YAMAHA

　PAS(Power Assist System)

　Service Training
X35E/X35F

0SNE

PAS Operations
Issue Date: January 14&15, 2009
1

Technical Features of
Drive Unit

1
Model : 0S8E CONFIDENTIAL

Drive unit housing

y Drive unit model: X35E0, X35F0
y Aluminum die casting Weight, 4.7kg
y The tensioner is directly secured to the D/U housing using the bolts.

— Merits of aluminum housing (when compared to resin housing)

c Increase of strength: Highly resistant to distortion and bottoming under heavy
load conditions.
d Improvement of heat radiation ability: Not easily to reach the temperature control of the controller.
e Improvement of quietness: Accuracy of portion between the shafts is improved
through the machining.
f Improvement of water-proof ability: Flatness of the sealant applied surface is improved by
machining the mating surface.
g Improvement of maintenance ability: Disassembly and reassembly are possible without
consideration of housing breakage.　

Water-proof permeable Groove (0.5 mm deep) is provided on the

membrane
(This permeable membrane is intended not
to produce any difference between the
Tensioner internal pressure and external pressure.)
housing mating surface to suppress the
sealant ooze volume.
* Sealant available on the market: TB 12150 3

Model : 0S8E CONFIDENTIAL

Components inside drive unit

Motor shaft
Torque sensor
Driven gear y Torque sensor, control
unit, and inverter are in
the Assy status.
Back
side

Inverter Assy
One-way [Holder]
clutch This holder
Control holds the
control PCB
PCB
and inverter
PCB, and
connects
them to the
SARCON sheet HSG using
(Protection of FET) the screws.
* SARCON sheet:This sheet makes the heat source element in contact with the housing to promote the [Inverter PCB]
heat radiation. This sheet needs to be replaced when opening the D/U. 6 FETs are
Incidentally, if the temperature control of the controller exceeds 80°C, the assist power
mounted on
becomes weak gradually. If the temperature control becomes 90°C, the assist power
this PCB.
4
becomes weak rapidly.

2
 Torque sensor
y Magnetostriction type torque sensor (non-contact type)
y This sensor detects changes in magnetic flux when
depressing the pedal and transfers them to the
controller.
Main, axle

y Torque sensor, control unit, and

inverter are assembled.

Bobbin Assy *1

<Cautions on disassembly>
y Demagnetization by shock, such as fall-
Knurling part down
y Magnetic flux is changed as screwdriver is
put close to the sensor. 5

Torque sensor Activation of magnetostriction sensor

Turned by
leg-power

Sensor jig and internal bushing activate

individually inside the torque sensor.
Bushing
Front sprocket Sensor jig
5-5=0 Hanger shaft 7-3=4

Expansion
Magnetic flux having
Symmetric magnetic flux difference on left
and right
Compression
Knurling part

Both
Bothends
endsof ofthe
thebushing
bushinghave
haveaastructure,
structure,ininwhich
whichthe
thefront
frontsprocket
sprocketand
andhanger
hanger
shaft
shaftare
arecoaxially
coaxiallyfixed.
fixed.
The
Thefront
frontsprocket
sprocketisissecured
securedwith
withthe
thetires
tiresinincontact
contactwith
withthe
theroad
roadsurface.
surface.
Therefore,
Therefore,when
whendepressing
depressingthethepedal,
pedal,aadifference
differenceininmagnetic
magneticresistance
resistanceis
isis
produced to convert a difference in magnetic flux into the electric
electric signal. 6
produced to convert a difference in magnetic flux into the electric signal.

3
Safety functions of controller
— Function stop (serious error), CT fault detection, thermistor chattering corresponding to
error log 　
Even though the controller is not currently in the error status, it is deemed that an error occurs
corresponding to the error log in the EEPROM, and then the assist function is stopped.

Number of Reason for Error item

judgement cycles setting
1 cycle Self-travel/ TS short-circuit (Fully opened)
sudden stop TS chattering (Voltage up⇔down is repeated.)
results directly. MotoryencoderyCT (Sudden stop)
EEPROM (Assist control impossible) faulty wiring
2 cycles Self- TS constant (Not changed smoothly)
travel/sudden TS bottom (Standard value increases.: During traveling)
stop may result. TS 0-point (0-point increases when the power is turned ON.)
Thermistor (Controller temperature increases.)
— Dash-out prevention measures when turning ON the switch during pedaling
The power ON during pedaling is judged to weaken the assist power at start-up.
→ Whether or not the vehicle is in the riding status is judged according to the acceleration
power of the vehicle.

