Yamaha X94 Series Service Manual
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Yamaha X94 Series Service Manual

Yamaha X94 Series Service Manual

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SERVICE MANUAL
e-Bike SYSTEMS
X94 Series

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  • Page 1 SERVICE MANUAL e-Bike SYSTEMS X94 Series...

  • Page 2: Electrical Components

    How to Use This Manual Searching for Manual Contents 1. Refer to the table on the following page to determine the applicable parts according to the model type code and product code. 2. This manual is divided into four parts: Gen- eral information, electrical components, Drive Unit, and service data.
  • Page 5 Index General Information INFO – Electrical Components ELEC Drive Unit Drive Unit Service Data Service Data...

  • Page 6: Table Of Contents

    CONTENTS CHAPTER 1 General Information Description ....................P1-1 Precautions relating to maintenance (1)............ P1-2 Cleaning and Maintenance ..............P1-2 Keep away from fire................P1-2 Proper tools ..................P1-2 Replacement parts................P1-3 Precautions for disassembly and reassembly ........P1-3 Handling the Battery Pack ..............P1-4 Servicing Precautions (2)................
  • Page 7 Diagnosis function ................P2-39 Speed sensor set ..................P2-45 Speed sensor inspection ..............P2-45 CHAPTER 3 Drive Unit Drive axle, Motor (drive axle with square-type end) ......... P3-1 Drive axle, Motor (drive axle with spline-type end [ISIS adapter]) ..P3-5 Removal of the parts from the drive axle (drive axle with square-type end)............

  • Page 8: Chapter 1 General Information

    Description INFO General Information Description È É 1. Drive Unit 4. Battery charger 5. Battery pack (The battery may differ depend- 2. Speed sensor set ing on the model.) a) Magnet sensor spoke type b) Pick up 3. È Display Unit (LED type) É...

  • Page 9: Precautions Relating To Maintenance (1)

    Precautions relating to maintenance (1) INFO Precautions relating to maintenance (1) Cleaning and Maintenance NOTICE When washing the bicycle, keep water away from the e-bike system. Water which comes in direct contact with the e-bike system can get inside and reduce performance.

  • Page 10: Replacement Parts

    Genuine pins, circlips (split rings), lock washers, etc. parts with new parts. Be sure to use genuine new Yamaha parts and recommended parts for oils and greases, including periodic replacement parts and repair parts. Do not use used parts because, even though...

  • Page 11: Handling The Battery Pack

    Precautions relating to maintenance (1) INFO Handling the Battery Pack 1. Use the dedicated battery charger for charging the battery pack. 2. The battery pack is a dedicated e-bike sys- tem battery. If it is connected to a product other than the e-bike system, it will cause a fluid leakage, “overheating, or breakage.”...

  • Page 12: Servicing Precautions (2)

    Servicing Precautions (2) INFO Servicing Precautions (2) Bearing Installation 1. When installing a bearing, the surface with the manufacturer’s mark and the size code should face outward. 2. When striking a bearing into the case, apply a parallel force to the outer race. 3.

  • Page 13: Precautions Relating To Maintenance (3)

    Precautions relating to maintenance (3) INFO Precautions relating to maintenance (3) Handling of the torque sensor 1. Keep away from magnets. 7. Do not reuse damaged drive axles. Do not use magnetized screwdrivers or per- The sensor shaft and the drive axle slide in form maintenance near large sources of a metal bearing.

  • Page 14: Specialized Tools And Equipment

    Specialized tools and equipment INFO Specialized tools and equipment The appropriate specialized tools must be used for inspection, adjustment, disassembly, and reas- sembly. Maintenance problems and mechanical breakage can be prevented by using the appropriate spe- cialized tools. ® Lithium soap based grease MULTEMP AC-N Lithium grease made from synthetic hydrocarbon All-purpose type grease with excellent water and...

  • Page 15: Chapter 2 Electrical Components

    – ELEC Electrical component wiring diagram Electrical Components Electrical component wiring diagram...

  • Page 16: Battery Pack

    – ELEC Battery pack Battery pack Battery pack display function By holding down the battery capacity indicator button “ ” on the battery pack, the following items can be checked. Length of time that the button is Display item Display time Details Page pushed...
  • Page 17 – ELEC Battery pack 3. If the battery capacity indicator lamps [1] and [4] are fast flash simultaneously when the battery capacity indicator button “ ” is pushed or connect the battery charger, see “Non-recoverable errors of battery pack”. (P. 2-10) Fast flashing 4.

