q READ THIS MANUAL CAREFULLY! It contains important safety information.
TABLE OF CONTENTS INTRODUCTION...................................................................1 LOCATION OF THE WARNING AND SPECIFICATION LABELS................................................................................3 DESCRIPTION......................................................................5 E-BIKE SYSTEMS................................................................6 SAFETY INFORMATION......................................................9 INSTRUMENT AND CONTROL FUNCTIONS..............
INTRODUCTION These original instructions have been prepared for your Drive Unit, display unit, battery pack and battery charger. FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
INTRODUCTION Please check your local riding laws and regulations before operating this e-Bike Systems bicycle. Drive Unit, Display Unit, Battery Pack, Battery Charger ORIGINAL INSTRUCTIONS ©2016 by Yamaha Motor Co., Ltd. 1st edition, March 2016 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
LOCATION OF THE WARNING AND SPECIFICATION LABELS Read and understand all of the labels on your battery pack and battery charger. These labels contain important information for safe and proper operation.
LOCATION OF THE WARNING AND SPECIFICATION LABELS Battery charger How to disconnect the plug. 1.GRASP 2.PULL Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model.
DESCRIPTION 1 2 b a 3 4 a c b 5 6 1. Drive Unit 2. Speed sensor set a) Magnet sensor spoke type b) Pick up 3. Display unit a) Display (detachable) b) Display holder c) Switch 4. Battery pack (rear carrier type 500 Wh/400 Wh) 5. Battery pack (down tube type 500 Wh/400 Wh) 6.
E-BIKE SYSTEMS The e-Bike Systems are designed to give you the optimal amount of power assist. It assists you within a standard range based on factors such as your pedaling strength, bicycle speed, and current gear. The e-Bike Systems do not operate in the following situations: • When the display unit’s power is off. • When you are moving 25 km/h or faster. • When you are not pedaling. • When there is no residual battery capacity. • When the automatic power off function* is operating.
E-BIKE SYSTEMS Power assist chart Assist power High High-Performance mode Standard mode Power-saving Eco mode +Eco mode Starting off Level road High-Performance mode A mode that can be counted on to provide powerful assist at all times. Inclined road Standard mode The recommended mode, balancing assist power and remaining assist distance. Steep incline Low Eco mode +Eco mode A mode for saving assist power to travel longer remaining assist distances.
E-BIKE SYSTEMS Conditions that could decrease remaining assist distance The remaining assist distance will decrease when riding in the following conditions: • Frequent starts and stops • Numerous steep inclines • Poor road surface conditions • When carrying heavy loads • When riding together with children • Riding into a strong head wind • Low air temperature • Worn-out battery pack • When using the headlight (applies only to models equipped with lights powered by the battery pack) • Remaining assist distan
SAFETY INFORMATION Never use this battery charger to charge other electrical appliances. Do not use any other charger or charging method to recharge the special batteries. Using any other charger could result in fire, explosion, or damage the batteries.
SAFETY INFORMATION Do not short the contacts of the battery pack. Doing so could cause the battery pack to become hot or catch fire, resulting in serious injury or property damage. Do not disassemble or modify the battery pack. Doing so could cause the battery pack to become hot or catch fire, resulting in serious injury or property damage. If the power cable is damaged, stop using the battery charger and have it inspected at an authorized dealer.
INSTRUMENT AND CONTROL FUNCTIONS Display unit Assist mode switch (up) Assist mode switch (down) Power switch Light switch Assist power meter Speedometer Assist mode indicator Function select switch Pushing assist switch Clock Function display USB receptacle Battery capacity indicator 11
INSTRUMENT AND CONTROL FUNCTIONS Display unit The display unit offers the following operations and information displays. 2 Battery Cover Close Waterproof seal Battery Check if the rated battery (CR2032) is installed in the rear of the display. If a battery is not installed, or if there is not sufficient battery power remaining, install a new battery. To adjust the time and set the units for distance and speed, see “Clock and km/mile settings”.
INSTRUMENT AND CONTROL FUNCTIONS 2 Power “On/Off” Power switch Each time you press the power switch, the power switches between “On” and “Off”. When you turn on the power, all of the displays light up. After that, the battery capacity indicator, speedometer, assist power meter, the function display such as average bicycle speed, and “STD” of assist mode indicator, and clock are displayed. TIP • When you turn on the power, the assist mode is automatically set to Standard mode.
INSTRUMENT AND CONTROL FUNCTIONS Assist mode indicator Assist mode switch (up) 2 Displaying and switching the assist mode The assist mode indicator displays the selected assist mode. • When you press the assist mode switch (up), the mode changes from “Off” to “+Eco” to “Eco” to “Std”, or from “Std” to “High”. • When you press the assist mode switch (down), the mode changes from “High” to “Std”, or from “Std” to “Eco”, or “Eco” to “+Eco” or “+Eco” to “Off”.
INSTRUMENT AND CONTROL FUNCTIONS 2 Battery capacity indicator The battery capacity indicator displays an estimate of how much capacity is left in the battery on an 11-segment scale. Battery capacity indicator 2 Assist power meter Assist power meter The assist power meter displays an estimate of the assist power during riding on an 8-segment scale. When the e-Bike Systems are not in operation, none of the segments of the assist power meter are displayed.
