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SERVICE MANUAL
e-Bike SYSTEMS
X94 Series
How to Use This ManualSearching for Manual Contents1. Refer to the table on the following page to
determine the applicable parts according tothe 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 thebeginning of the manual. Review the overallmakeup of the manual and search for thechapters and sections you need.
1
2
3
4
SymbolsImportant items in this manual are indicated by the following symbols:
Symbols indicate the following meanings or items:1 General information section
2 Electrical Components section
3 Drive Unit section
4 Service data section
5 Special tools
6 Types of grease
7 Tightening torque
8 Standard values or limits of use
9 Standard values for resistance (Ω), voltage (V),current (A)
0 Lithium-soap-based grease
A Lithium grease made from synthetic hydrocar-
bon oil and synthetic ester oil (MULTEMP AC-
N®)
B New 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
1 2
3 4
5 6 7
8 9
0 A B
GEN INFO ELEC – +
UnitDrive Service
Data
T R..
LS
Lis
t o
f p
art
typ
es a
nd
incl
ud
ed c
ran
k p
arts
acc
ord
ing
to
th
e m
od
el t
ype
cod
e an
d p
rod
uct
co
de
*1: I
n th
e di
agno
sis
sect
ion,
ref
er to
the
appl
icab
le p
ages
acc
ordi
ng to
the
type
of m
eter
dis
play
uni
t.*2
: For
the
illus
trat
ions
and
con
tent
s fo
r di
sass
embl
ing
the
driv
e un
it, r
efer
to th
e ap
plic
able
pag
es a
ccor
ding
to th
e sh
ape
of th
e cr
ank
arm
mou
nt.
Mat
er/D
isp
lay
*1B
atte
ryC
ran
k ax
le *
2In
clu
ded
cra
nk
par
ts
Mo
del
typ
e co
de
Pro
du
ct
cod
e
LE
DL
CD
Rea
r ca
rrie
rD
ow
n t
ub
eS
qu
are-
typ
eS
plin
e-ty
pe
(IS
IS)
Sp
rock
etS
pac
erS
pid
erN
ut,
lock
X94
101
0√
√√
√√
030
√√
√√
X94
201
0√
√√
√√
X94
301
0√
√√
√√
020
√√
√√
√
X94
401
0√
√√
√√
√
020
√√
√√
√√
X94
501
0√
√√
√√
√
X94
601
0√
√√
√√
√
020
√√
√√
√
Index
General Information GENINFO 1
Electrical ComponentsELEC 2
Drive Unit Drive Unit 3
Service Data Service Data 4
– +
CONTENTS
CHAPTER 1 General Information
Description ................................................................................................... P1-1
Precautions relating to maintenance (1).................................................... P1-2Cleaning 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)............................................................................ P1-5Bearing Installation ............................................................................... P1-5
Oil Seal Installation ............................................................................... P1-5
Circlip Installation.................................................................................. P1-5
Precautions relating to maintenance (3).................................................... P1-6Handling of the torque sensor............................................................... P1-6
Specialized tools and equipment ............................................................... P1-7
CHAPTER 2 Electrical Components
Electrical component wiring diagram ........................................................ P2-1
Battery pack ................................................................................................. P2-2Battery 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 ....................................................................................................... P2-6e-Bike system dedicated battery charger ............................................. P2-6
Display on battery capacity indicator lamps while charging.................. P2-7
Diagnosis mode ........................................................................................... P2-8Recoverable 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)............................................. P2-17Display unit’s display when there is an error ...................................... P2-17
Operating Procedures to Diagnosis Mode.......................................... P2-19
Diagnosis function (LCD type display unit) ............................................ P2-28Display unit’s display when there is an error ...................................... P2-28
Operating Procedures to Diagnosis Mode.......................................... P2-30
Diagnosis function .............................................................................. P2-39
Speed sensor set ....................................................................................... P2-45Speed 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]) .......... P3-5Removal 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 ....................................................................................... P4-1Other, 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
GENINFO
General InformationDescription
1. Drive Unit2. Speed sensor set
a) Magnet sensor spoke typeb) Pick up
3. È Display Unit (LED type)É Display Unit (LCD type)a) Display (detachable)b) Display holderc) Switch
4. Battery charger5. 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
1 2
43
5
È É
Description
1
1-2
GENINFOPrecautions relating to maintenance (1)
Precautions relating to maintenance (1)Cleaning and Maintenance
NOTICE
When washing the bicycle, keep wateraway from the e-bike system.Water which comes in direct contact withthe e-bike system can get inside andreduce performance. Steam cleaning isparticularly to be avoided.
1. Remove any mud or dust from the frameand Drive Unit to make sure that it does notget inside when performing service.
2. Use water or neutral cleanser to clean cov-ers, and wipe off water using a soft cloth toprevent scratching. Avoid wiping with a drycloth prior to washing.
Keep away from fireKeep the workplace away from open fire.
Keep away
from fire!
Proper toolsWhen servicing the bicycle, be sure to use thespecial tools intended for areas which requirespecial tools in order to prevent damage toparts. Also, work appropriate work should bedone using appropriate tools and measuringdevices. (Avoid using spanner wrenches. Useoffset or box wrenches instead.)
1
1-3
GENINFOPrecautions relating to maintenance (1)
Replacement partsReplace gaskets (packing), O-rings, cotterpins, circlips (split rings), lock washers, etc.with new parts.Be sure to use genuine new Yamaha parts andrecommended parts for oils and greases,including periodic replacement parts andrepair parts.Do not use used parts because, even thoughthese parts may appear to be the same, theymay not be genuine parts, or there is the riskthat their quality has changed due to previoususe.
Genuine parts
Precautions for disassembly and reassembly1. Inspect and measure parts as needed dur-
ing disassembly. Keep good records whichyou can refer to when reassembling parts.
2. Organize parts by sections so that you donot mix them up or lose them.
3. Use cleaning oil to clean Drive Unit partsafter disassembly and blow parts clean withcompressed air.
4. Reassemble parts while checking any cor-rections made to parts and referring to thedata collected prior to disassembly.
5. While reassembling parts make sure thateach part is clean and free of foreign mate-rial.
6. Perform reassembly while checking theactions 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
GENINFOPrecautions relating to maintenance (1)
Handling the Battery Pack1. 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 productother than the e-bike system, it will cause afluid leakage, “overheating, or breakage.”
3. Be sure to charge the e-bike system beforeoperating it for the first time or after it hasbeen unused for a long period of time.
4. Do not expose the battery pack to freshwater or seawater. It can cause the batterypack to overheat or rust.
5. Do not disassemble or modify the batterypack. It can cause a fluid leakage, overheat-ing, or breakage. To replace the batterypack, replace the entire assembly.
6. If charging is not completed even after thespecified charging time has elapsed, stopcharging. If charging is continued, it cancause a fluid leakage, overheating, orbreakage.
7. The battery pack should be sorted for envi-ronmental-friendly recycling. Do not dis-pose of the battery pack as householdwaste.
1-5
GENINFOServicing Precautions (2)
Servicing Precautions (2)Bearing Installation1. When installing a bearing, the surface with
the manufacturer’s mark and the size codeshould face outward.
2. When striking a bearing into the case, applya parallel force to the outer race.
3. When striking a bearing onto an axle, applya parallel force to the inner race.
Oil Seal Installation1. 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 greaseto the sealing lip before installing the oilseal.
Main lipOil Sub lip
Spring
Grease
Circlip Installation1. 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
GENINFOPrecautions relating to maintenance (3)
Precautions relating to maintenance (3)Handling of the torque sensor1. Keep away from magnets.
Do not use magnetized screwdrivers or per-form maintenance near large sources ofelectric power.
2. Avoid strong mechanical impact.Torque sensors which have been droppedor which have been removed through theuse of a hammer or the like cannot be usedbecause 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 caseby crushing can result in changes in thetorque sensor reference voltage. Torquesensor reference voltage changes can alsobe caused by the application of a force ofover 2 kgf on the sensor shaft while thecase is clamped in place.The installation of a one-way clutch havinga tightly-fitted spline can apply excessiveforce to the sensor shaft and result in volt-age changes.
4. Do not pull leads.Do not pull forcefully on the small circuitboard leads which connect the torque sen-sor body to the torque sensor. It can changethe torque sensor reference voltage.
5. Do not allow water to come in contact withthe Drive Unit. Any rust on the sensor shaft or the mainaxle can cause output fluctuations or canreduce the strength of the parts. Do not per-form servicing on the sensor in wet loca-tions.
6. Organic solventsDo not apply gasoline or solvent-basedlubricants (consumer spray-type lubricants)to the sensor shaft or the circuit board. Itcan reduce the unit’s ability to preventshort-circuits.
7. Do not reuse damaged drive axles.The sensor shaft and the drive axle slide ina metal bearing. It will be difficult to installthe one-way clutch and the sensor shaft ifthere are scratches on the surface of thedrive axle.
8. Do not disassemble the torque sensor.Do not disassemble the interior of the sen-sor because the torque sensor cannot bereadjusted. Torque sensors that have beendisassembled cannot be used.
1-7
GENINFOSpecialized tools and equipment
Specialized tools and equipmentThe 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 andheat resistance
Three Bond No.1215®
MULTEMP AC-N®
Lithium grease made from synthetic hydrocarbonoil and synthetic ester oil
Digital circuit tester
Device used for testing and measuring electricalcomponents
2-1
ELEC – +
Electrical ComponentsElectrical component wiring diagram
TO
BA
TT
ER
YW
IRE
LE
AD
2
B Or
P W
R Gy
Br
L
B
Y B
R
Gy
W
G L Sb
G
B
RG
yB
R
L Sb
R
SP
EE
D S
EN
SO
R
TO
LIG
HT
DIS
PL
AY
UN
IT (
LC
D T
YP
E)
DIS
PL
AY
UN
IT (
LE
D T
YP
E)
WIR
E L
EA
D 1
WIR
E L
EA
D 3
WIR
E L
EA
D 5
WIR
E L
EA
D 4
Y
YL
WR
B
W L
TO
MO
TO
R E
NC
OD
ER
CO
NT
RO
LL
ER
AS
SE
MB
LY
TO
RQ
UE
SE
NS
OR
AS
SE
MB
LY
MO
TO
R A
SS
EM
BLY
En
co
de
r le
ad
wire
in
sta
llatio
n lo
ca
tio
n
Electrical component wiring diagram
2
2-2
ELEC – +
Battery pack
Battery packBattery pack display functionBy holding down the battery capacity indicator button “ ” on the battery pack, the following itemscan be checked.
Length of time that the button is pushed
Display item Display time Details Page
When pushed
Normal state:Residual battery capacity
5 secondsSee the owner’s man-ual.
–
Error detected:Error display
5 seconds See “Error display”. P. 2-2
20 secondsTotal number of bat-tery charging cycle
5 seconds
See “How to check the total number of battery charging cycle”.
P. 2-4
30 secondsAbsolute battery capacity
5 secondsSee “How to check the absolute battery capacity”.