Model : 0S8E CONFIDENTIAL

Chain tensioner/Chain
tensioner/Chain guide
—Chain tensioner
y Specifications that the chain tensioner is secured to the D/U main body using
the bolts.
[Cautions on maintenance of chain tensioner]
y Loctite is applied after the chain tensioner has been secured using the
bolts.
(After secured using the bolts, check the activation for sticking.)
y Avoid using the lubricant for the pulley.
y Do not tighten the bolts slantwise when mounting. After secured using
the bolts, check the activation.

—Chain guide
y This chain guide prevents the chain, movement of which becomes poor due to
rust or elongation, from being caught in the portion between the sprocket and
tensioner.

[Replacement timing]
y If the dimension A shown in the Fig. is 2.5 mm or more when the chain is
assembled to the chain guide, the replacement is needed.

Light blue: PZ-type,

A Yellow: PV

4
 Technical Features of
Main Switch

CONFIDENTIAL
18.2ｍｍ
Main switch

39mm

68mm
yPush-type main switch
yFunctions of main switch
c Power ON/OFF
d Battery remaining capacity display
e Travel mode change-over: Mode is switched between [HIGH] and [LOW] with the [△] or [▽] button.
(This mode can be switched even during riding.)
f Auto eco mode ON/OFF changed-over (This mode can be switched even during riding.)
g Error indication:Indicated using flashing four remaining capacity lamps.
h Diagnosis check of drive unit

yWhen the switch is turned ON, the LEDs are indicated in the order described below. (When the switch is
ON, the traveling mode is in the LOW status.)
All LEDs are Remaining capacity
Assist level [Standard] indication
[Power] ON turned off. indication LED
Current remaining capacity indication 10
(0.04 s) All LEDs are lit. (0.5s)

5
Functions of main switch
„ Functions of battery capacity indication (Relative capacity)
y Remaining capacity is indicated at intervals of 25% using four lamps.
y If the remaining capacity is 10% or less, the lamp is flashing.
Remaining capacity Empty Full
indication 1 2 3 4
100 - 75% ■ ■ ■ ■
74 - 50% ■ ■ ■ ■
49 - 25% ■ ■ ■ ■
24 - 11% ■ ■ ■ ■
10 - 1%
(Slow flashing at intervals of 0.5s) ■ ■ ■ ■
1 - 0%
(Fast flashing at intervals of 0.2s) ■ ■ ■ ■

„ Error indication → Check using self-

self-diagnosis.
y If an error occurs, four remaining capacity lamps are flashing to inform it. (Assist function is
stopped.)
→ If a serious error occurs, it cannot be reset even after the power has been cycled.

Four lamps are flashing

11
at the same time.

“Auto Eco Mode”

Mode” Function

The “Auto Eco Mode” was introduced in response to those who desired a longer running distance.
The “Auto Eco Mode” provides a finely-tuned assist mode switch-over depending on pedal force.
It automatically shifts between three strengths of assist force (strong, medium and weak, or assist OFF) depending on
pedaling conditions, thus enabling power-saving riding without troublesome manual intervention by the rider. Naturally,
when load is applied such as when starting off and on uphill slopes it offers solid assistance to suit the mode by switching
to ON (Low) or Strong (High) mode.
As a result, The “Auto Eco Mode” extends the travel distance for 30% to 50% longer than the ordinary mode.
* This data is measured in the “YAMAHA Standardized Road”, 3km of flat road, 1km of 2degree up-hill and 1km of 2 degree down-hill.
**”Auto Eco Mode” is most efficient on the FLAT road, like a Netherlands. On the other hands, in the HILLY road, like a southern area of
Germany, the efficiency will decrease and the deference of travel distance between “Auto Eco Mode” and ordinary mode will be very small.
12

6
 Self Diagnosis of
Drive Unit

13

„ Checking of drive unit diagnosis and clearing of error log

Self-
Self-diagnosis
cTorque sensor 0-point voltage check/correction
dMotor current amount check
eError location display (only if an error occurs.)