  • Page 18: How To Check The Total Number Of Battery Charging Cycles

    – ELEC Battery pack How to check the total number of battery charging cycles Check the total number of battery charging cycles as follows: 1. Hold down the battery capacity indicator ” 1 for 20 seconds. button “ 2. The total number of battery charging cycles is indicated by the four battery capacity indi- cator lamps 2 on the battery pack.

  • Page 19: How To Check The Absolute Battery Capacity

    – ELEC Battery pack How to check the absolute battery capacity Check the * absolute battery capacity as fol- lows: 1. Hold down the battery capacity indicator ” 1 for 30 seconds. button “ 2. The * absolute battery capacity is indicated by the four battery capacity indicator lamps 2 on the battery pack.

  • Page 20: Charging

    – ELEC Charging Charging e-Bike system dedicated battery charger This battery charger 1 is a dedicated battery charger for the e-Bike system’s battery pack. Example of display on battery capacity display lamps on the battery pack while charging Preliminary charging When starting charge from a discharged state Fast flashing...

  • Page 21: Display On Battery Capacity Indicator Lamps While Charging

    – ELEC Charging Display on battery capacity indicator lamps while charging Some phenomena such as the following may occur while charging the battery pack, depend- ing on the battery pack’s state; however, these are not malfunctions. 1. Charging on stand-by Display on the battery capacity indicator lamps on the battery pack: [All four lamps flashing slowly at the same time].

  • Page 22: Diagnosis Mode

    – ELEC Diagnosis mode Diagnosis mode Recoverable errors of battery pack or battery charger If the battery pack or battery charger has the errors, the following procedure can be used to access the error diagnosis mode and confirm Turn on alternately the details regarding the error of the battery pack or battery charger.

  • Page 23: Battery Pack/Battery Charger Diagnosis Items

    – ELEC Diagnosis mode...
  • Page 24 – ELEC Diagnosis mode 2-10...

  • Page 25: Non-Recoverable Errors Of Battery Pack

    – ELEC Diagnosis mode Non-recoverable errors of battery pack If the battery pack has the errors, the following procedure can be used to access the error diagnosis mode and confirm the details regarding the error of the battery pack. 1. If there is a non-recoverable errors when the battery capacity indicator button “...
  • Page 26 – ELEC Diagnosis mode 2-12...
  • Page 27 – ELEC Diagnosis mode When the battery pack signal lead wire becomes disconnected Although the power to the display unit is turned • All of the LED displays of the display unit (LED type) turn on for 4 seconds, and then the power turns off automatically (LED) È...

  • Page 28: Temperature Protection Function

    – ELEC Diagnosis mode Temperature protection function If the battery pack’s internal temperature is -20°C or less or 80°C or higher while the battery pack is discharging (during the power assist), the tem- perature protection function of the battery pack operates and the battery pack stops discharging.

  • Page 29: Over-Discharge Protection Function

    – ELEC Diagnosis mode Over-discharge protection function If the battery pack becomes over-discharged, the over-discharge protection function of the battery pack operates. If the battery capacity indicator button “ ” is pushed at this time, the battery capacity indi- cator lamps do not turn on. The following procedure can be used to access the over-discharge protection function diagnostic mode and confirm the details...
  • Page 30 – ELEC Diagnosis mode 2-16...

  • Page 31: Diagnosis Function (Led Type Display Unit)

    – ELEC Diagnosis function (LED type display unit) Diagnosis function (LED type display unit) Display unit’s display when there is an error Detects system malfunctions, changes assist operation, and displays the errors as well as performing error code recording. Error displays are indicated by the display of “Er”...
  • Page 32 – ELEC Diagnosis function (LED type display unit) How Drive Unit malfunctions are displayed The 3 assist mode lamps 1, the “%” lamp 2, the “km” lamp 3, and the “km/h” lamp 4 will flash alternately, and “Er” will be displayed on the function display 5 of the display unit.

