YDX-MORO 07 Electric Mountain Bike
Product Information:
The product is the YDX-MORO electric bicycle model, available in
two variations: YDX-MORO 07 and YDX-MORO 05. It is manufactured by
Yamaha Motor Corporation, U.S.A. The assembly manual is for the
2022 edition of the product.
Product Usage Instructions:
Parts Location:
Before starting assembly, it is important to familiarize
yourself with the parts location.
- Body assembly
NOTICE:
When opening the part boxes, do not use sharp objects such as
cutters or scissors to avoid damaging the included parts. Wear
suitable protective gear, such as gloves, when handling and opening
the part boxes.
Included Parts:
Check the included parts and their quantities before starting
assembly.
| Part Names | Q’ty | Remarks |
|---|---|---|
| Front wheel | 1 | |
| Part box 1 | 2 | 1 each for left and right |
| Part box 2 | 1 | |
| Part box 3 | 1 | |
| Saddle | 1 | |
| Front axle | 2 | |
| Pedals | 1 | 1 each for left and right |
| Bell | 1 | |
| Front reflector | 1 | |
| Rear reflector | 1 | |
| Owner’s manual | 1 | |
| Battery charger | 1 |
Installing the Included Parts:
WARNING:
Tighten the bolts and nuts to the specified torques to ensure
proper operation and safety of the bicycle.
TIP:
Charge the battery pack following the instructions in the
owner’s manual before starting installation.
The letters inside the parts list boxes in the assembly
procedures indicate the following:
- A: Part in part box 1
- B: Part in part box 2
1. Installing the front wheel and fork end:
Remove the spacers from the front disc caliper and give them to
the customer. Explain how they are used.
- (For YDX-MORO 07) Align the holes in the front wheel with the
holes in the fork end and install the front wheel. Make sure the
disc rotor does not touch the disc pad. Install the front axle to
the fork end holes from the right side of the bicycle.
NOTICE:
Tighten the front axle to the specified torque and install it
securely to prevent the front wheel from coming off.
Once the front axle is tightened, the installation of the
included parts is complete.
2022
ASSEMBLY MANUAL
YDX-MORO 07 YDX-MORO 05
LIT-15666-00-15
PE65M7L PE65M7M PE65M7S PE65M5L PE65M5M PE65M5S
X2U-28107-12
FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha bicycle prior to delivery to the customer. Since some external parts of the bicycle have been removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. No adjustment of the power unit mechanism, which plays the most important part in riding, is necessary because it has been adjusted at the factory before shipping. It should be noted that the assembled bicycle should be thoroughly cleaned, checked, and adjusted prior to delivery to the customer.
IMPORTANT
The service specifications given in this assembly manual are based on the model as manufactured. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. The procedures below are described in the order that the procedures are carried out correctly and completely. Failure to do so can result in poor performance and possible harm to the bicycle and/or rider.
Follow the instructions in the Dealer Warranty Handbook, Procedure Section.
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.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
NOTICE
A NOTICE indicates special precautions that must be taken to avoid damage to the bicycle or other property.
TIP
A TIP provides key information to make procedures easier or clearer.
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PE65M7L/PE65M7M/PE65M7S PE65M5L/PE65M5M/PE65M5S
ASSEMBLY MANUAL ©2022 by Yamaha Motor Corporation, U.S.A.
First edition, May 2022 All rights reserved.
Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-15666-00-15
PARTS LOCATION
PARTS LOCATION
Body assembly
NOTICE
8 Do not use a cutter, scissors, or other sharp object to open the part boxes; otherwise, the included parts could be damaged.
8 Wear suitable protective gear such as gloves when handling and opening the part boxes.
2
1
1. Part box 1 2. Front wheel
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1
INCLUDED PARTS
INCLUDED PARTS
The parts listed as follows are included*. Check the parts and their quantities before starting assembly.