INSTRUMENT AND CONTROL FUNCTIONS 2 Function display Function select switch Function display The function display can display the following functions.
INSTRUMENT AND CONTROL FUNCTIONS 7 Remaining assist distance This displays an estimate of the distance (in kilometers or miles) that can be ridden with assist on the residual battery capacity of the battery installed. If you switch the assist mode when the remaining assist distance is displayed, the estimate of the distance that can be ridden with assist changes. The remaining assist distance estimate cannot be reset.
INSTRUMENT AND CONTROL FUNCTIONS 2 Pushing assist When you are on or off the bicycle and start moving it, you can use pushing assist without pedaling the bicycle. To use pushing assist, press and hold the pushing assist switch. Pushing assist will stop in the following situations: • When you release the pushing assist switch. • If you press another switch at the same time. • When you start to pedal. • If your bicycle speed exceeds 6 km/h. • If you select Off mode.
INSTRUMENT AND CONTROL FUNCTIONS 5. Press the function select switch, and the “minutes” on the clock will begin to flash. 6. Use the assist mode switches (up & down) to set the “hour”. 7. Press the function select switch, and the distance (km or mile) and speed (km/h or MPH) will begin to flash. 8. Use the assist mode switches (up & down) to switch between “km & km/h” and “mile & MPH”. 9. Press the power switch. The settings are saved and this function is exited.
INSTRUMENT AND CONTROL FUNCTIONS 2 Power supply to external devices Power can be supplied to most external devices (e.g. various smart phones etc.) by connecting a commercial USB 2.0 OTG cable. [To supply power] 1. Open the USB receptacle cap of the switch. 2. Connect the USB cable to the switch and external device. 3. Turn on the power of the vehicle. [To stop the power supply] 1. Turn off the power of the vehicle. 2. Disconnect the USB cable and put on the cap of the USB receptacle.
BATTERY PACK AND CHARGING PROCEDURE Battery capacity indicator lamp Battery capacity indicator Battery charger lamp Battery capacity indicator button Charger display The battery pack equipped for the Yamaha e-Bike Systems is a lithium-ion battery. The lithium-ion battery is lightweight and offers superior capacity. However, it does have the following characteristics. • Its performance decreases in extremely hot or cold environments. • It naturally loses its charge.
BATTERY PACK AND CHARGING PROCEDURE Appropriate charging environments For safe and efficient charging, use the battery charger in a location that is: • Flat and stable (when on the bicycle) • Free of rain or moisture • Out of direct sunlight • Well-ventilated and dry • Not accessible to children or pets • Temperature between 15–25 °C Inappropriate charging environments and solutions.
BATTERY PACK AND CHARGING PROCEDURE WARNING If a charging fault occurs during charging, remove the power plug of the battery charger from the socket and wait for the battery pack/battery charger to cool. [CHARGING THE BATTERY PACK MOUNTED ON THE BICYCLE] (Rear carrier type) 1. Connect the power plug of the battery charger to a household power outlet. 2.
BATTERY PACK AND CHARGING PROCEDURE Lock-release ring 3. See “Reading the charging status”, and check that the battery charger is charging the battery pack. 4. The battery capacity indicator lamps will light up one by one until all four are on. Then, when charging is complete, all of the lamps will go off. 5. Confirm that charging is complete, and then disconnect the charging plug from the battery pack. How to disconnect the plug (see the left figure) Grasp the lock-release ring. Pull it out straight. 6.
BATTERY PACK AND CHARGING PROCEDURE NOTICE • Do not connect the charging plug of the battery charger with the charging connector of the battery in a wet state. • Be sure to connect the charging plug only after the charging connector on the battery pack is completely dry. Otherwise the battery charger and battery may malfunction. • Do not apply excessive force to the charging plug or pull on the cord with the charging plug connected to the battery. Otherwise, the plug or connector may be damaged.
BATTERY PACK AND CHARGING PROCEDURE Top of the case Battery bottom TIP Mounting method of the battery pack (down tube type) • Insert the battery in the direction of the arrow so that the battery bottom is aligned to the top of the case. • Insert the upper part of the battery in the direction of the arrow so that the battery handle is aligned to the top of the key lock. • Press the upper part of the battery toward the frame until it clicks into place to secure it. Key lock Battery handle 11.
BATTERY PACK AND CHARGING PROCEDURE Reading the charging status Battery charger lamp Battery capacity indicator lamps (Rear carrier type) (Down tube type) Current status Lit power lamps indicate the amount of charging completed. A flashing power lamp indicates current progress. Details Charging During charging, the battery capacity indicator lamps light up one by one.
BATTERY PACK AND CHARGING PROCEDURE TIP For example, even if normal charging is started, if the battery temperature or the surrounding temperature is too high or too low, the charging may be extended or charging may be stopped without the battery being charged sufficiently in order to protect the battery.