Checking of error log

y Up to three past errors can be displayed.

Clearing of error log

y After the error log has been checked, the error log can be
cleared.

14

7
 How
HowtotoStart
StartDiagnosis
DiagnosisMode
Mode

5:
5: High>>Low
High>>Low
Operation
Operation >>High
>>High

1:Push
1:Push 4:Push
4:Push
2:Push
2:Push 6:Release
6:Release
&
& Keep
Keep &
& Keep
Keep

3:Release
3:Release

LED1&3 or
LED2&4 Start
turn on StartDiagnosis
Diagnosis
alternatively Mode
Mode
15

Lithium
LithiumModel
ModelDrive
DriveUnit
Unit
Diagnosis
DiagnosisMode
Mode

pllaayy Empty Auto

Diissp
Full
D Battery diagnosis item notice display eco or
IItteem
m 1 2 3 4 light mode
(1) Actual capacity of battery □ □ □ □
Blink 4 times in 0.5 second intervals, providing
notice of display item
Display
(2) Number of battery system
of charges □ □ □ □

Applicable item displayed for 5 seconds 　　　　　　

not
(3) Battery status 1 performed □ □ □ □
(4) Battery status 2 □ □ □ □
　　　　　　Change over of display items
(5) Torque sensor ■ ■ ■ □
　　　　　　When
　　　　　　 switch is not pressed,
item is repeatedly displayed. (6) Motor current detect □ □ □ □
(7) Motor ■ □ ■ □
(8) Controller □ ■ ■ □

Torque sensor 0 point Empty Full

Blinks 4 times at 0.5 second intervals to provide notice of display item
voltage
1 2 3 4
Less than 0～0.2V ■ □ □ □

Item content indicated for 5 seconds Less than 0.2～0.9V □ ■ □ □

Less than 0.9～1.5V ■ ■ □ □
Empty Full Less than 1.5～2.0V □ □ ■ □
Motor Current
(7)Motor (8)Controller 1 2 3 4 Less than 2.0～2.5V ■ □ ■ □
Not displayed if there 0～24% ■ □ □ □ Less than 2.5～3.0V □ ■ ■ □

is not a problem with 25～49% □ ■ □ □

■ Less than 3.0～3.5V ■ ■ ■ □

them. 50～74% ■ ■ ■
□ □ Less than 3.5～4.0V □ □ □ ■
75～100% ■
□ ■ ■
□ ■ □ Less than 4.0～4.5V ■ □ □ ■
16
　　■　Blinking 　　■On 　□Off 4.5～5.0V □ ■ □ ■

8
 Drive
DriveUnit
UnitDiagnosis
DiagnosisMode
Mode
Judgment
JudgmentofofTorque
TorqueSensor
Sensor00Point
PointVoltage
Voltage

◎ Confirm that value for the torque sensor 0 point voltage is the normal value shown in the table below
(check with no force applied to the pedal).
Item Notice 0 Point Voltage Display

◎ If lamp 2 is illuminated, torque sensor 0 point voltage is normal.

On
Diagnosis Function Table Off
1 　　2 　　3　 　4 1 　　2 　　3　 　4
Abnormal
Empty 　　　　　 　Full Less than 0～0.2V 　Full Less than 2.5～3.0V
(assist stopped) Empty 　　　　　

Empty 　　　　　 　Full Less than 0.2～0.9 Empty 　　　　　 　Full Less than 3.0～3.5V
Normal
Abnormal
Empty 　　　　　 　Full Less than 0.9～1.5V Empty 　　　　　 　Full Less than 3.5～4.0V
Assist force weakens (assist stopped)
　Full Less than 4.0～4.5V
if error not triggered Empty 　　　　　 　Full Less than 1.5～2.0V Empty 　　　　　

→ Needs to be Empty 　　　　　 　Full Less than 2.0～2.5Ｖ Empty 　　　　　 　Full Less than 4.5～5.0V
corrected (next page)
17

„ How to correct 0-
0-point voltage
c If the 0-point voltage deviates as the power is turned ON with the leg-power applied:
Riding continuously as it is will gradually return the assist function to its normal level.
(Every time the pedal is depressed, the assist power recovers by 1/8.)
d If the 0-point voltage deviates for other reason:
With the power turned ON and the pedal effort not applied,
the bicycle is left for 5 min. (until the power is turned OFF
by the auto power OFF function).
e Self-diagnosis Keep the [△] and [▽] buttons pressed at the same time while the
torque sensor 0-point voltage item is being displayed.
Item Notice

Adjustment is
completed.
Current 0-point
voltage is displayed.
Keep these Adjustment is then started.
buttons pressed (Lamps are lit for 0.3 sec.,
for 3 sec. like lamp 4→3→2→1→4.)