  • Page 33: Operating Procedures To Diagnosis Mode

    – ELEC Diagnosis function (LED type display unit) Operating Procedures to Diagnosis Mode This is the mode in which each type of diagno- sis and the content of error codes which are stored when there is an error are displayed. You can switch between speed sensor diagno- sis mode, Drive Unit diagnosis mode, and error log check mode by using the display unit...
  • Page 34 – ELEC Diagnosis function (LED type display unit) Speed Sensor Diagnosis Mode ” 1 until the Press the assist mode switch “ “HIGH” assist mode lamp is illuminated. Press the light switch “ ”. The “HIGH” assist mode lamp flashes rapidly (0.2 second).
  • Page 35 – ELEC Diagnosis function (LED type display unit) Speed Sensor Diagnosis Mode Display Method To determine if the controller is correctly rec- ognizing the speed sensor signal, rotate the wheel to which the speed sensor is connected and make sure that the number of rotations of the wheel indicated matches the actual num- ber of rotations.

  • Page 36: Drive Unit Diagnosis Mode Display Method

    – ELEC Diagnosis function (LED type display unit) Drive Unit Diagnosis Mode Display Method You can check the status of or malfunctions in the Drive Unit. 1. Go into Drive Unit diagnosis mode. See “Operating Procedures to Diagnosis Mode.” Confirm that the “STD” of the assist mode lamps is flashing fast.
  • Page 37 – ELEC Diagnosis function (LED type display unit) 1) Torque sensor reference voltage 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 “ ”...
  • Page 38 – ELEC Diagnosis function (LED type display unit) 2) Motor current a. “14” is displayed in the diagnosis mode dis- play 1 of the display unit. b. Press the function select switch “ ” button of the display unit. c. The diagnosis data display 2 of the display unit displays the motor output current (%) from “00”...
  • Page 39 – ELEC Diagnosis function (LED type display unit) 3) Error displays a. “16” is displayed in the diagnosis mode dis- play 1 of the display unit. b. Press the function select switch “ ” of the display unit. c. When there is a malfunction, “E2” (motor) or “E4”...
  • Page 40 – ELEC Diagnosis function (LED type display unit) Error Log Check Mode Display Method The three most recent types of error codes which are stored when there is an error are stored and these are displayed in order from the most recent every 10 seconds. 1.
  • Page 41 – ELEC Diagnosis function (LED type display unit) How to delete the malfunction history ” 1 dur- 1. While pressing the light switch “ ing the error code display, press the assist mode switch power assist decrease 2 and power assist increase 3 to switch. 2.

  • Page 42: Diagnosis Function (Lcd Type Display Unit)

    – ELEC Diagnosis function (LCD type display unit) Diagnosis function (LCD type display unit) Display unit’s display when there is an error Detects system malfunctions, changes assist operation, and displays the errors as well as performing error code recording. Error displays are indicated by the display of “Er”...
  • Page 43 – ELEC Diagnosis function (LCD type display unit) How Drive Unit malfunctions are displayed All segments of the assist mode indicator 1 and all segments of the battery capacity indi- cator 2 will flash alternately, and “Er” will be displayed on the speedometer section 3 of the display unit.