CHECKING THE RESIDUAL BATTERY CAPACITY You can check the estimate of how much capacity is left in the battery and to what extent it is charged. The check can be performed using either the display unit’s residual battery capacity indicator or the battery’s residual battery capacity indicator lamps. TIP • Even if the battery’s capacity reaches 0 (zero), you can still ride the bicycle as a regular bicycle.
CHECKING THE RESIDUAL BATTERY CAPACITY Display of the battery capacity indicator lamps and the estimate of the residual battery capacity When checking the residual battery capacity, push the battery capacity indicator button “ Display of the battery capacity indicator lamps (Rear carrier type) (Down tube type) Estimate of the residual battery capacity ”. Applicable situation 100–76 % 75–51 % From full charge (100 %), the battery capacity indicator lamps turn off, one by one.
PRE-OPERATION CHECK WARNING Be sure to perform the inspection before riding the bicycle. If there is anything you do not understand or find difficult, please consult a bicycle dealer. NOTICE • If you confirm there is a fault, have your bicycle inspected at a dealer as soon as possible. • The power assist mechanism consists of precision parts. Do not disassemble it. Along with performing the regular inspection before riding the bicycle, also perform the following inspections. No.
CLEANING AND STORAGE NOTICE Do not use high-pressure washers or steam jet cleaners since they can cause water seepage, resulting in property damage or malfunction of the Drive Unit or display unit or battery pack. Should water get inside one of these units, have an authorized dealer inspect your bicycle. Caring for the battery pack Use a moist, tightly-wrung towel to wipe off dirt on the battery case. Do not pour water directly on the battery pack, such as with a hose.
CLEANING AND STORAGE Long storage period (1 month or longer) and using it again after a long storage period • When storing the bicycle for a long period (1 month or longer), remove the battery pack and store it using the following procedure. • Decrease the residual battery capacity to where one or two lamps are lit, and store it indoors in a cool (10 to 20 °C), dry place. • Check the residual battery capacity once a month, and if only one lamp is flashing, charge the battery pack for about 10 minutes.
TRANSPORT The batteries are subject to the Dangerous Goods Legislation requirements. When being transported by third parties (e.g. via air transport or forwarding agency), special requirements on packaging and labels must be observed. To prepare the item for shipping, consult a hazardous materials expert. The customer can transport the batteries by road without further requirements. Do not transport damaged batteries.
CONSUMER INFORMATION Disposal The Drive Unit, battery pack, battery charger, display unit, speed sensor set, accessories and packaging should be sorted for environmental-friendly recycling. Do not dispose of the bicycle or its components as household waste.
TROUBLESHOOTING E-Bike Systems Symptom Pedaling is difficult. The Drive Unit turns on and off while riding. Check Action Is the display unit’s power on? Press the power switch on the display unit to turn the power on. Is the battery pack installed? Install a charged battery pack. Is the battery pack charged? Charge the battery pack. Has the bicycle remained stationary for 5 minutes or longer? Turn the power on again.
TROUBLESHOOTING Symptom Check Action The speedometer displays “Er”. There could be a problem inside the Drive Unit is malfunctioning. Turn on the power to the display unit and then leave it alone for 5 minutes. All indicators will turn off automatically. Turn the power on again. The assist mode indicator and battery capacity indicator flash rapidly alternately. The display unit shuts down immediately (approx. 4 seconds later) after switching the power on. Traveling range has decreased.
TROUBLESHOOTING Pushing assist function Symptom The pushing assist function turns off. Check Action Did the tires lock for a few seconds? Remove your finger from the pushing assist switch for a moment, and then press it again. Did you pedal while the pushing assist function was running? Take your feet off the pedals, and remove your finger from the pushing assist switch for a moment, and then press it again. Power supply of external devices via USB connection Symptom Power is not supplied.
TROUBLESHOOTING Battery pack and charger Symptom Cannot charge (Rear carrier type) (Rear carrier type) Check Action Is the power plug firmly connected? Is the charging plug firmly inserted in the battery pack? Reconnect and try charging again. If the battery pack still does not charge, the battery charger might be malfunctioning. Are the residual battery capacity lamps lit? Review charging method and try charging again.
TROUBLESHOOTING Symptom Check Both side lamps are flashing simultaneously. (Rear carrier type) The battery pack protection feature has been activated and the system cannot be used. Replace the battery pack at an authorized dealer as soon as possible. (Down tube type) The battery charger emits abnormal noises, foul odors or smoke. The battery charger becomes hot. After charging, all of the battery capacity indicator lamps do not light up when the battery capacity indicator button “ ” is pressed.
SPECIFICATIONS Range of assist speed Electric motor 0 to less than 25 km/h Type Brushless DC type Rated output 250 W Control method depends on pedaling torque and bicycle speed Assist power control method Rear carrier battery Length 370 mm 400 Wh/500 Wh Rear carrier battery Length 440 mm 500 Wh Down tube battery 400 Wh/500 Wh Charger Display unit (Power supply portion) Type PASB2/PASB5 (Lithium-ion battery) Voltage 36 V Capacity 11 Ah/13.
