Yamaha YDX-MORO 07 User manual

2022
ASSEMBLY MANUAL
YDX-MORO 07
YDX-MORO 05
PE65M7L
PE65M7M
PE65M7S
PE65M5L
PE65M5M
PE65M5S
LIT-15666-00-15 X2U-28107-12

79
FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha bicycle prior
to delivery to the customer. Since some external parts of the bicycle have been removed at the Yamaha fac-
tory for the convenience of packing, assembly by the Yamaha dealer is required. No adjustment of the power
unit mechanism, which plays the most important part in riding, is necessary because it has been adjusted at
the factory before shipping. It should be noted that the assembled bicycle should be thoroughly cleaned,
checked, and adjusted prior to delivery to the customer.
IMPORTANT
The service specifications given in this assembly manual are based on the model as manufactured. Yamaha
Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes
in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future
editions of this manual where applicable.
The procedures below are described in the order that the procedures are carried out correctly and completely.
Failure to do so can result in poor performance and possible harm to the bicycle and/or rider.
Particularly important information is distinguished in this manual by the following notations.
Follow the instructions in the Dealer Warranty Handbook, Procedure Section.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid pos-
sible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
the bicycle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
PE65M7L/PE65M7M/PE65M7S
PE65M5L/PE65M5M/PE65M5S
ASSEMBLY MANUAL
©2022 by Yamaha Motor Corporation, U.S.A.
First edition, May 2022
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-15666-00-15

PARTS LOCATION
– 1 –
79
Body assembly
PARTS LOCATION
1. Part box 1
2. Front wheel
8Do not use a cutter, scissors, or other sharp object to open the part boxes; otherwise, the included
parts could be damaged.
8Wear suitable protective gear such as gloves when handling and opening the part boxes.
NOTICE
1
2

INCLUDED PARTS
– 2 –
79
INCLUDED PARTS
The parts listed as follows are included*. Check the parts and their quantities before starting assembly.
Part box 1 details
Part box 2 details
Part box 3 details
* The form of the package is subject to change without notice.
No. Part names Q’ty Remarks
1Front wheel 1
2Part box 1 1
3Part box 2 1 2in part box 1
4Part box 3 1 2in part box 1
5Saddle 1
6Front axle 1 YDX-MORO 07 only
7Front axle 1 YDX-MORO 05 only
8Pedals 2 1 each for left and right
9Bell 1
0Front reflector 1
qRear reflector 1
wOwner’s manual 1
eBattery charger 1

INCLUDED PARTS
– 3 –
79
1
2
3
4
w
90
q
5
67
8
e

INSTALLING THE INCLUDED PARTS
– 4 –
79
INSTALLING THE INCLUDED
PARTS
TIP
8Charge the battery pack following the instruc-
tions in the owner’s manual before starting
installation.
8The letters inside the parts list boxes in the
assembly procedures indicate the following:
A: Part in part box 1
B: Part in part box 2
1. Installing the front wheel and fork end
Remove the spacers bfrom the front disc cali-
per a.
Give the removed spacers bto the customer,
explaining how it is used.
(For YDX-MORO 07)
Align the holes in the front wheel 1with the
holes in the fork end and install the front wheel
1.
Install it in such a way that the disc rotor cdoes
not touch the disc pad.
Install the front axle 2to the fork end holes
from the right side of the bicycle.
Tighten the bolts and nuts to the specified
torques. Failure to tighten the bolts and nuts to
the specified torques could prevent proper
operation of the bicycle and make it unsafe to
operate.
WARNING
a
b
a
c
1
2
1Front wheel 1
2Front axle 1 B

INSTALLING THE INCLUDED PARTS
– 5 –
79
Tighten the front axle 2to the specified torque.
(For YDX-MORO 05)
Align the holes in the front wheel 1with the
holes in the fork end and install the front wheel
1.
Install it in such a way that the disc rotor cdoes
not touch the disc pad.
Install the front axle 2to the fork end holes
from the right side of the bicycle.
Move the lever dof the front axle 2to “OPEN”
facing the notch e.
With the lever dcaught in the notch e, turn
and tighten until there is a little resistance in the
lever.
2
Tightening torque 11 N·m (1.1 kgf·m, 8.1 lb·ft)
Tighten the front axle 2to the specified torque
and install it securely. Otherwise, the front
wheel could come off.
WARNING
a
c
1
2
1Front wheel 1
2Front axle 1 B
e
d
d

INSTALLING THE INCLUDED PARTS
– 6 –
79
Free the lever d.
Determine the position to secure the lever d
and fasten it at “CLOSE”.
TIP
If the lever dof the front axle 2is too hard and
cannot be lowered, or if it is too loose and cannot
be lowered for it to be locked, turn the lever d
again to loosen or tighten it, adjusting so that it can
be fastened securely.
2. Installing the handlebar stem
Position the handlebar stem ain a straight line
with the front wheel.
Tighten the bolts band c, in that order, to the
specified torques.
d
8Position the lever when it cannot touch
obstacles while the bicycle is moving. If not,
the lever could be unlocked unexpectedly,
causing the front wheel to come off, result-
ing in an accident with severe injury or
death.
8Fasten the lever dat position where the tip
does not touch other parts when the lever
dis lowered.
8Fasten the lever dfacing backward from
the direction of travel in such a way that it
cannot easily touch obstacles that might be
encountered while riding.
WARNING
ba
c
Tightening torque 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Tightening torque 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