After the above correction has been completed, check the 0-point voltage level of the
torque sensor again.
If the 0-point voltage level cannot be improved using correction procedures, it is necessary
to replace the parts. 18

9
 Motor
MotorCurrent
CurrentDetect
DetectFunction
FunctionUsage
UsageProcedure
Procedure
◎ The motor current detect function can be used to display the change in the motor current (= assist force)
due to a different amount of force being applied to the pedal on the main switch battery remaining
indicator lamps.
■ The motor current detect function is activated by drive unit self diagnosis.
When motor current is detected, the auto eco
lamp blinks quickly as the item display and the
remaining indicator lamps are extinguished.

■ The motor current is normal if the four remaining indicator lamps are illuminated when the pedal is stepped on
strongly to activate the rear wheel brake.
(Reference) Test Riding Results
Pressing Remaining indicator Riding condition 残量ランプ表示
Force lamp display
Starting on flat road Empty ■ ■ ■ ■ Full
None Empty□□□□Full
Riding at 15 km/h on flat road Empty ■□□□ Full
Weak Empty □□□□ Full
↑ Empty ■□□□ Full 3.5% inclination (2°): Hill Empty ■□□□ Full

Empty ■ ■ □□ Full 7% inclination (7°): Steep hill Empty ■ ■ □□ Full

When low temperature control is activated: Pedal stepped on strongly to apply rear
Empty ■ ■ ■ □ Full Empty ■ ■ ■ □ Full
wheel brake
↓
Empty ■ ■ ■ ■ Full After riding 1 km when low temperature control is activated: Pedal stepped on
Strong Empty ■ ■ ■ ■ Full
strongly to apply rear wheel brake

■ When 4 lamps are not illuminated, drive unit or battery temperature control may have been activated.
Temperature control function Remaining indicator lamp display

Summer Drive unit temperature rises Check again after waiting for temperature to drop if immediately after riding bicycle.

Battery temperature rises Leave battery in cool location if immediately after riding bicycle, and check again when it is cool (2
– 3 hours).
Replace battery and check again if immediately after riding bicycle.

Winter Battery temperature drops Replace with battery that has been stored in a warm location with a temperature of 10°C or higher.
19
Ride bicycle for a while (approx. 1 km) and check again after temperature rises.

Trouble
TroubleHistory
HistoryDiagnosis
DiagnosisMode
Mode

◎ When trouble occurs, the four remaining indicator lamps on the main switch blink quickly to
provide notice. At this time, assist is stopped, and the trouble history is stored.

１　　　　２　　　　３　　　　４
Quick blinking Empty 　　　　　　　　　Full

After trouble judgment is made,

assist is immediately stopped.
(Stored in Diag.)

In the trouble history diagnosis mode,

the past trouble history can be checked.
20

10
 How
HowtotoStart
StartTrouble
TroubleHistory
HistoryDiagnosis
DiagnosisMode
Mode

5:
5: High>>Low
High>>Low
>>High>>Low
>>High>>Low
Operation
Operation

1:Push
1:Push 4:Push
4:Push
2:Push
2:Push 6:Release
6:Release
&
& Keep
Keep &
& Keep
Keep

3:Release
3:Release

21

Display
Displayof
ofTrouble
TroubleHistory
History(Diag
Diag.)
.) Diagnosis
((Diag.) DiagnosisResults
Results

◎ Up to three past trouble history records (including current record) can be displayed.

pllaayy
mD
em Diissp
IItte　　　　
　　　　　　　　　
● Stored diagnosis is displayed.
*1 Refer to display list for trouble content

● Up to 3 of the most recent diagnostic reports can be stored and displayed.