P. 2-5
Error display1. Depending on the model, the battery capac-
ity indicator lamps are arranged horizontallyor vertically as shown.In the explanations in this manual, the num-bers used for the battery capacity indicatorlamps are 4, 3, 2, and 1 from left to right orfrom top to bottom.Although the illustrations in this manualshow only the vertical-type battery capacityindicator, the operation of the lamps is thesame 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 whenthe battery capacity indicator button “ ” ispushed or connect the battery charger, see“Recoverable errors of battery pack or bat-tery charger”. (P. 2-8)
4 3 2 1
321
4
or
321
4321
4
321
4321
4
Off On
2
2-3
ELEC – +
Battery pack
3. If the battery capacity indicator lamps [1]and [4] are fast flash simultaneously whenthe battery capacity indicator button “ ” ispushed or connect the battery charger, see“Non-recoverable errors of battery pack”. (P.2-10)
321
4
Off Fast flashing
4. If all four battery capacity indicator lampsflash slowly at the same time when the bat-tery capacity indicator button “ ” ispushed, see “Temperature protection func-tion”. (P. 2-14)
If all four battery capacity indicator lampsflash slowly at the same time when con-nect the battery charger, see “Chargingon stand-by mode”. (P. 2-7)
321
4
Slow flashing
2-4
ELEC – +
Battery pack
How to check the total number of battery charging cyclesCheck the total number of battery chargingcycles as follows:1. Hold down the battery capacity indicator
button “ ” 1 for 20 seconds.2. The total number of battery charging cycles
is indicated by the four battery capacity indi-cator lamps 2 on the battery pack.
TIPWhile holding down the battery capacity indi-cator button “ ” for 20 seconds, the lamps willdisplay the currently applicable condition(residual battery capacity, * error diagnosis),for five seconds for each condition.
*The error diagnosis are displayed only for amalfunction, and is not displayed in normalstate.
The table below indicates the relationshipbetween the total number of battery chargingcycles and the battery capacity indicator lamps.
321
4 2
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 times701 times or more
321
4
321
4
321
4321
4
321
4321
4
321
4321
4
2-5
ELEC – +
Battery pack
How to check the absolute battery capacityCheck the *1 absolute battery capacity as fol-lows:1. Hold down the battery capacity indicator
button “ ” 1 for 30 seconds.2. The *1 absolute battery capacity is indicated
by the four battery capacity indicator lamps2 on the battery pack.
TIPWhile holding down the battery capacity indi-cator button “ ” for 30 seconds, the lamps willdisplay the currently applicable conditions(residual battery capacity, *2 error diagnosis,Total number of battery charging cycles), forfive seconds for each condition.
*1 Absolute battery capacity:Absolute battery capacity is not the relativespecified electric power capacity that thebattery pack has at any given point, but theactual electric capacity that the battery packitself can store. The capacity at the time ofshipment is considered 100%.
*2 The error diagnosis are displayed only dur-ing a malfunction, and is not displayed innormal state.
The table below indicates the relationshipbetween the absolute battery capacity and thebattery capacity indicator lamps.
321
4 2
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%
321
4321
4
321
4321
4
2-6
ELEC – +
Charging
Charging e-Bike system dedicated battery chargerThis battery charger 1 is a dedicated batterycharger for the e-Bike system’s battery pack.
1
321
4
321
4
321
4
321
4
321
4
321
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
ELEC – +
Charging
Display on battery capacity indicator lamps while chargingSome phenomena such as the following mayoccur while charging the battery pack, depend-ing on the battery pack’s state; however, theseare not malfunctions.1. Charging on stand-by
Display on the battery capacity indicatorlamps on the battery pack: [All four lampsflashing slowly at the same time].When the battery pack’s internal tempera-ture goes out of operating range, the batterypack changes to the “Charging on stand-by”state automatically.
TIP• Once the temperature inside the battery
pack becomes suitable for charging, thecharging starts automatically.(In such case, the charging time becomeslonger by the time during which all four bat-tery capacity indicator lamps on the batterypack were flashing simultaneously.)As much as possible, charge at an optimalroom temperature, approximately 15 to25°C.
• Even if you start charging properly, if thebattery pack exceeds the specified temper-ature range while charging, the chargingprocess is aborted to protect the batterypack. This may result in insufficient charg-ing. In such case, when checking the resid-ual battery capacity, not all of the fourbattery capacity indicator lamps on the bat-tery pack may not turn on. Cool down thebattery pack for a while, and charge again,preferably in a cool place.
• Even if the room temperature is within the 0to 45°C range, if attempting to charge thebattery pack immediately after driving, or ifthe battery pack had been left in the sunduring summer, the battery pack’s internaltemperature may be outside the allowabletemperature range for charging. If the roomtemperature is 30°C, it may take approxi-mately 4 hours until the battery pack’s inter-nal temperature is within the allowabletemperature range for charging.
321
4
Slow flashing
2. During pre-chargingDisplay on the battery capacity indicatorlamps on the battery pack: [Battery capacityindicator lamps [1] flash rapidly].3
21
4
Off Fast flashing
2-8
ELEC – +
Diagnosis mode
Diagnosis modeRecoverable errors of battery pack or battery chargerIf the battery pack or battery charger has theerrors, the following procedure can be used toaccess the error diagnosis mode and confirmthe details regarding the error of the batterypack or battery charger.1. If there is an error when the battery capacity
indicator button “ ” 1 on the battery packis 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 lampsturn on alternately, the residual batterycapacity is not displayed.
2. Hold down the battery capacity indicatorbutton “ ” 1 for 10 seconds.
3. The lighting display of the battery capacityindicator lamps indicates the error of thebattery pack or battery charger.
TIP• If the battery pack or battery charger is
operating normally, the battery capacityindicator lamps indicate the residual batterycapacity.
• If there are multiple errors, only the latesterror will be displayed.
• The error diagnosis mode can be accessedwhether the battery charger is connected ordisconnected.
or
Turn onalternately
Turn onalternately
321
4321
4
321
4321
4
1
Off On
2-9
ELEC – +
Diagnosis modeL
ist
of
bat
tery
pac
k/b
atte
ry c
har
ger
dia
gn
osi
s it
ems
Off
O
n
Bat
tery
cap
acit
y in
dic
a-to
r la
mp
s
Bat
tery
ca
pac
ity
ind
icat
or
lam
ps
Fau
lt
dev
ice
Fai
lure
Act
ion
1/3
and
2/4
tu
rn o
n a
lter
-n
atel
yH
old
dow
n th
e ba
ttery
ca
paci
ty
indi
cato
r bu
tton
“”
for
10 s
ec-
onds
Bat
tery
pa
ck
failu
re
Ove
rcha
rg-
ing
durin
g di
scha
rgin
g
1.C
onne
ct t
he b
atte
ry p
ack
to t
he d
edic
ated
bat
tery
cha
rger
for
the
e-B
ike
syst
eman
d ch
arge
it fo
r a
whi
le.
2.T
he b
atte
ry p
ack
retu
rns
to t
he n
orm
al s
tate
afte
r th
e st
ep 1
, in
stal
l the
bat
tery
pack
to th
e bi
cycl
e an
d rid
e it
for
a w
hile
.
3.If
the
batte
ry p
ack
erro
r oc
curs
aga
in, p
erfo
rm th
e fo
llow
ing:
•C
heck
the
Driv
e U
nit f
ailu
re.
•R
epla
ce th
e ba
ttery
pac
k.
Cha
rgin
g ov
er c
urre
nt
durin
g di
s-ch
argi
ng
Dis
char
ging
ov
er c
urre
nt
Sho
rt c
ircui
t
FE
T te
mpe
r-at
ure
faul
t
3 2 143 2 14
3 2 14 3 2 14 3 2 14 3 2 14 3 2 14
2-10
ELEC – +
Diagnosis mode
1/2
and
3/4
tu
rn o
n a
lter
-n
atel
yH
old
dow
n th
e ba
ttery
ca
paci
ty
indi
cato
r bu
tton
“”
for
10 s
ec-
onds
Bat
tery
ch
arge
rfa
ilure
Ove
rcha
rg-
ing
durin
g ch
argi
ng
Rep
lace
the
batte
ry c
harg
er.
The
bat
tery
pac
k w
ill r
etur
n to
the
norm
al s
tate
, afte
r th
e ba
ttery
pac
k is
inst
alle
d to
th
e bi
cycl
e an
d th
e bi
cycl
e is
rid
den
for
a w
hile
.
Cha
rgin
g ov
er c
urre
nt
durin
g ch
argi
ng
Zer
o ch
arg-
ing
curr
ent
1.D
isco
nnec
t the
cha
rgin
g pl
ug.
2.C
lean
the
char
ging
con
nect
or a
nd c
harg
ing
plug
, an
d dr
y th
em.
3.C
onne
ct th
e ch
argi
ng p
lug
to th
e ch
argi
ng c
onne
ctor
.4.
If th
e ba
ttery
pac
k er
ror
occu
rs a
gain
, rep
lace
the
batte
ry c
harg
er.
3 2 143 2 14
3 2 14 3 2 14 3 2 14 Not
tur
n o
n
2-11
ELEC – +
Non-recoverable errors of battery packIf the battery pack has the errors, the followingprocedure can be used to access the errordiagnosis mode and confirm the detailsregarding the error of the battery pack.1. If there is a non-recoverable errors when
the battery capacity indicator button “ ” 1on the battery pack is pushed or connectthe battery charger, the battery capacityindicator lamps [1] and [4] fast flash simulta-neously.
2. Hold down the battery capacity indicatorbutton “ ” 1 for 10 seconds.
3. The lighting display of the battery capacityindicator lamps indicates the error of thebattery pack.
321
4
1
Off Fast flashing
Diagnosis mode
2-12
ELEC – +
Diagnosis modeO
ff
On
F
ast f
lash
ing
Bat
tery
cap
acit
y d
isp
lay
lam
p
Bat
tery
ca
pac
ity
dis
pla
y la
mp
Fau
lt
dev
ice
Fai
lure
Act
ion
1 an
d 4
fla
sh r
apid
lyH
old
dow
n th
e re
sidu
al
batte
ry
capa
city
in
dica
tor
butto
n “
” fo
r 10
sec
-on
ds
FE
T fa
ilure
Rep
lace
the
batte
ry p
ack.
AF
E fa
ult
Hig
h-te
m-
pera
ture
ex
posu
re
Bat
tery
pa
ck
failu
reF
ET
tem
per-
atur
e fa
ult
Cel
ls u
nbal
-an
ced
The
rmis
tor
faul
t
Ove
r ch
arg-
ing
3 2 14
3 2 14 3 2 14 3 2 14 3 2 14 3 2 14 3 2 14 3 2 14
2-13
ELEC – +
Diagnosis mode
When the battery pack signal lead wire becomes disconnectedAlthough the power to the display unit is turnedon,• All of the LED displays of the display unit
(LED type) turn on for 4 seconds, and thenthe power turns off automatically (LED) È
• All segments of the display unit (LCD type)unit turn on for 4 seconds, and then thepower turns off automatically (LCD) É
If the motor is rotating (while running), thepower assist becomes weak and finally stopsit. The battery pack stops discharging after ashort time.
