Yamaha CROSS CORE 2018 Bedienungsanleitung

2018

ASSEMBLY MANUAL

CROSS CORE

PW70CRL

PW70CRM

PW70CRS

LIT-15666-00-03 X1M-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 fac-

tory for the convenience of packing, assembly by the Yamaha dealer is required. No adjustment of the power

unit mechanism, which plays the most important part in riding, is necessary because it has been adjusted at

the factory before shipping. It should be noted that the assembled bicycle should be thoroughly cleaned,

checked, and adjusted prior to delivery to the customer.

IMPORTANT

The service specifications given in this assembly manual are based on the model as manufactured. Yamaha

Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes

in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future

editions of this manual where applicable.

The procedures below are described in the order that the procedures are carried out correctly and completely.

Failure to do so can result in poor performance and possible harm to the bicycle and/or rider.

Particularly important information is distinguished in this manual by the following notations.

Follow the instructions in the Dealer Warranty Handbook, Procedure Section.

This is the safety alert symbol. It is used to alert you to potential personal

injury hazards. Obey all safety messages that follow this symbol to avoid pos-

sible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result

in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to

the bicycle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP

PW70CRL/PW70CRM/PW70CRS

ASSEMBLY MANUAL

First edition, April 2018

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

P/N LIT-15666-00-03

PARTS LOCATION

– 1 –

Body assembly

PARTS LOCATION

1. Part box 1

2. Front wheel

8Do not use a cutter, scissors, or other sharp object to open the part boxes; otherwise, the included

parts could be damaged.

8Wear suitable protective gear such as gloves when handling and opening the part boxes.

NOTICE

INCLUDED PARTS

– 2 –

INCLUDED PARTS

The parts listed as follows are included*. Check the parts and their quantities before starting assembly.

Part box 1 details

Part box 2 details

Part box 3 details

Part box 4 details

* The form of the package is subject to change without notice.

No. Part names Q’ty Remarks

1Front wheel 1

2Part box 1 1

3Part box 2 12in part box 1

4Part box 3 12in part box 1

5Part box 4 12in part box 1

6Saddle and seat post assembly 1

7Front axle 1

8Pedals 21 each for left and right

9Bell 1

0Front reflector 1

qRear reflector 1

wOwner’s manual 1

eButton cell battery 1win owner’s manual pouch

Standard CR2032

rBattery pack 1

tBattery charger 1

INCLUDED PARTS

– 3 –

INSTALLING THE INCLUDED PARTS

– 4 –

INSTALLING THE INCLUDED

PARTS

TIP

8Charge the battery pack following the instruc-

tions in the owner’s manual before starting

installation.

8The letters inside the parts list boxes in the

assembly procedures indicate the following:

A: Part in part box 1

B: Part in part box 2

C: Part in part box 3

1. Installing the front wheel and fork end

Remove the spacer bfrom the front disc cali-

per a.

Give the removed spacer bto the customer,

explaining how it is used.

Align the holes in the front wheel 1with the

holes in the fork end and install the front wheel

Install it in such a way that the disc rotor cdoes

not touch the disc pad.

Install the front axle 2to the fork end holes

from the left side of the bicycle.

Tighten the bolts and nuts to the specified

torques. Failure to tighten the bolts and nuts to

the specified torques could prevent proper

operation of the bicycle and make it unsafe to

operate.

WARNING

1Front wheel 1

2Front axle 1 B

INSTALLING THE INCLUDED PARTS

– 5 –

Move the lever dof the front axle 2to “OPEN”

facing the notch e.

With the lever dcaught in the notch e, turn

and tighten until there is a little resistance in the

lever.

Free the lever d.

Determine the position to secure the lever d

and fasten it at “CLOSE”.

TIP

If the lever dof the front axle 2is too hard and

cannot be lowered, or if it is too loose and cannot

be lowered for it to be locked, turn the lever d

again to loosen or tighten it, adjusting so that it can

be fastened securely.

2. Installing the handlebar stem

Position the handlebar stem ain a straight line

with the front wheel.

Tighten the bolts band c, in that order, to the

specified torques.

8Position the lever when it cannot touch

obstacles while the bicycle is moving. If not,

the lever could be unlocked unexpectedly,

causing the front wheel to come off, result-

ing in an accident with severe injury or

death.

8Fasten the lever dat position where the tip

does not touch other parts when the lever

dis lowered.

8Fasten the lever dfacing backward from

the direction of travel in such a way that it

cannot easily touch obstacles that might be

encountered while riding.

WARNING

Tightening torque

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)

Tightening torque

6 N·m (0.6 kgf·m, 4.4 lb·ft)

INSTALLING THE INCLUDED PARTS

– 6 –

3. Installing the handlebar

Install the handlebar aso that the knurled part

bis at the center of the handlebar holder c,

then tighten the 4 handlebar holder cbolts d

to the specified torque.

TIP

Install the handlebar aso that the brake levers e

are at a 30angle to the handlebar, as shown in the

illustration.

TIP

8Tighten bolts devenly in stages, in the order

shown in the illustration.

8Tighten in such a way that the gaps fabove

and below the handlebar holder care equal.

4. Installing the headlight

Install the headlight ato the bracket bas

shown, then tighten the bolt cto the specified

torque.

TIP

Install in such a way that the headlight points down-

ward from horizontal and shines on the road

approximately 33 feet (10 meters) ahead.

Tightening torque

6 N·m (0.6 kgf·m, 4.4 lb·ft)

The handlebar ashould not touch the frame

when it is turned fully to the left or right.

NOTICE

30°

Tightening torque

7 N·m (0.7 kgf·m, 5.2 lb·ft)

INSTALLING THE INCLUDED PARTS

– 7 –

5. Installing the front reflector

Install the front reflector 1in the position a

shown in the illustration, then tighten it together

with the stay 2and screw 3.

TIP

Adjust so that the front reflector 1faces straight

ahead, then tighten the screw.

6. Installing the bell

Install the bell 1in the position ashown, then

tighten it with the screw 2.

1Front reflector 1 B

2Stay 1 B

3Screw 1 B

1Bell 1 B

2Screw 1 B

INSTALLING THE INCLUDED PARTS

– 8 –

7. Routing the wires

Confirm that wires are routed in order starting

from front to back

Front brake wire 1

Rear brake wire 2

Rear shift wire 3

Front shift wire 4

Headlight lead 5

Switch unit lead 6

Display unit lead 7

Clamp the front brake wire 1and front shift

wire 4with the wire clip 8at the position

shown in the illustration.

Clamp the front shift wire 4, and headlight lead

5with the plastic locking ties 9at the position

shown in the illustration.

Clamp the rear brake wire 2, rear shift wire 3

and display unit lead 7with the plastic locking

ties 0at the position shown in the illustration.

Clamp the front shift wire 4and switch unit lead

6with the wire clip qat the position shown in

the illustration.

Check that the front brake wire 1, front shift

wire 4, headlight lead 5, wire clip 8, and plas-

tic locking ties 9are placed as shown in the

illustration.

Be sure to route the wires as shown in the illus-

tration. If not, they could interfere with handle-

bar operation which could cause loss of

control.

WARNING

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