When 1 type stored…
stored… Displayed for 30 seconds
When 2 types stored…
stored… Displayed for 10 seconds and 20 seconds
When 3 types stored…
stored… Displayed for 10 seconds each
*1

Empty Full
Trouble item
1 2 3 4
☆ No trouble history □ ■ ■ ■
Torque sensor trouble □ ■ □ □
　　 　　■　Blinking　　■On　　□Off
Motor trouble □ □ ■ □
Encoder trouble □ □ □ ■ ☆When there is no trouble history, lamp 1 to 4 go
On and Off repeatedly in a flowing pattern.
Excessive battery voltage □ ■ ■ □
• Encoder ⇒ Motor circuit board
CT trouble □ □ ■ ■
• CT ⇒ Controller
22

11
 Trouble
TroubleHistory
History(Diag
(Diag.)
.) Deletion
(Diag.) DeletionProcedure
Procedure
　　　　
◎ The following procedure is used to delete the trouble history.
　　　　　　　　　

● With the stored diag.

diag. Record displayed:
1:Push
1:Push
&
& Keep
Keep

1:
1: High>>Low
High>>Low

•When the trouble history is checked in the breakdown diagnosis mode, even when trouble
has not currently occurred, refer to the applicable service manual or other document, and
implement the appropriate procedures according to the trouble history.

•After the parts which have broken are repaired, assist riding cannot be performed
unless the trouble history is deleted
23

Technical Features of
Battery/Charger

24

12
Model : 0S8E

Merits and demerits of general lithium ion battery

Positive
PTC element electrode Gas exhaust valve
MMeeriritsts Memory
Memory effect
effect is
is not
not observed.
observed. Gasket
cap
Current shutoff
mechanism
Positive electrode
tab
Charging/discharging
Charging/discharging efficiency
efficiency is
is almost
almost 100%.
100%. Separator

Average
Average activation
activation voltage
voltage is
is approximately
approximately 33
times
times larger
larger than
than that
that of
of the
the alkaline
alkaline battery.
battery.
Mass
Mass energy
energy density
density is
is approximately
approximately twice
twice
larger
larger than
than that
that of
of the
the alkaline
alkaline battery.
battery.
Self-
Self-discharge is
Self-discharge is small
small (approx.
(approx. 5%/month
5%/month at
at
room
room temperature).
temperature). Negative
Negative
electrode
riittss Sub-
electrode tab
Sub -charging is
Sub-charging is needed
needed when
when left
left
meer
Positive
Deem
Exterior can Insulation
D for
for an
an extended
extended period
period of
of time.
time. plate
electrode

Flammable
Flammable fluid
fluid is
is used
used for
for the
the electrolyte.
electrolyte. The
The lithium
lithium ion
ion battery
battery also
also
(Safety
(Safety considerations
considerations are are needed.)
needed.) has
has merits
merits and
and demerits.
demerits.
Low-
Low-temperature characteristics
Low-temperature characteristics are
are inferior.
inferior. Therefore,
Therefore, please
please instruct
instruct
to
to correctly
correctly understand
understand the
the
Vulnerable
Vulnerable to
to over-
over-discharge and
over-discharge and over-
over-charge.
over-charge. features
features and
and operate
operate the
the
battery
battery properly.
properly.
Price
Price becomes
becomes high.
high.
25

Model : 0S8E

Cautions on handling of lithium ion battery and summary

• About charging
– If the fully charged battery is charged continuously or if it is left at a high-
high-temperature, the battery may deteriorate.
　　In particular, if the battery is charged in an environment with a temperature of 40°C or more, the battery may
deteriorates quickly.
– Charge the battery in a cool place.
y If the battery is charged immediately after riding during the summer or if the battery is charged in a
completely closed room, the charging may not be started or stopped halfway.
– Recommended charging temperature: 15 to 25° 25°C
– No memory effect is observed even though the additional charging is made like alkaline battery.
• About discharging and storage
– Deep over-charge may cause the battery to deteriorate.
– If the battery is left for an extended period of time (3 to 6 months longer) with it kept mounted on the vehicle after
riding until lamp 1 is flashing, the battery may deteriorate.
– When traveled until the lamp starts flashing, store the battery after the sub-charging has been performed.
(Remaining capacity lamp 2 is lit.)
– If the bicycle is not used for an extended period of time, check the remaining capacity once a month. If the lamp
1 flashes, this shows that the remaining capacity is approx. 20 to 30%.
Sub-charging is needed until lamp 1 to 2 is lit.
• About marine and air transportation (Applicable to hazardous substance)
– According to the U.N. transport regulations, it has been required since January, 2003, that all Class 9 battery
boxes with an equivalent lithium content of more than 8g (lithium ion L-type battery is applicable to this battery
box) shall be tested according to the test standards (drop test, etc.) for the packaging status in the marine and air
transportations and the acceptance certificate shall be attached to the battery packages.
• About recycling
– The electrolyte of the lithium ion battery contains flammable organic solvent. If the battery is
disassembled, this may cause the battery to ignite.ignite.
– The used battery must be returned to the sales company. (As defined in the EU battery directive.)