Action:Check the battery pack signal lead wire (gray)for a wire break or disconnection.→ Replace the DC plug or power lead wire.
A
after4 seconds
B
after4 seconds
2-14
ELEC – +
Diagnosis mode
Temperature protection functionIf the battery pack’s internal temperature is -20°Cor less or 80°C or higher while the battery pack isdischarging (during the power assist), the tem-perature protection function of the battery packoperates and the battery pack stops discharging.If the battery capacity indicator button “ ” ispushed at this time, the battery capacity indi-cator lamps [1], [2], [3], and [4] flash slowly atthe same time.
TIPThe battery pack automatically recovers whenthe battery pack’s internal temperature returnsto the allowable temperature range for charg-ing.
321
4
Slow flashing
2-15
ELEC – +
Diagnosis mode
Over-discharge protection functionIf the battery pack becomes over-discharged,the over-discharge protection function of thebattery pack operates.If the battery capacity indicator button “ ” ispushed at this time, the battery capacity indi-cator lamps do not turn on.The following procedure can be used toaccess the over-discharge protection functiondiagnostic mode and confirm the detailsregarding the malfunction of the battery pack.
*First connect the battery charger to thebattery.
*Because the battery voltage is insufficientwhen the battery pack is over-discharged,the battery capacity indicator lamps will notturn on or flash if the battery pack is notconnected to the battery charger.
321
4
Off
2-16
ELEC – +
Rep
lace
th
e b
atte
ry p
ack
Th
e L
ED
lam
ps
[1]
and
[4]
are
fl
ash
ing
rap
idly
at
the
sam
e ti
me.
Th
e L
ED
lam
p [
1] is
fla
shin
g r
ap-
idly
.
Th
e L
ED
lam
p [
3] is
illu
min
ate.
Th
e L
ED
lam
p [
3] is
illu
min
ate.
Th
e L
ED
lam
ps
[1]/
[2]
and
[3]
/[4]
are
tu
rn
on
alt
ern
atel
y.
If th
e ba
ttery
pac
k do
es n
ot r
etur
n to
nor
mal
vo
ltage
eve
n af
ter
one
hour
from
the
star
t of
the
prel
imin
ary
char
ging
, the
bat
tery
cha
rger
w
ill s
top
the
oper
atio
n of
the
prel
imin
ary
char
g-in
g.In
this
cas
e, a
ll LE
D la
mps
of t
he b
atte
ry
pack
will
goe
s ou
t.
Th
is is
th
e b
atte
ry p
ack’
so
ver-
dis
char
ged
sta
te.
Th
is is
th
e b
atte
ry p
ack’
so
ver-
dis
char
ged
sta
te.
The
bat
tery
pac
k is
in th
e “N
on-r
ecov
erab
le e
rror
”
Thi
s is
the
“Pre
limin
ary
char
ging
(In
itial
cha
rgin
g) s
tate
”
-> T
his
is n
orm
al.
If t
he
bat
tery
pac
k b
eco
mes
th
e n
orm
al c
har
gin
g s
tatu
s, t
he
bat
tery
pac
k is
no
rmal
.
All
LE
D la
mp
s g
oes
ou
t.
Rep
lace
th
e b
atte
ry p
ack
Ove
r-d
isch
arg
ing
of
the
bat
tery
pac
k 3 2 14 3 2 143 2 14
3 2 14
3 2 14
3 2 143 2 14
100%
3 2 14
1-24
%
3 2 14
25-4
9%
3 2 14
50-7
4%
3 2 14
75-9
9%
3 2 14
LED
lam
ps d
oes
not i
llum
inat
e w
hen
you
push
ed th
e “P
US
H”
butto
n.
Ple
ase
conn
ect t
he b
atte
ry p
ack
to
the
batte
ry c
harg
er.
Dis
conn
ect t
he b
atte
ry p
ack
from
the
batte
ry c
harg
er, a
nd
push
the
“PU
SH
” bu
tton.
Hol
d do
wn
the
“PU
SH
” bu
tton
for
10 s
econ
ds.
Hol
d do
wn
the
“PU
SH
” bu
tton
for
10 s
econ
ds.
Diagnosis mode
2-17
ELEC – +
Diagnosis function (LED type display unit)
Diagnosis function (LED type display unit)Display unit’s display when there is an errorDetects system malfunctions, changes assistoperation, and displays the errors as well asperforming error code recording.Error displays are indicated by the display of“Er” and an error code indicating the type oferror. You can switch between “Er” and theerror code display by pressing the functionselect switch “ ”.When a malfunction which may reflect aabnormal operation is displayed, the malfunc-tion is recorded to prevent recurrence of thecondition, and thereafter the power assist willbe immediately blocked after the power isturned on and the error will be displayed on thefunction display in display unit.
How communication errors are displayedThe 3 assist mode lamps 1, the “%” lamp 2,the “km” lamp 3, and the “km/h” lamp 4 willflash at the same time, and “Er” will be dis-played on the function display 5 of the displayunit.When the function select switch “ ” 6 ispressed, error code “12” or “13” will be dis-played.
TIP• The error code is not stored.• See “List of error codes and corresponding
power assist operations” for more details.• If there is a communication error, the power
cannot be turned off using the “POWER”switch of the display unit. To turn the poweroff, remove the battery.
5 2
34
6
1
Slow flashing Slow flashing
2-18
ELEC – +
Diagnosis function (LED type display unit)
How Drive Unit malfunctions are displayedThe 3 assist mode lamps 1, the “%” lamp 2,the “km” lamp 3, and the “km/h” lamp 4 willflash alternately, and “Er” will be displayed onthe function display 5 of the display unit.When the function select switch “ ” 6 ispressed, error code “16” or higher will be dis-played.
TIP• Error codes are stored.• See “List of error codes and corresponding
power assist operations” for more details.
Alternately flashes
5 2 3
4
6
1
How speed sensor malfunctions are displayedThe “HIGH”, “STD”, or “ECO” assist modelamps 1 are displayed with a slow flash (0.5seconds).
TIP• Error codes are not stored.• See “List of error codes and corresponding
power assist operations” for more details.• In assist off mode, displays of malfunctions
cannot be made using the assist mode lamp.
1
Slow flashing Slow flashing
Recovery method when there is a speed sensor malfunctionThe display will return to normal when thespeed sensor returns to normal condition.
2-19
ELEC – +
Diagnosis function (LED type display unit)
Operating Procedures to Diagnosis ModeThis is the mode in which each type of diagno-sis and the content of error codes which arestored when there is an error are displayed.You can switch between speed sensor diagno-sis mode, Drive Unit diagnosis mode, anderror log check mode by using the display unitaccording to the following procedures.1. Make sure that the power is turned off to the
display unit.Press the power switch “ ” 1 to turn onthe power.When the power is turned on, all lamps andsegments of the display unit will illuminate.After approximately 2 seconds, the lampsand segments will turn off, and then the dis-play will return to normal.
2. Press the power switch “ ” 1 again, andcontinue pressing the switch until only the 3assist mode lamps 2 are illuminated.(Approximately 10 seconds)Confirm that only the 3 assist mode lamps2 are illuminated, and then release thepower switch “ ” 1.
TIPSteps 1 and 2 must be performed within 30seconds.
3. Press the assist mode switch “ ” 3 or“ ” 4 to change the assist mode.When the assist mode is changed, one ofthe assist mode lamps 2 will illuminate.You can select each diagnostic mode bychanging the assist mode.
4. Press the light switch “ ” 5.The “HIGH”, “STD”, or “ECO” assist modelamp 2 will flash rapidly (0.2 second) toindicate each of the diagnostic modes.
TIPIf you pressed the wrong switch, turn off thepower and perform steps 1–4 again.
2 1
2
3
4
2 5
2-20
ELEC – +
Diagnosis function (LED type display unit)
Speed Sensor Diagnosis ModePress the assist mode switch “ ” 1 until the“HIGH” assist mode lamp is illuminated.Press the light switch “ ”.The “HIGH” assist mode lamp flashes rapidly(0.2 second).For more information about the speed sensordiagnosis mode, see “Speed sensor diagnosismode display method”.
Drive Unit Diagnosis ModePress the assist mode switch “ ” 1 → “ ”2 or “ ” 2 → “ ” 1 until the “STD” assistmode lamp is illuminated.Press the light switch “ ”.The “STD” assist mode lamp flashes rapidly(0.2 second).For more information about the drive unit diag-nosis mode, see “Drive unit diagnosis modedisplay method”.
Error Log Check ModePress the assist mode switch “ ” 2 until the“ECO” assist mode lamp is illuminated.Press the light switch “ ”.The “ECO” assist mode lamp flashes rapidly(0.2 second).For more information about the error log checkmode, see “Error log check mode”.
1
2
Fast flashing
2-21
ELEC – +
Diagnosis function (LED type display unit)
Speed Sensor Diagnosis Mode Display MethodTo determine if the controller is correctly rec-ognizing the speed sensor signal, rotate thewheel to which the speed sensor is connectedand make sure that the number of rotations ofthe wheel indicated matches the actual num-ber of rotations.
1. Go into speed sensor diagnosis mode.See “Operating Procedures to DiagnosisMode.”Confirm that the “HIGH” lamp of the assistmode lamps is flashing fast.
2. When you raise and rotate the wheel (withthe speed sensor), the rotation number dis-play 1 on the display unit will change.Before rotating the wheel (with the speedsensor), “0” will be displayed on the rotationnumber display 1 of the display unit.When you rotate the wheel (with the speedsensor) 1 time, “1” will be displayed on therotation number display 1 of the displayunit.When you rotate the wheel (with the speedsensor) 12 times, “12” will be displayed onthe rotation number display 1 of the displayunit.When you rotate the wheel (with the speedsensor) 13 times, the display of the rotationnumber display 1 of the display unit willreturn to “1”.Thereafter, each time the wheel (with thespeed sensor) is rotated, the number ofrotation number display 1 on the displayunit will be from “1” to “12”.
TIP• You should at least rotate the wheel (with
speed sensor) 3 times and make sure that “3”is displayed.
• If the speed sensor malfunctions, the numberof rotations displayed on the display unit willincrease before the wheel (with speed sensor)is rotated even once, or the number will notincrease even when the wheel (with speedsensor) is rotated once (or there is a delay inthe increase in the value).
Fast flashing
Number of Wheel
Rotations
Rotation number display of the display unit
1 rotation
12 rotations
13 rotations
1
2-22
ELEC – +
Diagnosis function (LED type display unit)
Drive Unit Diagnosis Mode Display MethodYou can check the status of or malfunctions inthe Drive Unit.
1. Go into Drive Unit diagnosis mode.See “Operating Procedures to DiagnosisMode.”Confirm that the “STD” of the assist modelamps is flashing fast.After the diagnosis mode indicator of thedisplay unit has displayed “1” for up to 10seconds, you can check the torque sensorreference voltage, motor current, error dis-plays (“E2”, “E4”), and the display unit func-tion check.
