Yamaha CROSS CORE 2018 User manual

2018
ASSEMBLY MANUAL
CROSS CORE
PW70CRL
PW70CRM
PW70CRS
LIT-15666-00-03 X1M-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
PW70CRL/PW70CRM/PW70CRS
ASSEMBLY MANUAL
©2018 by Yamaha Motor Corporation, U.S.A.
First edition, April 2018
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-15666-00-03

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
Part box 4 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 12in part box 1
4Part box 3 12in part box 1
5Part box 4 12in part box 1
6Saddle and seat post assembly 1
7Front axle 1
8Pedals 21 each for left and right
9Bell 1
0Front reflector 1
qRear reflector 1
wOwner’s manual 1
eButton cell battery 1win owner’s manual pouch
Standard CR2032
rBattery pack 1
tBattery charger 1

INCLUDED PARTS
– 3 –
79
1
2
0q
w
6
78
9
3
4
5
r
t
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
C: Part in part box 3
1. Installing the front wheel and fork end
Remove the spacer bfrom the front disc cali-
per a.
Give the removed spacer bto the customer,
explaining how it is used.
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 left 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
ab
a
c1
2
1Front wheel 1
2Front axle 1 B

INSTALLING THE INCLUDED PARTS
– 5 –
79
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”.
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.
ed
d
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
a
b
c
c
Tightening torque 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Tightening torque 6 N·m (0.6 kgf·m, 4.4 lb·ft)

INSTALLING THE INCLUDED PARTS
– 6 –
79
3. Installing the handlebar
Install the handlebar aso that the knurled part
bis at the center of the handlebar holder c,
then tighten the 4 handlebar holder cbolts d
to the specified torque.
TIP
Install the handlebar aso that the brake levers e
are at a 30angle to the handlebar, as shown in the
illustration.
TIP
8Tighten bolts devenly in stages, in the order
shown in the illustration.
8Tighten in such a way that the gaps fabove
and below the handlebar holder care equal.
4. Installing the headlight
Install the headlight ato the bracket bas
shown, then tighten the bolt cto the specified
torque.
TIP
Install in such a way that the headlight points down-
ward from horizontal and shines on the road
approximately 33 feet (10 meters) ahead.
a
b
d
d
c
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
a
e
30°
d
cf
f
a
b
c
Tightening torque 7 N·m (0.7 kgf·m, 5.2 lb·ft)

INSTALLING THE INCLUDED PARTS
– 7 –
79
5. Installing the front reflector
Install the front reflector 1in the position a
shown in the illustration, then tighten it together
with the stay 2and screw 3.
TIP
Adjust so that the front reflector 1faces straight
ahead, then tighten the screw.
6. Installing the bell
Install the bell 1in the position ashown, then
tighten it with the screw 2.
12
3
a
1Front reflector 1 B
2Stay 1 B
3Screw 1 B
a
1
2
1Bell 1 B
2Screw 1 B

INSTALLING THE INCLUDED PARTS
– 8 –
79
7. Routing the wires
Confirm that wires are routed in order starting
from front to back
Front brake wire 1
Rear brake wire 2
Rear shift wire 3
Front shift wire 4
Headlight lead 5
Switch unit lead 6
Display unit lead 7
Clamp the front brake wire 1and front shift
wire 4with the wire clip 8at the position
shown in the illustration.
Clamp the front shift wire 4, and headlight lead
5with the plastic locking ties 9at the position
shown in the illustration.
Clamp the rear brake wire 2, rear shift wire 3
and display unit lead 7with the plastic locking
ties 0at the position shown in the illustration.
Clamp the front shift wire 4and switch unit lead
6with the wire clip qat the position shown in
the illustration.
Check that the front brake wire 1, front shift
wire 4, headlight lead 5, wire clip 8, and plas-
tic locking ties 9are placed as shown in the
illustration.
9
4
1
5
8
0
2
3
7
q6
9
4
1
5
8
0
2
3
7
q6
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
5
1
4
8
9

INSTALLING THE INCLUDED PARTS
– 9 –
79
Check that the front brake wire 1, rear brake
wire 2, rear shift wire 3, front shift wire 4, dis-
play unit lead 7, wire clip 8, and plastic locking
ties 0are placed as shown in the illustration.
Check that the rear brake wire 2, rear shift wire
3, and speed sensor lead ware routed as
shown in the illustration.
8. Tightening the seat pin
Insert the saddle and seat post 1, then tighten
the bolt ato the specified torque.
7
0
3
4
1
8
2
3
2w
a
b
1
Tightening torque 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
1Saddle and seat post 1 A