26

13
Model : 0S8E CONFIDENTIAL

Specifications of battery for 0S8E and 0S8F

Item Specification in ‘08 Remarks

Typ. capacity 8.1 Ah Standard pattern discharge
Cycle service life 700 to 900 cycles Standard pattern discharge
Temperature of charging
0 to 30°C Recommended: 15 to 25°C
environment
Charging from a remaining
Charging time Approx. 4 hrs.
capacity of 10%
Weight 1900 g
Case color Black

27

Model : 0S8E CONFIDENTIAL

Battery label indication

Part No. is printed.

28

14
Guidelines for battery charging and cycle life

1 When battery is repeatedly discharged and charged, its capacity to hold electricity
(actual capacity) will gradually decrease.

Portion that is no longer able to

hold electricity (deteriorated)
Actual Actual
capacity Actual Capacity to hold electricity
capacity capacity Actual
capacity (actual capacity)

2 Deterioration of the battery will be accelerated depending upon usage conditions, storage status,
ambient temperature when charging and the temperature.
(1) Carrying of heavy loads, continual climbing of steep hills, repeated frequent starts and stops
(2) Charging of the battery while it is hot
(3) Excessive discharging of battery
(4) Storage in a location with a temperature of 40°C or higher
Actual Riding on flat road (25°C)
capacity
Riding on ordinary road (25°C)
Replacement guideline

The harsher the usage conditions, the faster the battery will deteriorate. 29
No. of repeated charges

The battery does not do well at hot or cold temperatures.

Deterioration of the battery will be accelerated when it becomes hot.
During charging of battery
Ended by
Deterioration
abnormal Charging of the battery will be stopped in the event it reaches the charging stop
accelerated
temperature
temperature during charging, and the charging lamp will be extinguished. (Ended
Charge
standby
Charge stop by abnormal temperature)
temperature
Problem occurs
Temperature at which When this happens, the assisted distance will be shorter since the battery is
charging can25℃
start
not fully charged.
Range in which Suitable
battery can be temperature
charged 15℃ While riding!
During the summer, in the event the battery temperature rises due to going
0℃
up steep hills or operating the bicycle under other harsh conditions, the assist
force will weaken.
Attention!
Even when the battery is not charged that many times, the battery will deteriorate
depending upon how the bicycle is used and with the passage of time, resulting
in a shorter available riding distance.
It is time to change the battery when the riding distance is significantly shorter.
Advice on How to Maximize Battery Life!
(1) Do not place in a location where the temperature will exceed 40°C. (in a vehicle, etc.)
(2) Allow the battery to cool down after riding the bicycle before charging the battery. 30
(3) Charge the battery after it has been as fully discharged as possible.

15
Model : 0S8E CONFIDENTIAL

Battery: Low-
Low-temperature and high-
high-temperature characteristics

y When the temperature inside the cell is 2°C, the output becomes approximately
33%. However, approx. 10min.-ride will return the output to 100%.

100% output

35% output

Battery temperature
after approx. 10 min.-ride

31

Model : 0S8E CONFIDENTIAL

Charging environment temperature ♦ Description stated in instruction manual

y Indoor chargeable temperature stated in the

instruction manual
: 0°C to 30°C (Recommended charging
temperature: 15 to 25°C)

→ If the battery is charged immediately

after riding during the summer or if the
battery is charged in a completely
closed room, the charging may not be
started or may be stopped halfway.

→ The battery is charged at appropriate

room temperature.