Fast flashing
List of Drive Unit Diagnosis Mode Display Methods
Inspection items
Diagnosis mode
display
Press operating
buttonDiagnosis data display
Press operating button
1) Torque sensor
reference voltage
Values are displayed from 0.0 to 5.0 (V)
To 2) Motor current
2) Motor current
Motor output current in “HIGH” mode is displayed as 00 to “FL (= FULL)”(= % output).
To 3) Error display
3) Error display There is no display when there are no errors.When there is an error, either “E2” (motor) or “E4” (controller) are displayed.
To 4) Display unit function check
4) Display unit function check
All segments and lamps are illuminated.(Segments and lamps that are not illuminated indicate a malfunction.)
Power goes off
or
2-23
ELEC – +
Diagnosis function (LED type display unit)
1. Torque sensor reference voltage display
a. “10” is displayed in the diagnosis mode dis-play 1 of the display unit.
b. Press the function select switch “ ” of thedisplay unit.
c. Displayed in units of 0.1 V from 0.0 to 5.0 Vin the diagnosis data display 2 of the dis-play unit.
d. The torque sensor is normal if the displayvoltage is 0.2 to 1.1 V.Perform a torque sensor reference voltageadjustment if values outside of this rangeare displayed.
e. Press the light switch “ ” of the displayunit.
f. Proceed to 2) Motor current.
2. Torque sensor reference voltage adjustmentfunctionTurn the power on to the display unit and letit stand.Guideline: Until the power to the display
unit is turned off automatically(about 5 min.).
TIPDo not place feet on the pedals while perform-ing a torque sensor reference voltage adjust-ment.
1) Torque sensor reference voltage1
2 2
* Determining whether or not the torque sen-sor is good0.2 to 1.1 V = normalIf the torque sensor is outside of this range→ Implement the torque sensor reference
voltage adjustment function.If the torque sensor remains outside of itsnormal range after torque sensor referencevoltage adjustment→ Torque sensor malfunction (replace)
2-24
ELEC – +
Diagnosis function (LED type display unit)
a. “14” is displayed in the diagnosis mode dis-play 1 of the display unit.
b. Press the function select switch “ ” buttonof the display unit.
c. The diagnosis data display 2 of the displayunit displays the motor output current (%)from “00” to “FL (= FULL)”.
d. Confirm that the diagnosis data display 2 ofthe display unit displays “FL” when applyingthe rear brake and strongly pressing on thepedals.• “FL” is displayed: good• “FL” is not displayed: If the bicycle was
ridden immediately before checking themotor current, it is possible that the bat-tery or the controller temperature controlis working; therefore, wait until the bicyclecools down. If the bicycle was not riddenimmediately before checking the motorcurrent, recheck using a battery that isoperating properly.
• “FL” is not displayed: The batteryresponse is weak in winter (low tempera-tures), so use a battery that has beenstored in a heated room.
• “FL” is not displayed: Replace the control-ler assembly.
e. Press the light switch “ ” of the displayunit.
f. Proceed to 3) Error displays.
2) Motor current1
2 2
2-25
ELEC – +
Diagnosis function (LED type display unit)
a. “16” is displayed in the diagnosis mode dis-play 1 of the display unit.
b. Press the function select switch “ ” of thedisplay unit.
c. When there is a malfunction, “E2” (motor) or“E4” (controller) will be displayed on thediagnosis data display 2 of the display unit.
TIPCheck the error code if “E2” or “E4” are dis-played.
d. Press the light switch “ ” of the displayunit.
e. Proceed to 4) Display unit function check.
TIPCheck the error code if E2 or E4 are displayed.
• When there is no malfunction the next “18” isdisplayed without the diagnosis mode “16”being displayed.
• Perform a final check to make sure there isno error display in this mode when perform-ing repairs or replacing parts.
a. “18” is displayed in the diagnosis mode dis-play 1 of the display unit.
b. Press the function select switch “ ” 2 ofthe display unit.
c. All segments and all lamps of the displayunit will illuminate.
d. Replace the display unit if there are seg-ments or lamps which are not illuminated.
e. Press the light switch “ ” 3 of the displayunit.
f. The power to the display unit is turned off.
3) Error displays
4) Display unit function check
1
or
2 2
1
3
2
OnOn
2-26
ELEC – +
Diagnosis function (LED type display unit)
Error Log Check Mode Display MethodThe three most recent types of error codeswhich are stored when there is an error arestored and these are displayed in order fromthe most recent every 10 seconds.
1. Go into error log check mode.See “Operating Procedures to DiagnosisMode.”Confirm that the “ECO” lamp of the assistmode lamps is flashing fast.The display unit displays the three mostrecent error codes in the order stored as“E1” to “E3”. To display the error codes,press the function select switch “ ” of thedisplay unit.“0” will be displayed when there are noerrors.When other error codes are stored, the dis-play will switch to the next error in 10 sec-onds.
Fast flashing
List of Error Log Check Mode Display Methods
Number of error codes
How error codes are displayed on the display unit
When there are no error codes
When there is 1 error code
When there are 2 error codes
When there are 3 error codes
Error code displays
([E1] along with the error code are displayed for 10 seconds)
Error code displays
Error code displays
([E2] along with the error code are displayed for 10 seconds)
Error code displays
Error code displays
Error code displays
([E1] along with the error code are displayed for 10 seconds)
([E2] along with the error code are displayed for 10 seconds)
([E3] along with the error code are displayed for 10 seconds)
2-27
ELEC – +
Diagnosis function (LED type display unit)
How to delete the malfunction history1. While pressing the light switch “ ” 1 dur-
ing the error code display, press the assistmode switch power assist decrease 2 andpower assist increase 3 to switch.
1
3
2
2. The diagnostic display pattern will stop, alllamps will turn on and off twice (“8.8.” will beshown in the error code display 1 of thedisplay unit), and the history will be deleted.The power to the display unit will be turnedoff at this time.
TIPBe sure to clear the diagnosis history afterreplacing the motor or other parts.
Repeats 2 times
1
2-28
ELEC – +
Diagnosis function (LCD type display unit)
Diagnosis function (LCD type display unit)Display unit’s display when there is an errorDetects system malfunctions, changes assistoperation, and displays the errors as well asperforming error code recording.Error displays are indicated by the display of“Er” and an error code indicating the type oferror. You can switch between “Er” and theerror code display by pressing the functionselect switch “s”. When a malfunction which may reflect a seri-ous abnormal operation is displayed, the mal-function is recorded to prevent recurrence ofthe condition, and thereafter the power assistwill be immediately blocked after the power isturned on and the error will be displayed on thespeedometer section in display unit.
How communication errors are displayedAll segments of the assist mode indicator 1and battery capacity indicator 2 will flash atthe same time, and “Er” will be displayed onthe speedometer section 3 of display unit.When the function select switch “s” 4 ispressed, error code “12”, “13” or “15” will bedisplayed.
TIP• The error code is not stored.• See “List of error codes and corresponding
power assist operations” for more details.• If there is a communication error, the power
cannot be turned off using the “POWER”switch of the display unit. To turn the poweroff, remove the battery.
3
1
24
Slow flashing
2-29
ELEC – +
Diagnosis function (LCD type display unit)
How Drive Unit malfunctions are displayedAll segments of the assist mode indicator 1and all segments of the battery capacity indi-cator 2 will flash alternately, and “Er” will bedisplayed on the speedometer section 3 ofthe display unit. When the function selectswitch “s” 4 is pressed, error code “16” orhigher will be displayed.
TIP• Error codes are stored.• See “List of error codes and corresponding
power assist operations” for more details.
Alternatelyflashes
1
4
3
2
How speed sensor malfunctions are displayedThe “HIGH”, “STD”, or “ECO” assist mode indi-cator 1 are displayed with a slow flash (0.5seconds).The function display part 2 are displayed with“----” when you select as follwing functions.• Average bicycle speed• Maximum bicycle speed• Trip meter• Odometer
TIP• Error codes are not stored.• In assist off mode, displays of malfunctions
cannot be made using the assist mode dis-play.
• Average bicycle speed, maximum bicyclespeed, tripmeter, and odometer are notupdated when speed sensor malfunction isoccurred.
• See “List of error codes and correspondingpower assist operations” for more details.
Recovery method when there is a speed sensor malfunctionThe display will return to normal when thespeed sensor returns to normal condition.
1
2
Slow flashing
2-30
ELEC – +
Diagnosis function (LCD type display unit)
Operating Procedures to Diagnosis ModeThis is the mode in which each type of diagno-sis and the content of error codes which arestored when there is an error are displayed.You can switch between speed sensor diagno-sis mode, Drive Unit diagnosis mode, anderror log check mode by using the display unitaccording to the following procedures.1. Make sure that the power is turned off to the
display unit.Press the power switch “ ” 1 to turn onthe power.When the power is turned on, all segmentsof the display unit will come on.After approximately 2 seconds, the seg-ments will turn off, and then the display willreturn to normal.
2. Press the power switch “ ” 1 again, andcontinue pressing the switch until only the 3assist mode indicators 2 come on.(Approximately 10 seconds)Confirm that only the 3 assist mode indica-tors 2 have come on, and then release thepower switch “ ” 1.
TIPSteps 1 and 2 must be performed within 30seconds.
3. Press the assist mode switch “ ” 3 or“ ” 4 to change the assist mode.When the assist mode is changed, one ofthe assist mode indicators 2 will come on.You can select each diagnostic mode bychanging the assist mode.
4. Press the light switch “ ” 5.The “HIGH”, “STD”, or “ECO” assist modeindicator 2 will flash rapidly (0.2 second) toindicate each of the diagnostic modes.
TIPSteps 2-4 must be performed within 30 seconds.
If you pressed the wrong switch, turn off thepower and perform steps 1–4 again.
1
1
2
4
3
5
2-31
ELEC – +
Diagnosis function (LCD type display unit)
Speed Sensor Diagnosis ModePress the assist mode switch “ ” 1 until the“HIGH” assist mode indicator comes on.Press the light switch “ ” 3.The “HIGH” assist mode indicator flashes rap-idly (0.2 second).For more information about the speed sensordiagnosis mode, see “Speed sensor diagnosismode display method”.
Drive Unit Diagnosis ModePress the assist mode switch “ ” 1 → “ ”2 or “ ” 2 → “ ” 1 until the “STD” assistmode indicator comes on.Press the light switch “ ” 3.The “STD” assist mode indicator flashes rap-idly (0.2 second).For more information about the drive unit diag-nosis mode, see “Drive unit diagnosis modedisplay method”.
Error Log Check ModePress the assist mode switch “ ” 2 until the“ECO” assist mode indicator comes on.Press the light switch “ ” 3.The “ECO” assist mode indicator flashes rap-idly (0.2 second).For more information about the error log checkmode, see “Error log check mode”.
31
2
31
2
31
2
Fast flashing
2-32
ELEC – +
Diagnosis function (LCD type display unit)
Speed Sensor Diagnosis Mode Display MethodTo determine if the controller is correctly rec-ognizing the speed sensor signal, rotate thewheel to which the speed sensor is connectedand make sure that the number of rotations ofthe wheel indicated matches the actual num-ber of rotations.
