Yamaha YDX-MORO Pro User manual

2020
ASSEMBLY MANUAL
YDX-MORO Pro
YDX-MORO
PB65MPL
PB65MPM
PB65MPS
PB65ML
PB65MM
PB65MS
LIT-15666-00-11 X1V-28107-10
X1V-28107-10.book 1 ページ ２０２０年８月３日 月曜日 午後４時１１分

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
PB65MPL/PB65MPM/PB65MPS
PB65ML/PB65MM/PB65MS
ASSEMBLY MANUAL
©2020 by Yamaha Motor Corporation, U.S.A.
First edition, July 2020
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-15666-00-11
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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
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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
4Part box 3 1
5Front axle 1 YDX-MORO Pro only
6Front axle 1 YDX-MORO only
7Saddle 1
8Pedals 2 1 each for left and right
9Bell 1
0Front reflector 1
qRear reflector 1
wBattery end cap 1
eButton cell battery 1 rin owner’s manual pouch
Standard CR2032
rOwner’s manual 1
tBattery pack 1
yBattery charger 1
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INCLUDED PARTS
– 3 –
79
1
2
3
4
5
0
w
78
9q
er
t
6
y
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INSTALLING THE INCLUDED PARTS
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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 Pro)
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 A
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INSTALLING THE INCLUDED PARTS
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79
Tighten the front axle 2to the specified torque.
(For YDX-MORO)
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.
Free the lever d.
Determine the position to secure the lever d
and fasten it at “CLOSE”.
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 A
e
d
d
d
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INSTALLING THE INCLUDED PARTS
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79
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.
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.
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)
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
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INSTALLING THE INCLUDED PARTS
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79
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. Installing the display unit’s button cell bat-
tery
Loosen the bolts (Torx) aand remove the dis-
play unit bfrom the bracket c.
Turn the button cell battery cover don the back
of the display unit bin direction e, remove it,
then install the button cell battery 1.
Mount the button cell battery cover d, then turn
it in direction funtil it locks.
d
ce
e
30°
a
f
Tightening torque 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
a
a
c
b
Tightening torque 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
d
ef
1
b
g1Button cell battery 1 A
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INSTALLING THE INCLUDED PARTS
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79
After installing the button cell battery, install the
display unit onto the bracket following the
removal procedure in reverse order.
5. Installing the display unit’s
Maintain a clearance of 1 to 2 mm between the
bracket of the compact multifunction meter set
aand the handlebar holder bas shown, install
the set, and then tighten the bolt cto the spec-
ified torque.
After installing, remove the protective film.
6. 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
Adjust so that the front reflector 1faces straight
ahead, then tighten the screw.
7. Installing the bell
Install the bell 1in the shown, then tighten it
with the screw 2.
8Install the button cell battery with the plus
(+) mark facing upward.
8Check that the O-ring gis properly
installed.
NOTICE
a
b
c
1〜2mm
Tightening torque 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
1
2
3
Tightening torque 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
1Front reflector 1 A
2Stay 1 A
3Screw 1 A
1
2
Tightening torque 0.8 N·m (0.08 kgf·m, 0.59 lb·ft)
1Bell 1 A
2Screw 1 A
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