INSTALLING THE INCLUDED PARTS
– 7 –
79
3. Installing the handlebar
Install the handlebar aso that the 3rd horizon-
tal line from the top of the alignment mark b
shown is positioned at the lower end of the hole
in the upper handlebar holder c, and then
tighten the 4 bolts dof the handlebar holder c
to the specified torque.
TIP
8Tighten bolts devenly in stages, in the order
shown in the illustration.
8Tighten in such a way that the gaps eabove
and below the handlebar holder care equal.
Install the handlebar aso that the brake lever
fis at a 30angle to the handlebar, as shown
in the illustration.
4. Adjusting the display unit position
Maintain a clearance of 1 to 2 mm between the
bracket of the display unit aand the handlebar
stem bas shown, install the set, and then
tighten the bolt cto the specified torque.
TIP
Adjust the display unit screen so that it is parallel to
the handlebar stem b.
a
c
d
d
b
Tightening torque 6 N·m (0.6 kgf·m, 4.4 lb·ft)
The handlebar ashould not touch the frame
when it is turned fully to the left or right.
NOTICE
d
ce
e
30°
a
f
Tightening torque 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
1〜2mm
b
a
c
Tightening torque 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
(0.04–0.08 in)

INSTALLING THE INCLUDED PARTS
– 8 –
79
5. Installing the front reflector
Install the front reflector 1, stay 2, and screw
3as shown, and then tighten them together to
the specified torque.
TIP
Install the front reflector 1while adjusting it so that
it faces to the front and making sure that the wires,
etc. do not contact the front reflector.
6. Installing the bell
Install the bell 1in the shown, then tighten it
with the screw 2.
7. Routing the wires
Confirm that hoses and wires are routed in
order starting from front to back
Front brake hose 1
Rear brake hose 2
Dropper seat wire 3
Shift wire 4
Display unit lead 5
Switch unit lead 6
Clamp the front brake hose 1and rear brake
hose 2with the wire clip 7at the position
shown in the illustration.
Clamp the front brake hose 1and dropper seat
wire 3with the wire clip 8at the position
shown in the illustration.
Clamp the dropper seat wire 3and shift wire 4
with the wire clip 9at the position shown in the
illustration.
Clamp the switch unit lead 6at the position
shown with the wire clip 0.
1
2
3
Tightening torque 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
1Front reflector 1 B
2Stay 1 B
3Screw 1 B
1
2
Tightening torque 0.8 N·m (0.08 kgf·m, 0.59 lb·ft)
1Bell 1 B
2Screw 1 B
1
2
3
4
5
6
7
8
9
q
0
Be sure to route the wires as shown in the illus-
tration. If not, they could interfere with handle-
bar operation which could cause loss of
control.
WARNING

INSTALLING THE INCLUDED PARTS
– 9 –
79
Secure the front brake hose 1with the wire
clamp qat the position shown in the illustra-
tion.
Clamp the dropper seat wire 3and display unit
lead 5with the plastic locking ties wat the
position shown in the illustration.
Make sure that the front brake hose 1, rear
brake hose 2, and shift wire 4are routed as
shown.
120 mm
(4.72 in)
3
w
5
1
2
4

INSTALLING THE INCLUDED PARTS
– 10 –
79
Check that the rear brake hose 2, shift wire 4,
and speed sensor lead eare routed as shown
in the illustration.
8. Installing the saddle
Pinch the rail of the saddle 1with the saddle
clamps aand b, and then tighten the seat
post c, bolts d, and nuts eto the specified
torque.
Adjust the seat post cheight, and then tighten
the seat pin fto the specified torque.
TIP
8Face the mark “▲” gof the saddle clamp a
toward the front, and then install the saddle.
8Be careful that the dropper seat wire is not too
tensioned or too slack when installing the seat
post cor adjusting its height.
8Do not overtighten the seat pin f. Otherwise, it
could cause the dropper seat not to operate
smoothly.
4e
2
Tightening torque 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
Tightening torque 9 N·m (0.9 kgf·m, 6.6 lb·ft)
a
b
c
d
e
1
d
gf
1Saddle 1 A