1. Go into speed sensor diagnosis mode.See “Operating Procedures to DiagnosisMode.”Confirm that the assist mode display isflashing “HIGH” rapidly (0.2 seconds).
Fast flashing
2. When you raise and rotate the wheel (withthe speed sensor), the rotation numberdisplay 1 on the display unit will change.Before rotating the wheel (with the speedsensor), “0” will be displayed on the rotationnumber display 1 of the display unit.When you rotate the wheel (with the speedsensor) 1 time, “1” will be displayed on therotation number display 1 of the display unit.When you rotate the wheel (with the speedsensor) 12 times, “12” will be displayed onthe rotation number display 1 of the displayunit.When you rotate the wheel (with the speedsensor) 13 times, the display of the rotationnumber display 1 of the display unit willreturn to “1”.Thereafter, each time the wheel (with thespeed sensor) is rotated, the number ofrotations display 1 on the display unit will befrom “1” to “12”.
TIP• You should at least rotate the wheel (with the
speed sensor) 3 times and make sure that “3”is displayed.
• If the speed sensor malfunctions, the numberof rotations displayed on the display unit willincrease before the wheel (with the speedsensor) is rotated even once, or the numberwill not increase even when the wheel (withthe speed sensor) is rotated once (or there isa delay in the increase in the value).
Number of Wheel
Rotations
Rotation number display of the display unit
1 rotation
12 rotations
13 rotations
2-33
ELEC – +
Diagnosis function (LCD type display unit)
Drive Unit Diagnosis Mode Display MethodYou can check the status of or malfunctions inthe Drive Unit.
1. Go into Drive Unit in diagnosis mode.See “Operating Procedures to DiagnosisMode.”Confirm that the assist mode display isflashing “STD” fast (0.2 seconds).After the diagnosis mode indicator of thedisplay unit has displayed “1” for up to 10seconds, you can check the torque sensorreference voltage, motor current, error dis-plays (“E2”, “E4”), and the display unit func-tion check.
Fast flashing
List of Drive Unit Diagnosis Mode Display Methods
Inspection items
Diagno-sis mode display
Press operating
buttonDiagnosis data display
Press operating button
1) Torque sensor
reference voltage
Values are displayed from 0.0 to 5.0 (V)
To 2) Motor current
2) Motor current
Motor output current in “HIGH” mode is displayed as 0 to 100 (= % output).
To 3) Error display
3) Error display There is no display when there are no errors.When there is an error, either “E2” (motor) or “E4” (controller) are displayed.
To 4) Display unit function check
4) Display unit function check
All segments are illuminated(segments that are not illuminated indicate a malfunction.)
Power goes off
or
2-34
ELEC – +
Diagnosis function (LCD type display unit)
1. Torque sensor reference voltage display
a. “10” is displayed in the diagnosis mode dis-play 1 of the display unit.
b. Press the function select switch “s” of thedisplay unit.
c. Displayed in units of 0.1 V from 0.0 to 5.0 Vin the diagnosis data display 2 of the dis-play unit.
d. The torque sensor is normal if the displayvoltage is 0.2 to 1.1 V. Perform a torque sensor reference voltageadjustment if values outside of this rangeare displayed.
e. Press the light switch “ ” of the displayunit.
f. Proceed to 2) Motor current.
2. Torque sensor reference voltage adjustmentfunctionTurn the power on to the display unit and letit stand.Guideline: Until the power to the display
unit is turned off automatically(about 5 min.).
TIPDo not place feet on the pedals while perform-ing a torque sensor reference voltage adjust-ment.
1) Torque sensor reference voltage
* Determining whether or not the torque sen-sor is good0.2 to 1.1 V = normalIf the torque sensor is outside of this range→Implement the torque sensor reference
voltage adjustment function.If the torque sensor remains outside of itsnormal range after torque sensor referencevoltage adjustment→Torque sensor malfunction (replace)
2-35
ELEC – +
Diagnosis function (LCD type display unit)
a. “14” is displayed in the diagnosis mode dis-play 1 of the display unit.
b. Press the function select switch “s” of thedisplay unit.
c. The diagnosis data display 2 of the displayunit displays the motor output current (%)from “0” to “100”.
d. Confirm that the diagnosis data display 2 ofthe display unit displays “100” when apply-ing the rear brake and strongly pressing onthe pedals.• “100” is displayed: good• “100” is not displayed: If the bicycle was
ridden immediately before checking themotor current, it is possible that the bat-tery or the controller temperature controlis working; therefore, wait until the bicyclecools down. If the bicycle was not riddenimmediately before checking the motorcurrent, recheck using a battery that isoperating properly.
• “100” is not displayed: The batteryresponse is weak in winter (low tempera-tures), so use a battery that has beenstored in a heated room.
• “100” is not displayed: Replace the con-troller assembly.
e. Press the light switch “ ” of the displayunit.
f. Proceed to 3) Error displays.
2) Motor current
2-36
ELEC – +
Diagnosis function (LCD type display unit)
a. “16” is displayed in the diagnosis mode dis-play 1 of the display unit.
b. Press the function select switch “s” of thedisplay unit.
c. When there is a malfunction, “E2” (motor) or“E4” (controller) will be displayed on thediagnosis data display 2 of the display unit.
TIPCheck the error code if “E2” or “E4” are dis-played.
d. Press the light switch “ ” of the displayunit.
e. Proceed to 4) Display unit function check.
TIPCheck the error code if E2 or E4 are displayed.
• When there is no malfunction the next “18” isdisplayed without the diagnosis mode “16”being displayed.
• Perform a final check to make sure there isno error display in this mode when perform-ing repairs or replacing parts.
3) Error displays
or
a. “18” is displayed in the diagnosis mode dis-play 1 of the display unit.
b. Press the function select switch “s” 2 ofthe display unit.
c. All segments of the display unit 3 will illumi-nate.
d. Replace the display unit if there are seg-ments which are not illuminated.
e. Press the light switch “ ” 4 of the displayunit.
f. The power to the display unit is turned off.
4) Display unit function check
4
2
3
2-37
ELEC – +
Diagnosis function (LCD type display unit)
Error Log Check Mode Display MethodThe three most recent types of error codeswhich are stored when there is an error arestored and these are displayed in order fromthe most recent every 10 seconds.
1. Go into error log check mode.See “Operating Procedures to DiagnosisMode.”Confirm that the assist mode display isflashing “ECO” fast (0.2 seconds).The display unit displays the three mostrecent error codes in the order stored as“E1” to “E3”. To display the error codes,press the function select switch “ ” of thedisplay unit.“0” will be displayed when there are noerrors.When other error codes are stored, the dis-play will switch to the next error in 10 sec-onds.
Fast flashing
List of Error Log Check Mode Display Methods
Number of error codes
How error codes are displayed on the display unit
When there are no error codes
When there is 1 error code
When there are 2 error codes
When there are 3 error codes
Error code displays
([E1] along with the error code are displayed for 10 seconds)
Error code displays
([E2] along with the error code are displayed for 10 seconds)
Error code displays
Error code displays
Error code displays
Error code displays
([E1] along with the error code are displayed for 10 seconds)
([E2] along with the error code are displayed for 10 seconds)
([E3] along with the error code are displayed for 10 seconds)
2-38
ELEC – +
Diagnosis function (LCD type display unit)
How to delete the malfunction history1. While pressing the light switch “ ” 1 dur-
ing the error code display, press the assistmode switch power assist decrease 2 andpower assist increase 3 to switch.
2
3 1
Fast flashing
2. The diagnostic display pattern will stop, allsegment lights will turn on and off twice,and the history will be deleted.The power to the display unit will be turnedoff at this time.
TIPBe sure to clear the diagnosis history afterreplacing the motor or other parts.
Repeats 2 times
2-39
ELEC – +
Diagnosis function (LCD type display unit)D
iag
no
sis
fun
ctio
nL
ist
of
erro
r co
des
an
d c
orr
esp
on
din
g p
ow
er a
ssis
t o
per
atio
ns.
Dis
pla
y p
atte
rnF
ault
d
evic
eEr
ror
code
sF
ault
det
ails
Po
wer
ass
ist
beh
avio
r an
d e
rro
r co
de
reco
rd*R
esto
rati
on
Max
Lev
elA
ctio
n
Dis
play
uni
t
12S
topp
ed th
e co
mm
unic
atio
ns
to th
e di
spla
y un
it.
Pow
er a
ssis
t is
norm
al.
Err
or c
ode
does
not
rec
ord.
0R
epla
ce th
e di
spla
y un
it as
sem
-bl
y.
13C
omm
unic
atio
n da
ta fa
ilure
to
disp
lay
unit.
Dis
play
uni
t15
Dis
play
com
es o
ff fr
om th
e ho
lder
.
Pow
er a
ssis
t will
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
does
not
rec
ord.
0R
epla
ce th
e di
spla
y un
it as
sem
-bl
y.
Enc
oder
16D
isco
nnec
ted
or r
ed w
ire is
sh
ort-
circ
uite
d.P
ower
ass
ist w
ill im
med
iate
ly s
top
afte
r de
term
ine
the
erro
r.E
rror
cod
e w
ill r
ecor
d.1
1.C
heck
the
enco
der
conn
ecto
r.2.
Rep
lace
the
enco
der
lead
w
ire.
3.R
epla
ce th
e m
otor
ass
embl
y.17
Bla
ck w
ire is
sho
rt-c
ircui
ted.
Tor
que
Sen
-so
r
20D
isco
nnec
ted.
Pow
er a
ssis
t will
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
1
1.R
epla
ce th
e en
code
r le
ad
wire
.2.
Rep
lace
the
torq
ue s
enso
r as
sem
bly.
21S
hort
-circ
uite
d.
22W
iring
failu
re b
etw
een
the
torq
ue s
enso
r an
d th
e co
ntro
l-le
r.
or or
Alte
rnat
ely
flash
es
Alte
rnat
ely
flash
es
2-40
ELEC – +
Diagnosis function (LCD type display unit)
Tor
que
Sen
-so
r
23A
bnor
mal
vol
tage
. (de
tect
ed
durin
g ru
nnin
g / w
ith s
light
vo
ltage
ris
e)
Pow
er a
ssis
t will
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
2
1.P
erfo
rm th
e to
rque
sen
sor
ref-
eren
ce v
olta
ge a
djus
tmen
t.2.
Rep
lace
the
torq
ue s
enso
r as
sem
bly.
24A
bnor
mal
vol
tage
. (de
tect
ed
durin
g ru
nnin
g / w
ith h
igh
con-
stan
t vol
tage
)
25A
bnor
mal
vol
tage
. (de
tect
ed
durin
g ru
nnin
g / o
ther
s)
26A
bnor
mal
vol
tage
. (de
tect
ed
durin
g ru
nnin
g at
low
spe
eds)
27
Wiri
ng fa
ilure
bet
wee
n th
e co
il an
d th
e ci
rcui
t boa
rd. (
wire
ch
atte
ring:
nea
rly d
isco
n-ne
cted
)R
epla
ce th
e to
rque
sen
sor
asse
mbl
y.