No. 1 Front wheel 2 Part box 1 3 Part box 2 4 Part box 3
Part names
Q’ty
Remarks
1
1
1 2 in part box 1
1 2 in part box 1
Part box 1 details
5 Saddle
1
Part box 2 details
6 Front axle 7 Front axle 8 Pedals 9 Bell 0 Front reflector q Rear reflector w Owner’s manual
1 YDX-MORO 07 only 1 YDX-MORO 05 only 2 1 each for left and right 1 1 1 1
Part box 3 details
e Battery charger
1
* The form of the package is subject to change without notice.
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2
7
INCLUDED PARTS
1 5
6
7
2
8
9
0
q
w
3
4
e
9
3
7
INSTALLING THE INCLUDED PARTS
INSTALLING THE INCLUDED PARTS
WARNING
Tighten the bolts and nuts to the specified torques. Failure to tighten the bolts and nuts to the specified torques could prevent proper operation of the bicycle and make it unsafe to operate.
TIP
8 Charge the battery pack following the instructions in the owner’s manual before starting installation.
8 The letters inside the parts list boxes in the assembly procedures indicate the following: A: Part in part box 1 B: Part in part box 2
1. Installing the front wheel and fork end Remove the spacers b from the front disc caliper a. Give the removed spacers b to the customer, explaining how it is used.
b
a a 2
(For YDX-MORO 07) Align the holes in the front wheel 1 with the holes in the fork end and install the front wheel 1. Install it in such a way that the disc rotor c does not touch the disc pad. Install the front axle 2 to the fork end holes from the right side of the bicycle.
1 Front wheel 2 Front axle
1
1
B
9
1 c
4
7
INSTALLING THE INCLUDED PARTS
Tightening torque 11 N·m (1.1 kgf·m, 8.1 lb·ft)
2
Tighten the front axle 2 to the specified torque.
WARNING
Tighten the front axle 2 to the specified torque and install it securely. Otherwise, the front wheel could come off.
a 2
(For YDX-MORO 05) Align the holes in the front wheel 1 with the holes in the fork end and install the front wheel 1. Install it in such a way that the disc rotor c does not touch the disc pad. Install the front axle 2 to the fork end holes from the right side of the bicycle.
1 Front wheel 2 Front axle
1
1
B
1 c
d
e d
Move the lever d of the front axle 2 to “OPEN” facing the notch e. With the lever d caught in the notch e, turn and tighten until there is a little resistance in the lever.
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5
7
INSTALLING THE INCLUDED PARTS
Free the lever d.
Determine the position to secure the lever d
d
and fasten it at “CLOSE”.
WARNING
8 Position the lever when it cannot touch obstacles while the bicycle is moving. If not, the lever could be unlocked unexpectedly, causing the front wheel to come off, resulting in an accident with severe injury or death.
8 Fasten the lever d at position where the tip does not touch other parts when the lever d is lowered.
8 Fasten the lever d facing backward from the direction of travel in such a way that it cannot easily touch obstacles that might be encountered while riding.
Tightening torque 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
b a
c
TIP
If the lever d of the front axle 2 is too hard and cannot be lowered, or if it is too loose and cannot be lowered for it to be locked, turn the lever d again to loosen or tighten it, adjusting so that it can be fastened securely.
2. Installing the handlebar stem Position the handlebar stem a in a straight line with the front wheel. Tighten the bolts b and c, in that order, to the specified torques.
Tightening torque 8 N·m (0.8 kgf·m, 5.9 lb·ft)
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a b
INSTALLING THE INCLUDED PARTS
Tightening torque 6 N·m (0.6 kgf·m, 4.4 lb·ft)
d c
d
3. Installing the handlebar Install the handlebar a so that the 3rd horizontal line from the top of the alignment mark b shown is positioned at the lower end of the hole in the upper handlebar holder c, and then tighten the 4 bolts d of the handlebar holder c to the specified torque.
NOTICE
The handlebar a should not touch the frame when it is turned fully to the left or right.
TIP
d
8 Tighten bolts d evenly in stages, in the order
shown in the illustration.
8 Tighten in such a way that the gaps e above
and below the handlebar holder c are equal.
c
e
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e a 30°
Install the handlebar a so that the brake lever f is at a 30 angle to the handlebar, as shown in the illustration.
f
Tightening torque 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
a b
4. Adjusting the display unit position Maintain a clearance of 1 to 2 mm between the bracket of the display unit a and the handlebar stem b as shown, install the set, and then tighten the bolt c to the specified torque.