  • Page 44: Operating Procedures To Diagnosis Mode

    – ELEC Diagnosis function (LCD type display unit) Operating Procedures to Diagnosis Mode This is the mode in which each type of diagno- sis and the content of error codes which are stored when there is an error are displayed. You can switch between speed sensor diagno- sis mode, Drive Unit diagnosis mode, and error log check mode by using the display unit...
  • Page 45 – ELEC Diagnosis function (LCD type display unit) Speed Sensor Diagnosis Mode ” 1 until the Press the assist mode switch “ “HIGH” assist mode indicator comes on. Press the light switch “ ” 3. The “HIGH” assist mode indicator flashes rap- idly (0.2 second).
  • Page 46 – ELEC Diagnosis function (LCD type display unit) Speed Sensor Diagnosis Mode Display Method To determine if the controller is correctly rec- ognizing the speed sensor signal, rotate the wheel to which the speed sensor is connected and make sure that the number of rotations of the wheel indicated matches the actual num- ber of rotations.
  • Page 47 – ELEC Diagnosis function (LCD type display unit) Drive Unit Diagnosis Mode Display Method You can check the status of or malfunctions in the Drive Unit. 1. Go into Drive Unit in diagnosis mode. See “Operating Procedures to Diagnosis Mode.” Confirm that the assist mode display is flashing “STD”...
  • Page 48 – ELEC Diagnosis function (LCD type display unit) 1) Torque sensor reference voltage 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 the display unit.
  • Page 49 – ELEC Diagnosis function (LCD type display unit) 2) Motor current a. “14” is displayed in the diagnosis mode dis- play 1 of the display unit. b. Press the function select switch “s” of the display unit. c. The diagnosis data display 2 of the display unit displays the motor output current (%) from “0”...
  • Page 50 – ELEC Diagnosis function (LCD type display unit) 3) Error displays a. “16” is displayed in the diagnosis mode dis- play 1 of the display unit. b. Press the function select switch “s” of the display unit. c. When there is a malfunction, “E2” (motor) or “E4”...
  • Page 51 – ELEC Diagnosis function (LCD type display unit) Error Log Check Mode Display Method The three most recent types of error codes which are stored when there is an error are stored and these are displayed in order from the most recent every 10 seconds. 1.
  • Page 52 – ELEC Diagnosis function (LCD type display unit) How to delete the malfunction history ” 1 dur- 1. While pressing the light switch “ ing the error code display, press the assist mode switch power assist decrease 2 and power assist increase 3 to switch. Fast flashing 2.

  • Page 53: Error Codes List

    – ELEC Diagnosis function (LCD type display unit) 2-39...
  • Page 54 – ELEC Diagnosis function (LCD type display unit) 2-40...
  • Page 55 – ELEC Diagnosis function (LCD type display unit) 2-41...
  • Page 56 – ELEC Diagnosis function (LCD type display unit) 2-42...
  • Page 57 – ELEC Diagnosis function (LCD type display unit) 2-43...
  • Page 58 – ELEC Diagnosis function (LCD type display unit) 2-44...

  • Page 59: Speed Sensor Set

    – ELEC Speed sensor set Speed sensor set Speed sensor inspection 1. Pickup • Check that the pickup is installed at the specified location on the bike. • Check that the pickup is not damaged. 2. Magnet sensor Magnet sensor a.

  • Page 60: Chapter 3 Drive Unit

    Drive Drive axle, Motor (drive axle with square-type end) Unit Drive Unit Drive axle, Motor (drive axle with square-type end) 4.5 Nm (0.45 kgf 40 Nm (4.0 kgf • • 11 12 1.3 Nm (0.13 kgf • 4.5 Nm (0.45 kgf •...
  • Page 61 Drive Drive axle, Motor (drive axle with square-type end) Unit 4.5 Nm (0.45 kgf 40 Nm (4.0 kgf • • 11 12 1.3 Nm (0.13 kgf • 4.5 Nm (0.45 kgf • 0.75 Nm (0.075 kgf 27 28 • Order Job/Part Q’ty Remarks...
  • Page 62 Drive Drive axle, Motor (drive axle with square-type end) Unit 4.5 Nm (0.45 kgf 40 Nm (4.0 kgf • • 11 12 1.3 Nm (0.13 kgf • 4.5 Nm (0.45 kgf • 0.75 Nm (0.075 kgf 27 28 • Job/Part Order Q’ty Remarks...
  • Page 63 Drive Drive axle, Motor (drive axle with square-type end) Unit 4.5 Nm (0.45 kgf • 40 Nm (4.0 kgf • 11 12 1.3 Nm (0.13 kgf • 4.5 Nm (0.45 kgf • 0.75 Nm (0.075 kgf 27 28 • Job/Part Order Q’ty Remarks...
  • Page 64 Drive Drive axle, Motor (drive axle with spline-type end [ISIS]) Unit Drive axle, Motor (drive axle with spline-type end [ISIS]) 40 Nm (4.0 kgf • 25.5 Nm (2.55 kgf • 4.5 Nm (0.45 kgf • 11 12 1.3 Nm (0.13 kgf •...
  • Page 65 Drive Drive axle, Motor (drive axle with spline-type end [ISIS]) Unit 40 Nm (4.0 kgf • 25.5 Nm (2.55 kgf • 4.5 Nm (0.45 kgf • 12 13 1.7 Nm (0.17 kgf • 4.5 Nm (0.45 kgf • 0.75 Nm (0.075 kgf 28 29 •...
  • Page 66 Drive Drive axle, Motor (drive axle with spline-type end [ISIS]) Unit 40 Nm (4.0 kgf • 25.5 Nm (2.55 kgf • 4.5 Nm (0.45 kgf • 12 13 1.7 Nm (0.17 kgf • 4.5 Nm (0.45 kgf • 0.75 Nm (0.075 kgf 28 29 •...
  • Page 67 Drive Drive axle, Motor (drive axle with spline-type end [ISIS]) Unit 40 Nm (4.0 kgf • 25.5 Nm (2.55 kgf • 4.5 Nm (0.45 kgf • 12 13 1.7 Nm (0.17 kgf • 4.5 Nm (0.45 kgf • 0.75 Nm (0.075 kgf 28 29 •...

