spline-type end [ISIS adapter]) .......... P3-5
Removal of the parts from the drive axle
(drive axle with square-type end).......................................................... P3-9
Removal of the parts from the drive 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 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
GEN
INFO
General Information
Description
1. Drive Unit
2. Speed sensor set
a) Magnet sensor spoke type
b) Pick up
3. ÈDisplay Unit (LED type)
ÉDisplay 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
12
43
5
ÈÉ
Description
1

1-2
GEN
INFO
Precautions relating to maintenance (1)
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
GEN
INFO
Precautions relating to maintenance (1)
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,
including 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
GEN
INFO
Precautions relating to maintenance (1)
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
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
charging. If charging is continued, it can
cause a fluid leakage, overheating, or
breakage.
7. The battery pack should be sorted for envi-
ronmental-friendly recycling. Do not dis-
pose of the battery pack as household
waste.

1-5
GEN
INFO
Servicing Precautions (2)
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
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 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
GEN
INFO
Precautions relating to maintenance (3)
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
because the torque sensor reference volt-
age can change significantly due to varia-
tions 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 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 can
reduce the strength of the parts. Do not per-
form servicing on the sensor in wet loca-
tions.
6. Organic solvents
Do not apply gasoline or solvent-based
lubricants (consumer spray-type lubricants)
to the sensor shaft or the circuit board. It
can reduce the unit’s ability to prevent
short-circuits.
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 sen-
sor because the torque sensor cannot be
readjusted. Torque sensors that have been
disassembled cannot be used.

1-7
GEN
INFO
Specialized tools and equipment
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
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

2-1
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 (LCD TYPE)
DISPLAY UNIT (LED TYPE)
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
Electrical component wiring diagram
2

2-2
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
pushed
Display item Display time Details Page
When pushed
Normal state:
Residual battery
capacity
5 seconds See the owner’s man-
ual. –
Error detected:
Error display 5 seconds See “Error display”. P. 2-2
20 seconds Total number of bat-
tery charging cycle 5 seconds
See “How to check
the total number of
battery charging
cycle”.
P. 2-4
30 seconds Absolute battery
capacity 5 seconds
See “How to check
the absolute battery
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.
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 battery capacity indicator button “ ” is
pushed or connect the battery charger, see
“Recoverable errors of battery pack or bat-
tery charger”.
(P. 2-8)
4321
3
2
1
4
or
3
2
1
4
3
2
1
4
3
2
1
4
3
2
1
4
Off On
2

2-3
ELEC
–+
Battery pack
3. If the battery capacity indicator lamps [1]
and [4] are fast flash simultaneously when
the battery capacity indicator button “ ” is
pushed or connect the battery charger, see
“Non-recoverable 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 flashing

2-4
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
button “ ” 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
(residual battery capacity, * error diagnosis),
for five 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
Off On Slow flashing
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
0 to 100 times 401 to 500 times
101 to 200 times 501 to 600 times
201 to 300 times 601 to 700 times
301 to 400 times 701 times or
more
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

2-5
ELEC
–+
Battery pack
How to check the absolute battery capacity
Check the *1absolute battery capacity as fol-
lows:
1. Hold down the battery capacity indicator
button “ ” 1for 30 seconds.
2. The *1absolute battery 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
(residual battery capacity, *2error diagnosis,
Total number of battery charging cycles), for
five seconds for each condition.
*1Absolute battery 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%.
*2The error diagnosis are displayed only dur-
ing a malfunction, and is not displayed in
normal state.
The table below indicates the relationship
between the absolute battery capacity and the
battery capacity indicator lamps.
3
2
1
42
1
On
Display of the absolute battery capacity
Off On
battery capacity indicator
lamps on battery pack
Absolute battery
capacity (%)
battery capacity indicator
lamps on battery pack
Absolute battery
capacity (%)
0 to 24% 50 to 74%
25 to 49% 75 to 100%
3
2
1
4
3
2
1
4
3
2
1
4
3
2
1
4

2-6
ELEC
–+
Charging
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