12mm
c (0.040.08 in)
TIP
Adjust the display unit screen so that it is parallel to the handlebar stem b.
Tightening torque 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
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INSTALLING THE INCLUDED PARTS
Tightening torque 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
3 1
2
1
5. Installing the front reflector Install the front reflector 1, stay 2, and screw 3 as shown, and then tighten them together to the specified torque.
1 Front reflector 2 Stay 3 Screw
1
B
1
B
1
B
TIP
Install the front reflector 1 while adjusting it so that it faces to the front and making sure that the wires, etc. do not contact the front reflector.
6. Installing the bell Install the bell 1 in the shown, then tighten it with the screw 2.
1 Bell 2 Screw
1
B
1
B
2
Tightening torque 0.8 N·m (0.08 kgf·m, 0.59 lb·ft)
4
60
2 9 7
381 5
q
7. Routing the wires
WARNING
Be sure to route the wires as shown in the illustration. If not, they could interfere with handlebar operation which could cause loss of control.
Confirm that hoses and wires are routed in order starting from front to back
Front brake hose 1 Rear brake hose 2 Dropper seat wire 3 Shift wire 4 Display unit lead 5 Switch unit lead 6 Clamp the front brake hose 1 and rear brake hose 2 with the wire clip 7 at the position shown in the illustration. Clamp the front brake hose 1 and dropper seat wire 3 with the wire clip 8 at the position shown in the illustration. Clamp the dropper seat wire 3 and shift wire 4 with the wire clip 9 at the position shown in the illustration. Clamp the switch unit lead 6 at the position shown with the wire clip 0.
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12(40.7m2min)
w
INSTALLING THE INCLUDED PARTS
Secure the front brake hose 1 with the wire clamp q at the position shown in the illustration. Clamp the dropper seat wire 3 and display unit lead 5 with the plastic locking ties w at the position shown in the illustration.
5 3
Make sure that the front brake hose 1, rear brake hose 2, and shift wire 4 are routed as shown.
2 4
1
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INSTALLING THE INCLUDED PARTS
Check that the rear brake hose 2, shift wire 4, and speed sensor lead e are routed as shown in the illustration.
2
4
e
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9
1
e d
a
b c d
g
f
Tightening torque 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) Tightening torque 9 N·m (0.9 kgf·m, 6.6 lb·ft)
8. Installing the saddle Pinch the rail of the saddle 1 with the saddle clamps a and b, and then tighten the seat post c, bolts d, and nuts e to the specified torque. Adjust the seat post c height, and then tighten the seat pin f to the specified torque.
1 Saddle
1
A
TIP
8 Face the mark “” g of the saddle clamp a toward the front, and then install the saddle.
8 Be careful that the dropper seat wire is not too tensioned or too slack when installing the seat post c or adjusting its height.
8 Do not overtighten the seat pin f. Otherwise, it could cause the dropper seat not to operate smoothly.
10
INSTALLING THE INCLUDED PARTS
Tightening torque 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
3 1
2 4
9. Installing the rear reflector Install the rear reflector 1, band 2, screw 3, and nut 4 as shown, and then tighten them together to the specified torque. Secure them to the frame with the band 2.
1 Rear reflector 2 Band 3 Screw 4 Nut
1
B
1
B
1
B
1
B
1
TIP
8 Adjust the rear reflector 1 so that it is facing
straight backward, then tighten it.
8 When assembling the rear reflector 1 to the
frame, adjust the length by cutting the adjust-
ment pad inside the band to fit the frame.