  • Page 68: Drive Axle, Motor (Drive Axle With Spline-Type End [Isis Adapter])

    Drive Drive axle, Motor Unit 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.
  • Page 69 Drive Drive axle, Motor Unit 2. Remove the following parts: • Plate washer 1 • Clutch boss assembly 2 3. Remove the following parts: • One-way outer boss 1 • Driven gear assembly 2 • Gear cover 3 4. Remove the following parts: •...

  • Page 70: Removal Of The Torque Sensor Assembly And Drive Axle

    Drive Drive axle, Motor Unit 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 sensor assembly because it cannot be readjusted.
  • Page 71 Drive Drive axle, Motor Unit 2. Install the following part: • Heat-dissipating sheet 1 NOTICE Precautions Thermal protection may be compromised by an ill-fitting heat-dissipating sheet, so be sure to replace the heat-dissipating sheet with a new one when the assembly is disassembled.

  • Page 72: Installation Of The Bearing Housing

    Drive Drive axle, Motor Unit Installation of the Bearing Housing ® 1. Apply Three Bond 1215 to the following sealant parts: • Housing complete 1 Apply a continuous 2 to 3 mm thick coating as shown in the drawing (area indicated by dark line).

  • Page 73: Installation Of The Stator Cover

    Drive Drive axle, Motor Unit Installation of the Stator Cover ® 1. Apply Three Bond 1215 to the following sealant parts: • Motor complete 1 Apply a continuous 2 to 3 mm thick coating as shown in the drawing (area indicated by dark line).

  • Page 74: Tightening Torque

    Tightening Torque/ Service Lubricants, areas to apply sealant and specified types Data Service Data Tightening Torque Unit: Nm kgf·m (in) Screw Tightening Tightening locations Q’ty Notes diameter torque Drive sprocket lock nut 40 (4.0) Left hand screw Stator cover installation 4.5 (0.45) Motor assembly and bearing housing 4.5 (0.45)

  • Page 75: Cable, Wire, And Pipe Routing Diagram

    Service Cable, Wire, and Pipe routing diagram Data Cable, Wire, and Pipe routing diagram Ê Route the encoder lead wires 1 Wire lead 2 A Crank sensor 2 Torque sensor plate through the outer side of holder projections as shown in the draw- 3 Wire lead 3 (Yellow) È...

  • Page 76: Troubleshooting

    Service Troubleshooting Data Troubleshooting Symptom Check point/method Possible cause/check Part replacement/action Check for appropriate air Is the air pressure in the tires Repair puncture, replace pressure. normal? tube. Check for punctures. Is the gear-shifting working Check the gear shifting sys- Replace the gear shifting sys- smoothly? tem.
  • Page 77 Service Troubleshooting Data Symptom Check point/method Possible cause/check Part replacement/action 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. Alternately flashes Check the error log according...

  • Page 78: Service Data

    Service Troubleshooting Data Symptom Check point/method Possible cause/check Part replacement/action 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.
  • Page 79 Service Troubleshooting Data Symptom Check point/method Possible cause/check Part replacement/action When pressing the battery Hold down the battery capac- Replace the parts according capacity indicator button on ity indicator button on the bat- (See Chapter 2 “Battery to “Battery pack/battery the battery pack, lamps [1]/[3] tery pack for 10 seconds.
  • Page 81 Yamaha X94 Series Service Manual 7th edition Published October 2014 Unauthorized reproduction prohibited Published by: Yamaha Motor Co., Ltd.

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