28
Wiri
ng fa
ilure
bet
wee
n th
e co
il an
d th
e ci
rcui
t boa
rd. (
wire
ch
atte
ring:
nea
rly d
isco
n-ne
cted
)
29A
bnor
mal
no-
load
vol
tage
.
1.P
erfo
rm th
e to
rque
sen
sor
ref-
eren
ce v
olta
ge a
djus
tmen
t.2.
Rep
lace
the
torq
ue s
enso
r as
sem
bly.
30A
bnor
mal
vol
tage
.(d
etec
ted
durin
g ru
nnin
g/w
ith
high
con
stan
t vol
tage
.)2
Rep
lace
the
torq
ue s
enso
r as
sem
bly.
31A
bnor
mal
vol
tage
.(d
etec
ted
durin
g ru
nnin
g/w
ith
slig
ht v
olta
ge r
ise.
)
Dis
pla
y p
atte
rnF
ault
d
evic
eEr
ror
code
sF
ault
det
ails
Po
wer
ass
ist
beh
avio
r an
d e
rro
r co
de
reco
rd*R
esto
rati
on
Max
Lev
elA
ctio
n
or
Alte
rnat
ely
flash
es
Alte
rnat
ely
flash
es
2-41
ELEC – +
Diagnosis function (LCD type display unit)
Cra
nk s
en-
sor
32T
orqu
e se
nsor
or c
rank
sen
sor
failu
re.
Pow
er a
ssis
t will
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
1
1.R
epla
ce th
e to
rque
sen
sor.
2.R
epla
ce th
e cr
ank
sens
or.
3.R
epla
ce th
e en
cord
er le
ad
wire
.4.
Rep
lace
the
driv
e ax
le a
ssem
-bl
y.
33S
hort
-circ
uite
d or
cra
nk s
en-
sor
failu
re.
1.R
epla
ce th
e cr
ank
sens
or.
2.R
epla
ce th
e en
cord
er le
ad
wire
.3.
Rep
lace
the
driv
e ax
le a
ssem
-bl
y.
Mot
or
403
lead
wire
s ar
e di
scon
nect
ed.
Pow
er a
ssis
t will
imm
edia
tely
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
1
1.R
epla
ce th
e co
ntro
ller
asse
m-
bly.
2.R
epla
ce th
e m
otor
ass
embl
y.
41Y
ello
w le
ad w
ire is
dis
con-
nect
ed. (
U p
hase
)
Pow
er a
ssis
t will
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
Rep
lace
the
cont
rolle
r as
sem
bly.
42B
lue
lead
wire
is d
isco
n-ne
cted
. (V
pha
se)
43W
hite
lead
wire
is d
isco
n-ne
cted
. (W
pha
se)
Dis
pla
y p
atte
rnF
ault
d
evic
eEr
ror
code
sF
ault
det
ails
Po
wer
ass
ist
beh
avio
r an
d e
rro
r co
de
reco
rd*R
esto
rati
on
Max
Lev
elA
ctio
n
or
Alte
rnat
ely
flash
es
Alte
rnat
ely
flash
es
2-42
ELEC – +
Diagnosis function (LCD type display unit)
Mot
or o
r C
ontr
olle
r
50A
bnor
mal
vol
tage
of t
he s
en-
sor
for
U p
hase
cur
rent
whi
le
the
mot
or is
not
ope
ratin
g.
Pow
er a
ssis
t will
imm
edia
tely
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
1R
epla
ce th
e co
ntro
ller
asse
mbl
y.51
Abn
orm
al v
olta
ge o
f the
sen
-so
r fo
r V
pha
se c
urre
nt w
hile
th
e m
otor
is n
ot o
pera
ting.
52A
bnor
mal
vol
tage
of t
he s
en-
sor
for
W p
hase
cur
rent
whi
le
the
mot
or is
not
ope
ratin
g.
53O
ver
curr
ent i
s ap
plie
d to
the
U p
hase
of t
he m
otor
.
Pow
er a
ssis
t will
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
21.
Rep
lace
the
cont
rolle
r as
sem
-bl
y.2.
Rep
lace
the
mot
or a
ssem
bly.
54O
ver
curr
ent i
s ap
plie
d to
the
V p
hase
of t
he m
otor
.
55O
ver
curr
ent i
s ap
plie
d to
the
W p
hase
of t
he m
otor
.
56A
bnor
mal
DC
cur
rent
Pow
er a
ssis
t will
imm
edia
tely
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
1
60N
ot w
ithin
the
12V
out
put
rang
e
Pow
er a
ssis
t will
imm
edia
tely
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
1R
epla
ce th
e co
ntro
ller
asse
mbl
y.
70E
xter
nal m
emor
y da
ta e
rror
Pow
er a
ssis
t will
imm
edia
tely
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
1R
epla
ce th
e co
ntro
ller
asse
mbl
y.
71F
ailu
re in
dat
a re
adin
g
Dis
pla
y p
atte
rnF
ault
d
evic
eEr
ror
code
sF
ault
det
ails
Po
wer
ass
ist
beh
avio
r an
d e
rro
r co
de
reco
rd*R
esto
rati
on
Max
Lev
elA
ctio
n
or
Alte
rnat
ely
flash
es
Alte
rnat
ely
flash
es
2-43
ELEC – +
Diagnosis function (LCD type display unit)
Mot
or o
r C
ontr
olle
r
80D
etec
ted
circ
uit b
oard
tem
per-
atur
e is
too
low
. (–2
0°C
)
Pow
er a
ssis
t will
sto
p af
ter
dete
rmin
e th
e er
ror.
Err
or c
ode
will
rec
ord.
2R
epla
ce th
e co
ntro
ller
asse
mbl
y.81
Det
ecte
d ci
rcui
t boa
rd te
mpe
r-at
ure
is to
o hi
gh. (
125°
C)
(incl
udin
g D
C c
ircui
t)
82S
enso
r on
the
boar
d is
nea
rly
deta
ched
.
Oth
ers
89D
etec
ted
circ
uit b
oard
tem
per-
atur
e is
too
high
. (90
°C)
Pow
er a
ssis
t is
norm
al.
Err
or c
ode
will
rec
ord.
0
1.C
heck
the
envi
ronm
ent o
f us
age.
2.R
epla
ce th
e co
ntro
ller
asse
m-
bly.
Dis
pla
y p
atte
rnF
ault
d
evic
eEr
ror
code
sF
ault
det
ails
Po
wer
ass
ist
beh
avio
r an
d e
rro
r co
de
reco
rd*R
esto
rati
on
Max
Lev
elA
ctio
n
or
Alte
rnat
ely
flash
es
Alte
rnat
ely
flash
es
2-44
ELEC – +
Diagnosis function (LCD type display unit)
*Res
tora
tion
Max
Lev
el:
Ass
ist m
ode
lam
ps 1
are
di
spla
yed
with
a s
low
fla
shes
.F
unct
ion
disp
lays
2 a
re
disp
laye
d w
ith “
----
”.
Spe
ed S
en-
sor
–T
he v
ehic
le s
peed
has
not
go
ne o
ut th
ough
the
mot
or is
ro
tatin
g.
Pow
er a
ssis
t bec
omes
wea
k.E
rror
cod
e do
es n
ot r
ecor
d.0
1.C
heck
the
spee
d se
nsor
lead
co
nnec
tor.
2.C
heck
the
gap
betw
een
the
pick
up
and
the
mag
net s
enso
r sp
oke
type
. (S
ee “
Spe
ed s
en-
sor”
for
the
spec
ified
gap
.)3.
Rep
lace
the
spee
d se
nsor
set
.
–A
bnor
mal
wid
th o
f the
pul
se(d
etec
ted
durin
g ru
nnin
g)
All
segm
ents
or
LED
tu
rned
off
Bat
tery
90D
etec
ted
batte
ry v
olta
ge is
too
high
.(45
V)
Pow
er a
ssis
t will
sto
p af
ter
dete
rmin
e th
e er
ror.
(Als
o di
spla
y un
it w
ill tu
rn o
ff)E
rror
cod
e w
ill r
ecor
d.
1
Rep
lace
the
batte
ry.
All
segm
ents
or
LED
tu
rned
off.
Whe
n yo
u tu
rn o
n th
e m
ain
switc
h, a
ll se
gmen
ts o
r LE
D w
ill tu
rn o
n du
ring
4 se
cond
s, th
en a
utom
ati-
cally
turn
off.
91C
an’t
rece
ive
data
from
bat
-te
ry c
orre
ctly
.
Pow
er a
ssis
t will
imm
edia
tely
sto
p af
ter
dete
rmin
e th
e er
ror.
(Als
o di
spla
y un
it w
ill tu
rn o
ff)E
rror
cod
e w
ill r
ecor
d.
1.C
heck
the
batte
ry c
omm
unic
a-tio
n co
nnec
tor.
2.R
epla
ce th
e pl
ug D
C.
3.R
epla
ce th
e co
ntro
ller
asse
m-
bly.
4.R
epla
ce th
e ba
ttery
.
Leve
l
0If
the
syst
em d
etec
ts th
is e
rror
, the
pow
er a
ssis
t mod
e w
ill b
e do
wn
or tu
rns
to o
ff.B
ut w
hen
the
syst
em is
res
tore
d to
nor
mal
, the
pow
er a
ssis
t mod
e w
ill r
etur
n to
nor
mal
and
the
erro
r in
dica
tor
will
be
unsh
own
imm
edia
tely
.
1If
the
syst
em d
etec
ts th
is e
rror
pre
scrib
ed n
umbe
r of
tim
es, t
he p
ower
ass
ist m
ode
turn
s to
off
and
the
erro
r in
dica
tor
is d
ispl
ayed
on
the
disp
lay
unit.
But
they
can
ret
urn
to n
orm
al, i
f the
sys
tem
will
not
det
ect a
ny e
rror
s w
hen
the
pow
er is
cyc
led.
2If
the
syst
em d
etec
ts th
is e
rror
pre
scrib
ed n
umbe
r of
tim
es, t
he p
ower
ass
ist m
ode
turn
s to
off,
and
the
erro
r in
dica
tor
is d
ispl
ayed
on
the
disp
lay
unit.
The
y ca
n no
t ret
urn
to n
orm
al, e
ven
if th
e po
wer
is c
ycle
d.
Dis
pla
y p
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1 2
1
2-45
ELEC – +
Speed sensor set
Speed sensor setSpeed sensor inspection1. Pickup• Check that the pickup is installed at the
specified location on the bike.• Check that the pickup is not damaged.
2. Magnet sensor
a. Check that the magnet sensor is not dam-aged.
b. Check that no metallic foreign material hasadhered to the magnet sensor.
c. Check that the magnetic surface of the mag-net sensor is facing the sensing point on thepickup.
d. Install the magnet sensor to match the cen-ter of the magnet sensor and the cutoutpoint a of the pickup.
e. Check that the center location of the magnetsensor 1 is within specification.
f. Check that the gap 2 between the pickupand the magnet sensor is within specifica-tion.