INSTALLING THE INCLUDED PARTS
– 11 –
79
9. Installing the rear reflector
Install the rear reflector 1, band 2, screw 3,
and nut 4as shown, and then tighten them
together to the specified torque.
Secure them to the frame with the band 2.
TIP
8Adjust the rear reflector 1so that it is facing
straight backward, then tighten it.
8When assembling the rear reflector 1to the
frame, adjust the length by cutting the adjust-
ment pad inside the band to fit the frame.
10. Installing the pedals
Install the pedals 1to the crank a, then tighten
to the specified torque.
TIP
8Right-hand screw (marked R) for right pedal
8Left-hand screw (marked L) for left pedal
12
3
4
Tightening torque 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
1
1Rear reflector 1 B
2Band 1 B
3Screw 1 B
4Nut 1 B
1
a
L R
Tightening torque 40 N·m (4.0 kgf·m, 30 lb·ft)
1Pedals (left and right) 1
each B

INSTALLING THE INCLUDED PARTS
– 12 –
79
11. Checking the operation of the speed sensor
A. Press the power button ato turn on the power.
B. After turning on the power, hold the power but-
ton adown for approximately 10 seconds
within 30 seconds. Make sure that the assist
mode indicator bis switched to the magenta
display, and then release the power button a.
C. Change the white flashing indicator position of
the battery capacity indicator eusing the assist
mode switch (up) cor assist mode switch
(down) d.
When changed to the status fshown, push the
select button gto confirm.
D. When the mode enters the speed sensor confir-
mation mode, both the assist mode indicator b
and the battery capacity indicator ewill be dis-
played as shown h.
E. When the rear wheel is lifted and it is rotated,
the white lighting indicator of the battery capac-
ity indicator ewill move from the right to the left
one time per turn.
Check that both the moving timing of the white
lighting indicator and the rotating position of the
rear wheel remain constant.
F. After checking the operation, press the power
button ato quit.
TIP
8Rotate the rear wheel 3 turns at least, and then
make sure that the indicator of the battery
capacity indicator emoves 3 times.
8When the indicator of the battery capacity indi-
cator ereaches to the left end, it will return to
the right end.
a
b
c
g
d
e
MMM
WWW
W
M
W
M
W
・・・ Magenta
・・・ White
・・・ Flashing White
b
e
f
MMM
W
M
M
M
W
b
e
h
・・・ Magenta
・・・ White
・・・ Flashing magenta
・・・ No light

INSTALLING THE INCLUDED PARTS
– 13 –
79
12. Adjusting the opening of the front and rear
brake levers
Before adjusting the opening of the brake
levers, grip the brake levers approximately 10
times to pump them.
Turn the adjusting screw 1to adjust the open-
ing of the tip of the brake lever afrom the tip of
the grip.
TIP
Adjust to a position at which it is easy for the cus-
tomer to operate the front and rear brake levers and
within the range of play of the brake levers.
a
b
c1bdirection Opening gets larger.
cdirection Opening gets smaller.
After adjusting the brake lever opening, check
that the rotation of the front and rear wheels is
not heavy.
NOTICE

PREDELIVERY INSPECTION
– 14 –
79
PREDELIVERY INSPECTION
8Handlebar orientation, height, angle, and tightening
Installing the head cap to the handlebar post: 2.5 N·m (0.25 kgf·m, 1.8lb·ft)
Installing the handlebar bracket to the handlebar post: 8N·m (0.8kgf·m, 5.9 lb·ft)
Installing the handlebar to the handlebar holder: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
8Saddle orientation, height, angle, and tightening
Installing the saddle: 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Tightening the seat pin: 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
* Check that the saddle is firmly fastened.
8Operation of the dropper seat
* Adjust the operation using the wire adjusting screw of the dropper seat lever.
8Various fittings adjusted to the customer’s riding posture
* Including brake lever angle, fork suspension air pressure, etc.
Installing the brake lever: 3.8N·m (0.38kgf·m, 2.8lb·ft)
8Inspection of the wheels, hubs, and spokes
Tightening the front axle: 11 N·m (1.1 kgf·m, 8.1 lb·ft)
8Tightening of the pedals: 40 N·m (4.0 kgf·m, 30 lb·ft)
8Tightening of the screws of each part
Installing the display unit: 3.8N·m (0.38kgf·m, 2.8lb·ft)
Installing the front reflector: 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
Installing the bell: 0.8N·m (0.08kgf·m, 0.59 lb·ft)
Installing the rear reflector: 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
8Brake performance
8Shift changing operation
8Looseness of the chain
8Bell sound
8Battery pack locking operation
* Check that the battery pack locks securely.
8Check of battery pack and battery charger operation
8Operation of the meter, switches, and drive unit
8Installation state of the reflectors
8Maximum tire air pressure
YDX-MORO 07 (PE65M7)
Front tire: 280 kPa (2.8kgf/cm2, 40.6 psi)
Rear tire: 280 kPa (2.8kgf/cm2, 40.6 psi)
YDX-MORO 05 (PE65M5)
Front tire: 280 kPa (2.8kgf/cm2, 40.6 psi)
Rear tire: 280 kPa (2.8kgf/cm2, 40.6 psi)
After completing the installation, inspect the items as follows and check that there are no problems
before delivering the bicycle. Adjust controls and saddle height to the customer’s satisfaction
according to this manual.
WARNING