32

16
Model : 0S8E CONFIDENTIAL

Battery protection function

„ Activation conditions and statuses
— Conditions
If any of the following conditions is detected, the protection function is
activated. As a result, the battery is no longer used.
c Over-charge is detected.
y The battery is charged using a charger other than that specified.
d Over-discharge is detected.
e Unusual temperature is detected.
y The battery is put inside the car and exposed to the direct sunlight during the
summer.
y The battery is put in front of the fan heater and exposed to the hot air flow during
the winter.

— Indication method: If the protection function is activated, the remaining

capacity indication LEDs 1 and 4 are flashing at the same time.
- If the PCB inside the battery functions xxx
y The activation of the protection function is indicated when
pressing the remaining battery capacity indication check button.
y The activation of the protection function is indicated when the
battery is connected to the charger.
- If the PCB inside the battery does not function (in the self-shutdown status) xxx
y The activation of the protection function is indicated when the battery is connected to the
charger. 33

Model : 0S8E CONFIDENTIAL

Battery protection function
— How to check the contents when protection function is activated.
When the battery protection function is activated, keep the [PUSH] button pressed for 10
sec. to check the contents of the protection function (what conditions cause the
protection function to activate).

Indication after [PUSH] button has Judgement

been kept pressed for 10 sec.. results
LEDs 2 and 3 are
Over-charge
lit for 5 sec.
Battery is
connected LEDs 1 and 3 are Unusual
to the lit for 5 sec. temperature
charger.
LEDs 1 and 2 are
lit for 5 sec.
Over-charge

LEDs 2 and 3 are

Over-charge
lit for 5 sec.
Sole LEDs 1 and 3 are Unusual
battery unit lit for 5 sec. temperature
The voltage drops and the BMC does not function in the over-
　　　　　　　 discharge status. Therefore, the LEDs are not lit unless the
battery is connected to the charger. 34

17
Model : 0S8E CONFIDENTIAL

Battery deterioration judgement function

— Judgement conditions
If either “total operation-hour” or “total discharge capacity” exceeds its threshold value, the battery is
judged as deteriorated.
L-type: 8 years or total discharge capacity of 4000Ah or more, whichever comes earlier.
* The counting of the total operation-hour is started when the battery is charged
for the first time.
When the battery is charged during the setup at the sales shop, it is then
started to count the total operation-hour.

— Indication after judgement

y Status after judgement
- When the battery is connected to the charger for the first time after the judgement
conditions have been detected, the battery cannot be charged or discharged
permanently.
(Charging FET and discharging FET are turned OFF.)
y If the deterioration is judged, the remaining capacity indication LEDs are flashing
repeatedly at intervals of 1 sec. in order, like 1→2→3→ 4→1→2→ xxx.
- If the PCB inside the battery functions xxx
y The judgement is indicated when pressing the remaining battery capacity indication check button.
y The judgement is indicated when the battery is connected to the charger.
- If the PCB inside the battery does not function (in the self-shutdown status) xxx
y The judgement is indicated when the battery is connected to the charger.

35

Model : 0S8E
Battery LED indications <mounted on vehicle/during discharging/left as it is>
■Lit. 　　■Off. 　　*Slow flashing (at intervals of 1 sec.) 　　**Fast flashing (at intervals of 0.5 sec.)
Operation Contents of Battery remaining Status
indication capacity LEDs
Press the [PUSH] Relative capacity ■ ■ ■ ■ Relative capacity　75 to 100
button once. indication
■ ■ ■ ■ Relative capacity　50 to 74
■ ■ ■ ■ Relative capacity　25 to 49
■ ■ ■ ■ Relative capacity　11 to 24
＊ ■ ■ ■ Relative capacity　1 to 10
** ■ ■ ■ Relative capacity　0
Error indication ■ ■ ■ ■ Battery error
■ ■ ■ ■ Replace
Keep [PUSH] ■ ■ ■ ■ Battery voltage error
Flashing the
button pressed
alternately ■ ■ ■ ■ BMC voltage error battery.
■ ■ ■ ■ for 10 sec.
■ ■ ■ ■ EEPROM error
Keep the [PUSH] Total charging ＊ ■ ■ ■ Charging cycles 0 to 50 cycles
button pressed cycles indication
■ ■ ■ ■ Charging cycles　 51 to 100 cycles
for 20 sec.
＊ ＊ ■ ■ Charging cycles 101 to 150 cycles
■ ■ ■ ■ Charging cycles 151 to 200 cycles
＊ ＊ ＊ ■ Charging cycles 201 to 250 cycles
■ ■ ■ ■ Charging cycles 251 to 300 cycles
＊ ＊ ＊ ＊ Charging cycles 301 to 350 cycles
■ ■ ■ ■ Charging cycles 351 cycles or more
Keep the [PUSH] Actual capacity ■ ■ ■ ■ Actual capacity 0 to 24
button pressed indication
for 30 sec. ■ ■ ■ ■ Actual capacity 24 to 49