Center location of the magnet sensor 1
5 mm
Gap (between the pickup and magnet sensor) 2
10 mm or less
Magnet sensor
Pickup
1 1
2
a
3-1
Drive Unit
Drive UnitDrive axle, Motor (drive axle with square-type end)
FWDFWD
1
11 12
13
31
32
10
30
29
25
22
19
2120
2627 28
18
1716
23
24
33
7 65
23
4
89
14
15LS
New
New
4.5 Nm (0.45 kgf • m)T.R.40 Nm (4.0 kgf • m)T.R.
1.3 Nm (0.13 kgf • m)T.R.0.75 Nm (0.075 kgf • m)T.R.
4.5 Nm (0.45 kgf • m)T.R.
* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.
Order Job/Part Q’ty RemarksRemoval of the Drive axle,Motor
Follow the work procedures for removal.
Drive Unit assembly1 Lock nut 1 Left-hand screw2 Sprocket 13 Spacer 14 Spider 1 for spider type only5 Button head bolt 36 Cover assembly 17 Stator cover 18 Flanged bolt 69 Housing complete 1
Drive axle, Motor (drive axle with square-type end)
3
3-2
Drive UnitDrive axle, Motor (drive axle with square-type end)
FWDFWD
1
11 12
13
31
32
10
30
29
25
22
19
2120
2627 28
18
1716
23
24
33
7 65
23
4
89
14
15LS
New
New
4.5 Nm (0.45 kgf • m)T.R.40 Nm (4.0 kgf • m)T.R.
1.3 Nm (0.13 kgf • m)T.R.
0.75 Nm (0.075 kgf • m)T.R.
4.5 Nm (0.45 kgf • m)T.R.
* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.
Order Job/Part Q’ty Remarks10 Plate washer 111 Oil seal 112 Clutch boss assembly 113 One-way outer boss 114 Driven gear assembly 115 Gear cover 116 Heat-dissipating sheet 117 Heat-dissipating sheet 118 Tapping screw 519 Wire lead 1 couplers 2 Disconnect.20 Wire lead 3 couplers 1 Disconnect.21 Wire lead 4 couplers 1 Disconnect.
3
3-3
Drive UnitDrive axle, Motor (drive axle with square-type end)
FWDFWD
1
11 12
13
31
32
10
30
29
25
22
19
2120
2627 28
18
1716
23
24
33
7 65
23
4
89
14
15LS
New
New
4.5 Nm (0.45 kgf • m)T.R.40 Nm (4.0 kgf • m)T.R.
1.3 Nm (0.13 kgf • m)T.R.
0.75 Nm (0.075 kgf • m)T.R.
4.5 Nm (0.45 kgf • m)T.R.
* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.
Order Job/Part Q’ty Remarks22 Wire lead 5 couplers 1 Disconnect.23 Controller assembly 1 NOTICE
• Do not touch the circuit board with greasy or dirtyfingers.
• Do not drop the circuit board or subject it toimpact.
24 Wire lead 2 125 Wire lead 1 126 Wire lead 3 127 Wire lead 4 128 Wire lead 5 129 Tapping screw 230 Holder 1
3-4
Drive UnitDrive axle, Motor (drive axle with square-type end)
FWDFWD
1
11 12
13
31
32
10
30
29
25
22
19
2120
2627 28
18
1716
23
24
33
7 65
23
4
89
14
15LS
New
New
4.5 Nm (0.45 kgf • m)T.R.40 Nm (4.0 kgf • m)T.R.
1.3 Nm (0.13 kgf • m)T.R.
0.75 Nm (0.075 kgf • m)T.R.
4.5 Nm (0.45 kgf • m)T.R.
* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.
Order Job/Part Q’ty Remarks31 Torque sensor assembly 132 Drive axle 1 Both end shapes of the drive axle is different by the
specifications of Drive Unit.33 Motor complete 1
Reverse the removal process for installation.
3-5
Drive UnitDrive axle, Motor (drive axle with spline-type end [ISIS])
Drive axle, Motor (drive axle with spline-type end [ISIS])
FWDFWD
3
2
21
1
11 12
13
31
32
10
30
29
25
22
19
2120
2627 28
18
1716
23
24
33
4
89
14
15
New
New
LS
7 65
4.5 Nm (0.45 kgf • m)T.R.
40 Nm (4.0 kgf • m)T.R.
1.3 Nm (0.13 kgf • m)T.R.
0.75 Nm (0.075 kgf • m)T.R.
25.5 Nm (2.55 kgf • m)T.R.
4.5 Nm (0.45 kgf • m)T.R.
* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.
Order Job/Part Q’ty RemarksRemoval of the Drive axle,Motor
Follow the work procedures for removal.
Drive Unit assembly1 Screw 22 Adapter 23 Lock nut 1 Left-hand screw4 Spider 15 Button head bolt 36 Cover assembly 17 Stator cover 18 Flanged bolt 69 Housing complete 1
3-6
Drive UnitDrive axle, Motor (drive axle with spline-type end [ISIS])
FWDFWD
3
2
21
1
12 13
14
32
33
11
31
30
26
23
20
2221
2728 29
19
1817
24
25
34
8
7 6
5
4
910
15
16LS
New
New
New
4.5 Nm (0.45 kgf • m)T.R.
40 Nm (4.0 kgf • m)T.R.
1.7 Nm (0.17 kgf • m)T.R.
0.75 Nm (0.075 kgf • m)T.R.
4.5 Nm (0.45 kgf • m)T.R.
25.5 Nm (2.55 kgf • m)T.R.
* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.
Order Job/Part Q’ty Remarks10 Plate washer 111 Oil seal 112 Clutch boss assembly 113 One-way outer boss 114 Driven gear assembly 115 Gear cover 116 Heat-dissipating sheet 117 Heat-dissipating sheet 118 Tapping screw 519 Wire lead 1 couplers 2 Disconnect.20 Wire lead 3 couplers 1 Disconnect.21 Wire lead 4 couplers 1 Disconnect.
3-7
Drive UnitDrive axle, Motor (drive axle with spline-type end [ISIS])
FWDFWD
3
2
21
1
12 13
14
32
33
11
31
30
26
23
20
2221
2728 29
19
1817
24
25
34
8
7 6
5
4
910
15
16LS
New
New
New
4.5 Nm (0.45 kgf • m)T.R.
40 Nm (4.0 kgf • m)T.R.
1.7 Nm (0.17 kgf • m)T.R.
0.75 Nm (0.075 kgf • m)T.R.
4.5 Nm (0.45 kgf • m)T.R.
25.5 Nm (2.55 kgf • m)T.R.
* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.
Order Job/Part Q’ty Remarks22 Wire lead 5 couplers 1 Disconnect.23 Controller assembly 1 NOTICE
• Do not touch the circuit board with greasy or dirtyfingers.
• Do not drop the circuit board or subject it toimpact.
24 Wire lead 2 125 Wire lead 1 126 Wire lead 3 127 Wire lead 4 128 Wire lead 5 129 Tapping screw 230 Holder 1
3-8
Drive UnitDrive axle, Motor (drive axle with spline-type end [ISIS])
FWDFWD
3
2
21
1
12 13
14
32
33
11
31
30
26
23
20
2221
2728 29
19
1817
24
25
34
8
7 6
5
4
910
15
16LS
New
New
New
4.5 Nm (0.45 kgf • m)T.R.
40 Nm (4.0 kgf • m)T.R.
1.7 Nm (0.17 kgf • m)T.R.
0.75 Nm (0.075 kgf • m)T.R.
4.5 Nm (0.45 kgf • m)T.R.
25.5 Nm (2.55 kgf • m)T.R.
* The actual lead wire may differ with the variety of Drive Unit from the pictures shown.
Order Job/Part Q’ty Remarks31 Torque sensor assembly 132 Drive axle 1 Both end shapes of the drive axle is different by the
specifications of Drive Unit.33 Motor complete 1
Reverse the removal process for installation.
3-9
Drive UnitDrive axle, Motor
Removal of the parts from the drive axle (drive axle with square-type end)1. Remove the following parts:• Locknut (Left-hand screw)• Drive sprocket or spider• Spacer (for sprocket only)• Flanged bolt
Removal of the parts from the drive axle (drive axle with spline-type end)1. Remove the following parts:• Screw• Adapter• Locknut (Left-hand screw)• Spider• Flanged bolt
Removal of the Controller Assembly1. Separate the housing complete from the
motor complete.
TIPSeparator ribs a are provided in 3 locationsfor separating the housing complete.
NOTICE
• Take care not to scratch the mating sur-faces of the housing complete and themotor complete with screwdrivers orother tools.
• Take care not to damage the boards ofthe controller assembly and the torquesensor assembly with tools.
a
a
a
3-10
Drive UnitDrive axle, Motor
2. Remove the following parts:• Plate washer 1• Clutch boss assembly 2
12
3. Remove the following parts:• One-way outer boss 1• Driven gear assembly 2• Gear cover 3
1
3
2
4. Remove the following parts:• Heat-dissipating sheet 1• Tapping screw 2
2
1
5. Disconnect the following couplers:• Wire lead 1 couplers 1• Wire lead 3 coupler 2• Wire lead 4 coupler 3• Wire lead 5 coupler 4
2
4
3
1
6. Remove the following part:• Controller assembly 1
NOTICEPrecautions
• Do not touch the board of the controllerassembly with greasy or dirty fingers.
• Do not drop the board or subject it toimpact.
1
3-11
Drive UnitDrive axle, Motor
Removal of the Torque sensor assembly and Drive axle.1. Remove the following parts:• Tapping screw 1• Holder 2• Torque sensor assembly 3• Drive axle 4
NOTICE
Do not disassemble the torque sensorassembly because it cannot be readjusted.
Installation of the Drive axle and Controller assembly1. Install the following parts:• Drive axle 1• Torque sensor assembly 2• Holder 3• Tapping screw 4
TIPTIP
When installing the drive axle, align the cut outparts a of the torque sensor assembly 2 withthe projections b on the motor complete 5.
2
4
3 1
T R..
0.75 Nm ( 0.075 kgf·m)
1
3
5
b
a
2
4
Installation of the Controller assembly1. Install the following parts and connect the
following couplers:• Controller assembly• Wire lead 5 coupler• Wire lead 4 coupler• Wire lead 3 coupler• Wire lead 1 coupler• Tapping screw
NOTICETIP
The tapping screw of the controller assem-bly must be installed because it also servesas a ground.
T R..
1.3 Nm ( 0.13 kgf·m)
3-12
Drive UnitDrive axle, Motor
2. Install the following part:• Heat-dissipating sheet 1
NOTICEPrecautions
Thermal protection may be compromisedby an ill-fitting heat-dissipating sheet, sobe sure to replace the heat-dissipatingsheet with a new one when the assembly isdisassembled.
TIPTIP
• Put the heat-dissipating sheet to designatedlocation of controller.
• The heat-dissipating sheet should not bestretched more than 10% beyond its originaldimensions.
1 New
3. Install the following parts:• Gear cover• Driven gear assembly• One-way outer boss• Clutch boss assembly• Plate washer
TIPWhen installing the gear cover, align the pro-jections a of the gear cover with the cut outparts b of the motor complete.
ab
ab
3-13
Drive UnitDrive axle, Motor
Installation of the Bearing Housing1. Apply Three Bond 1215® to the following
parts:• Housing complete 1
Apply a continuous 2 to 3 mm thick coatingas shown in the drawing (area indicated bydark line).