INSTALLING THE INCLUDED PARTS
– 10 –
79
9. Installing the rear reflector
Install the rear reflector 1as shown in the illus-
tration, then tighten it together with the stay 2
and screw 3.
After tightening the screw, attach the cap nut 4
to the tip of the screw.
TIP
Adjust the rear reflector 1so that it is facing
straight backward, then tighten it.
8Insert the seat post far enough that the raise
limit bis not visible. If installed at a posi-
tion at which the raise limit bis visible, the
seat post, clamp, or even frame may break,
which could cause the rider to lose control
and fall.
8Always tighten fasteners to the correct
torque. Bolts that are too tight can stretch
and deform. Bolts that are too loose can
move and fatigue. Either mistake can lead
to a sudden failure of the bolt, causing the
rider to lose control and fall.
Do not insert the seat post completely when
lowering the saddle. The bottom edge of the
seat post could touch parts inside the seat
pipe, breaking the seat post or the parts inside
the seat pipe. If the seat post is inserted fully,
lift it slightly then fasten it.
WARNING
NOTICE
1
4
3
2
1
1Rear reflector 1 B
2Stay 1 B
3Screw 1 B
4Cap nut 1 B

INSTALLING THE INCLUDED PARTS
– 11 –
79
10. Installing the pedals
Install the pedal 1to the crank a, then tighten
to the specified torque.
TIP
8Right screw for the right pedal
8Left screw for the left pedal
11. Installing the battery pack
Check that the battery pack 1is fully charged
according to owner’s manual procedures, then
install the battery pack 1.
12. Installing the display unit’s button cell bat-
tery
Loosen the bolts aand remove the display 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.
After installing the button cell battery, install the
display unit onto the bracket following the
removal procedure in reverse order.
Peel off the protective film after installing.
1a
Tightening torque 40 N·m (4.0 kgf·m, 30 lb·ft)
1Pedals (left and right) 1
each B
1
1Battery pack 1 C
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 B
8Install the button cell battery with the plus
(+) mark facing upward.
8Check that the O-ring gis properly
installed.
NOTICE

INSTALLING THE INCLUDED PARTS
– 12 –
79
13. Adjusting the display unit’s time
A. Press the power switch ato turn on the power.
B. Press and hold the function select switch b(2
seconds or longer) until the function display c
switches to the main menu display.
C. Press the “ ▼” assist mode switch d, display
“TIME ADJ” on the main menu display, then
press the function select switch bto set.
D. The hours value increases when the “ ▲” assist
mode switch fis pressed while the “Hour” sec-
tion of the clock eis flashing.
The hours value decreases when the “▼” assist
mode switch dis pressed.
Press the function select switch bto set the
hours.
E. The minutes value increases when the “ ▲”
assist mode switch fis pressed while the “Min-
ute” section of the clock eis flashing.
The minutes value decreases when the “ ▼”
assist mode switch dis pressed.
Press the function select switch bto set the
minutes.
F. The time is set and the mode returns to the nor-
mal mode.
TIP
If you make a mistake adjusting the time, start over
from step B.
G. Press the power switch ato complete adjust-
ment of the time.
14. Checking the operation of the speed sensor
A. Press the power switch ato turn on the power.
B. Long-press the power switch a(approximately
10 seconds) within 30 seconds after turning on
the power, check that the display switches to the
diagnosis function selection screen b, then
release the power switch a.
C. Press the “ ▼” assist mode switch c, display
“SPEED SNSR” on the diagnosis function
selection screen b, then press the function
select switch dto set.
d
ba
c
d
f
b
e
f
ba
e
d
da
b
c

INSTALLING THE INCLUDED PARTS
– 13 –
79
D. Check that the speedometer eis displayed and
that the speed sensor checking mode has been
set.
E. The number displayed on the speedometer e
counts up when the rear wheel is lifted off the
ground and turned.
The number increases by 1 for 1 turn. Check
that the position of the wheel at which the dis-
play counts up is stable.
F. After checking the operation, press the power
switch ato quit.
TIP
Turn the rear wheel at least 3 revolutions and check
that the display reads “3”.
15. Adjusting the opening of the front and rear
brake levers
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
e
a
bc
1
bdirection Opening gets smaller.
cdirection Opening gets larger.
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
8Saddle orientation, height, angle, and tightening
* Check that the saddle is firmly fastened.
8Various fittings adjusted to the customer’s riding posture
* Including brake lever angle, fork suspension air pressure, etc.
8Inspection of the wheels, hubs, and spokes
8Tightening of the brake wire
8Tightening of the pedals
8Tightening of the screws of each part
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
8Light, brightness, and angle of the headlight
* Check that the headlight shines on the road approximately 33 ft. (10 m) ahead.
8Installation state of the reflectors
8Maximum tire air pressure
Front tire: 515 kPa (5.1 kgf/cm2, 75 psi)
Rear tire: 515 kPa (5.1 kgf/cm2, 75 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