10. Installing the pedals
L R
Install the pedals 1 to the crank a, then tighten to the specified torque.
a
1
1 Pedals (left and right)
1 each
B
Tightening torque 40 N·m (4.0 kgf·m, 30 lb·ft)
TIP
8 Right-hand screw (marked R) for right pedal 8 Left-hand screw (marked L) for left pedal
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INSTALLING THE INCLUDED PARTS
11. Checking the operation of the speed sensor
A. Press the power button a to turn on the power.
g
B. After turning on the power, hold the power but-
ton a down for approximately 10 seconds
c
within 30 seconds. Make sure that the assist
mode indicator b is switched to the magenta
b
display, and then release the power button a.
d
ae
C. Change the white flashing indicator position of
f
the battery capacity indicator e using the assist
mode switch (up) c or assist mode switch
MMMM
b
(down) d. When changed to the status f shown, push the
select button g to confirm.
WWWW
e
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M Magenta W White
W Flashing White
h
M MMM
b
W
e
M Magenta M Flashing magenta W White
No light
D. When the mode enters the speed sensor confirmation mode, both the assist mode indicator b and the battery capacity indicator e will be displayed as shown h.
E. When the rear wheel is lifted and it is rotated, the white lighting indicator of the battery capacity indicator e will move from the right to the left one time per turn. Check that both the moving timing of the white lighting indicator and the rotating position of the rear wheel remain constant.
F. After checking the operation, press the power button a to quit.
TIP
8 Rotate the rear wheel 3 turns at least, and then make sure that the indicator of the battery capacity indicator e moves 3 times.
8 When the indicator of the battery capacity indicator e reaches to the left end, it will return to the right end.
12
b
c
1
INSTALLING THE INCLUDED PARTS
12. Adjusting the opening of the front and rear
brake levers
Before adjusting the opening of the brake
levers, grip the brake levers approximately 10
a
times to pump them. Turn the adjusting screw 1 to adjust the open-
ing of the tip of the brake lever a from the tip of
the grip.
b direction c direction
Opening gets larger. Opening gets smaller.
NOTICE
After adjusting the brake lever opening, check that the rotation of the front and rear wheels is not heavy.
TIP
Adjust to a position at which it is easy for the customer to operate the front and rear brake levers and within the range of play of the brake levers.
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PREDELIVERY INSPECTION
PREDELIVERY INSPECTION
WARNING
After completing the installation, inspect the items as follows and check that there are no problems before delivering the bicycle. Adjust controls and saddle height to the customer’s satisfaction according to this manual.
8 Handlebar orientation, height, angle, and tightening Installing the head cap to the handlebar post: 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) Installing the handlebar bracket to the handlebar post: 8 N·m (0.8 kgf·m, 5.9 lb·ft) Installing the handlebar to the handlebar holder: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
8 Saddle orientation, height, angle, and tightening Installing the saddle: 9 N·m (0.9 kgf·m, 6.6 lb·ft) Tightening the seat pin: 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) * Check that the saddle is firmly fastened.
8 Operation of the dropper seat * Adjust the operation using the wire adjusting screw of the dropper seat lever.
8 Various fittings adjusted to the customer’s riding posture * Including brake lever angle, fork suspension air pressure, etc. Installing the brake lever: 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
8 Inspection of the wheels, hubs, and spokes Tightening the front axle: 11 N·m (1.1 kgf·m, 8.1 lb·ft)
8 Tightening of the pedals: 40 N·m (4.0 kgf·m, 30 lb·ft) 8 Tightening of the screws of each part
Installing the display unit: 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) Installing the front reflector: 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) Installing the bell: 0.8 N·m (0.08 kgf·m, 0.59 lb·ft) Installing the rear reflector: 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) 8 Brake performance 8 Shift changing operation 8 Looseness of the chain 8 Bell sound 8 Battery pack locking operation * Check that the battery pack locks securely. 8 Check of battery pack and battery charger operation 8 Operation of the meter, switches, and drive unit 8 Installation state of the reflectors 8 Maximum tire air pressure YDX-MORO 07 (PE65M7) Front tire: 280 kPa (2.8 kgf/cm2, 40.6 psi) Rear tire: 280 kPa (2.8 kgf/cm2, 40.6 psi) YDX-MORO 05 (PE65M5) Front tire: 280 kPa (2.8 kgf/cm2, 40.6 psi) Rear tire: 280 kPa (2.8 kgf/cm2, 40.6 psi)
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