TIPTIP
• Before applying the sealant, thoroughlyclean all the mating surface of housing com-plete and motor complete.
• If there is any oil or grease on the housingcomplete or motor complete mating sur-faces, wipe the surfaces clean and thenapply sealant.
• Within 5 min. after applying the sealant, jointhe left and right halves together.
Three Bond 1215®
sealant1
2. Install the following part:• Housing complete T R.
.
4.5 Nm (0.45 kgf·m)
3-14
Drive UnitDrive axle, Motor
Installation of the Stator Cover1. Apply Three Bond 1215® to the following
parts:• Motor complete 1
Apply a continuous 2 to 3 mm thick coatingas shown in the drawing (area indicated bydark line).
TIPTIP
• Before applying the sealant, thoroughlyclean all the mating surface of stator coverand motor complete.
• Within 5 min. after applying the sealant, jointhe left and right halves together.
Three Bond 1215®
sealant
1
2. Install the following part: • Damper rubber 1• Stator cover 2
TIPTIP
• When assembling the stator cover, handtighten the three flanged bolts and thentighten them evenly.
• Install the Damper rubber 1 inside the statorcover.
• Be sure to replace the Damper rubber 1with a new one when the assembly is disas-sembled.
1
2
New
T R..
4.5 Nm (0.45 kgf·m)
2
4-1
Service Data
Service DataTightening Torque
Unit: Nm kgf·m (in)
Other, general tightening torquesThe tightening torques of bolts and nuts other than those with tightening force for specified locationsis determined by the screw diameter (width between two surfaces) and the pitch.
Lubricants, areas to apply sealant and specified types
Tightening locations Screw diameter Q’ty Tightening
torque Notes
Drive sprocket lock nut M27 1 40 (4.0) Left hand screwStator cover installation M5 3 4.5 (0.45)Motor assembly and bearing housing M5 6 4.5 (0.45)Circuit board installation M3 5 1.3 (0.13) Self-tapping screwHolder installation M3 2 0.75 (0.075) Self-tapping screwLCD type display holder M3 2 0.3 (0.03)ISIS adapter installation M8 2 25.5 (2.55) Torx T30
Screw diameter (width between two surfaces) ×
pitchTightening torque
M4 (7 mm) × P0.71.5 to 2.5 Nm
(0.15 to 0.25 kgf·m)
M5 (8 mm) × P0.83 to 4.5 Nm
(0.3 to 0.45 kgf·m)
M6 (10 mm) × P1.05 to 8 Nm
(0.5 to 0.8 kgf·m)
M8 (12 mm) × P1.2512 to 19 Nm
(1.2 to 1.9 kgf·m)
Where to apply Types of oils, grease, and sealants
All oil seal lips Lithium grease made from synthetic hydrocarbon oil andsynthetic ester oil (MULTEMP AC-N®)
Pawl kicks Lithium grease made from synthetic hydrocarbon oil andsynthetic ester oil (MULTEMP AC-N®)
Drive axle O-rings Lithium-soap-based greaseInterior of torque sensor bushing Lithium grease made from synthetic hydrocarbon oil and
synthetic ester oil (MULTEMP AC-N®)Spline of torque sensor Lithium grease made from synthetic hydrocarbon oil and
synthetic ester oil (MULTEMP AC-N®)Interiors of the drive axle assemblyand the one-way inner/outer bosses
Lithium grease made from synthetic hydrocarbon oil andsynthetic ester oil (MULTEMP AC-N®)
All driven gear surfaces Lithium grease made from synthetic hydrocarbon oil andsynthetic ester oil (MULTEMP AC-N®)
Motor assembly’s surface which con-tact to the gromet of power lead wire.
Lithium-soap-based grease
Mating surfaces between motorassembly and bearing housing
Three Bond 1215®
Width between surfaces
Screw diameter
Pitch
Tightening Torque/Lubricants, areas to apply sealant and specified types
4
4-2
Service DataCable, Wire, and Pipe routing diagram
Cable, Wire, and Pipe routing diagram1 Wire lead 22 Torque sensor plate3 Wire lead 3 (Yellow)4 Wire lead 4 (Blue)5 Wire lead 5 (White)6 Controller assembly7 Heat-dissipating sheet8 Wire lead 19 Wire lead 1 couplers 10 Wire lead 1 couplers 2
A Crank sensor
È Torque sensor positioner.É Apply the heat-dissipating sheet so
that it does not protrude from theheat sink plate. The heat-dissipat-ing sheet should not be stretchedbeyond 10% of its original dimen-sions.
Ê Route the encoder lead wiresthrough the outer side of holderprojections as shown in the draw-ing.
*The actual lead wire may differ with the variety of Drive Unit from the pictures shown.
3
15
4
0
9
7É
Ê
È
2A
8
6
4
4-3
Service DataTroubleshooting
TroubleshootingSymptom Check point/method Possible cause/check Part replacement/action
The pedal feels heavy.
Is the air pressure in the tires normal?
Check for appropriate air pressure.Check for punctures.
Repair puncture, replace tube.
Is the gear-shifting working smoothly?
Check the gear shifting sys-tem.
Replace the gear shifting sys-tem.
Is it being driven up a long slope in the summer, or car-rying a heavy load?
This is due to the tempera-ture rising in the battery pack or the Drive Unit assembly, and is not a malfunction.
The assist power is restored once the temperature of the battery pack or the Drive Unit assembly drops.
Is the ambient temperature low (around 10°C or below)?
Check the ambient tempera-ture.
During the winter, store the battery pack indoors before use.
The e-bike systems activates and cuts off during driving.
Is the battery pack securely locked?
Check the battery pack lock.
Check if the battery pack is securely locked.Inspect the battery pack ter-minals and wiring for loose connection.
The cruising distance is short.
Has the battery pack been sufficiently charged?
Charge until full.
Is it being used in a low-tem-perature environment?
Check the ambient tempera-ture.
This will be restored when the ambient temperature warms up.
Is the battery pack degrad-ing?
Check the battery pack’s Total number of battery charging cycles , actual capacity.
Replace the battery pack.
The 3 assist mode lamps, the “%” lamp, the “Km” lamp, and the “km/h” lamp are flashing at the same time, and “Er” is displaying on the LED type display unit.
Check the error according to the display on the display unit when the error occurred.(See Chapter 2 “How com-munication errors are dis-played”.)
Communication error.Check the “List of error codes and corresponding power assist operations”.
Replace parts according to “List of error codes and corre-sponding power assist opera-tions”.
All segments of the assist mode display and battery capacity indicator are flash-ing at the same time, and “Er” is displaying on the speed-ometer section of the LCD type display unit.
4-4
Service DataTroubleshooting
The 3 assist mode lamps, the “%” lamp, the “km” lamp, and the “km/h” lamp are flashing alternately, and “Er” is dis-playing on the LED type dis-play unit.
Check the error log according to the display on the display unit when the error occurred.(See Chapter 2 “How Drive Unit malfunctions are dis-played”.)
Drive Unit assembly error.Check “List of error codes and corresponding power assist operations”.
Replace parts according to “List of error codes and corre-sponding power assist opera-tions”.
All segments of the assist mode display and battery capacity indicator are flash-ing alternately, and “Er” is displaying on the speedome-ter section of the LCD type display unit.
One of the assist mode lamps in the display unit 1 is flashing.
Speed sensor set(See Chapter 2 “How speed sensor malfunctions are dis-played”.)
A state persists where the speed sensor unit cannot detect the signal correctly.
Inspect the speed sensor set lead wires, pick up, and mag-net sensor spoke type.
Symptom Check point/method Possible cause/check Part replacement/action
Alternatelyflashes
Alternatelyflashes
or
1
1
4-5
Service DataTroubleshooting
Although the power to the display unit is turned on, all of the LED display of the LED type display unit turn on for 4 seconds, and then the power turns off automatically.
Battery pack signal lead wires(See Chapter 2 “When the battery pack signal lead wire becomes disconnected”.)
Disconnection of signal lead wires in the battery pack.
Replace the lead wires for the DC plug or the power supply.
Although the power to the display unit is turned on, all segments of the LCD type display unit turn on for 4 sec-onds, and then the power turns off automatically.
Charged the battery pack, but the residual battery capacity display lamp on the display unit does not show [FL].
Was the charging started immediately after driving, or when the battery pack tem-perature was high?
Recharge the battery in a location where the tempera-ture is suitable for charging (0 to 45°C).
All four residual residual bat-tery capacity display lamp on the battery pack are slow flashing simultaneously while charging the battery pack.
This is not a malfunction. On standby for charging.
The charging will start once the internal temperature of the battery pack is within the 0 to 45°C range.
When pressing the battery capacity indicator button on the battery pack, all four bat-tery capacity indicator lamps flash slowly at the same time.
This is not a malfunction.See chapter 2 “Temperature protection function”.
The battery pack automati-cally recovers when the bat-tery pack’s internal temperature returns to the allowable temperature for charging.
Symptom Check point/method Possible cause/check Part replacement/action
after4 seconds
after4 seconds
4-6
Service DataTroubleshooting
When pressing the battery capacity indicator button on the battery pack, lamps [1]/[3] and [2]/[4] or [1]/[2] and [3]/[4] turn on alternately.
Hold down the battery capac-ity indicator button on the bat-tery pack for 10 seconds.(See Chapter 2 “Error diag-nosis mode”.)
(See Chapter 2 “Battery pack/battery charger diagno-sis items table”.)
Replace the parts according to “Battery pack/battery charger diagnosis items table”.
The battery capacity indicator lamps [1] and [4] on the bat-tery pack flash simulta-neously.
Hold down the battery capac-ity indicator button on the bat-tery pack for 10 seconds.(See Chapter 2 “Battery pack protection function diagnosis mode”.)
(See Chapter 2 “Batterypack/battery charger diagno-sis items table”.)
Replace the battery pack.
After disconnecting the charging plug on the battery charger from the battery pack, the battery capacity indicator lamps continue to light.
Charging connector on the battery pack.
Charging connector and charging plug are wet.
Clean the charging connector and charging plug, and dry them.
Abnormal sound is produced from the Drive Unit assembly.
Assist driving
Abnormal sound is produced during assist driving.
Check for sprocket wear or stretched chain
Abnormal sound is produced when the motor is operating.
Disassemble the Drive Unit.Inspect the driven gear.Replace the motor assembly.
Turn the crank.Turning the crank produces periodic abnormal sound.
Inspect the housing bearing.Inspect the bearing.
Turn off the power for manual pedalling.
Stepping on the pedal pro-duces abnormal sound and vibration (clicking).
Check the joints.If further tightening does not improve the problem, replace parts.
Symptom Check point/method Possible cause/check Part replacement/action
Yamaha X94 Series Service Manual7th edition
Published October 2014Unauthorized reproduction prohibitedPublished by: Yamaha Motor Co., Ltd.
SERVICE MANUAL
e-Bike SYSTEMS
X94 Series