■ ■ ■ ■ Actual capacity 50 to 74
■ ■ ■ ■ Actual capacity 75 to 100

36

18
Model : 0S8E CONFIDENTIAL

　Charger
y Specially designed for Li-ion battery and applicable to 230V-CE standards.
y Ferrite core is mounted on the AC cord to suppress the propagation of the noise current.
y Lighting of indicator
y During charging = Indicator is lit in yellow green.
y Charging standby = Indicator is flashing in yellow green.
y Error occurs. = Indicator is flashing in red or is lit in red.

Ferrite core

„ LEDs on battery are lit during charging.

Reason why four LEDs are still lit for a certain

period of time after they have been lit.
CC/CV charging method

37

Model : 0S8E
CONFIDENTIAL

Charging of lithium ion battery

Charging
Chargingamount
amountisisstabilized
stabilizedby
bymeans
means of
ofthe
theCC/CV
0→100%充電　L CC/CVcharging
No.8 chargingmethod
method(2.0A/29.0V).
(2.0A/29.0V).
50 10

45 9
LED 1 lit + LED 4 lit
LED 1 slow LED 2 lit + LED 3 slow LED 3 lit + LED 4 slow
40 flashing LED 2 slow 8
flashing flashing
flashing

35 7
[Ah] [Ah]
[A]/Capacity

30 6
[V] [V]

[A]/容量
Voltage

Voltage
電圧[V][V]
25 5 電流[A][A]
Current
電圧

Capacity [Ah]
Current

容量[Ah]
電流

20 4

15 3

10 2

5 1

0 0
0 30 60 90 120 150 180 210 240 270 300
時間
Time[min]
[min]
38

19
 LED indications when the battery is Battery : ■Lit, 　＊Slow flashing (at intervals of 0.5 sec.) 　**Fast flashing (at intervals of 0.2 sec.)
Charger : ●Lit in green 　★Flashing in green 　
connected to the charger. ★Flashing in red (Multiple flashing patterns are provided.)

Status LED on charger LEDs on battery Remarks

● (3 min.)
Waiting for proper temperature → Charging is started when the temperature
Temperature standby → Subsequently, * * * *
reaches the proper level.
LED is turned off.
★ Preparations for main charging (Fully discharged battery is left.)
Pre-charging ** ■ ■ ■
(Flashing) → Charging is started after a certain period of time has elapsed.

■ ■ ■ ■ ■ ■ ■ ■ Over-charge is detected. Non chargeable

Activation of protection ●, ★, Off Unusual temperature is Non chargeable

■ ■ ■ ■
function (Any status) Keep the [PUSH] button detected. /dischargeable.
Battery is pressed for 10 sec. Non chargeable
connected to ■ ■ ■ ■ Over-discharge is detected.
/dischargeable
the charger. Non chargeable
Deterioration judgement ↑ ■ ■ ■ ■ Lit in order, like 1→2→3→4→1 xxx
/dischargeable.
■ ■ ■ ■ Any of the following errors is shown (5 sec.).

　　Flashing alternately ■ ■ ■ ■ Over-current charge

★
Charge error ■ ■ ■ ■ ■ ■ ■ ■ Over-voltage charge
(Flashing) Replace the battery
■ ■ ■ ■ Charging current 0A or charger.
Keep the [PUSH] button
pressed for 10 sec. Current exists when the
■ ■ ■ ■
charging is completed.
Relative capacity 0 ● **

Relative capacity 1 to 10 ● *

During Relative capacity 11 to 24 ● ■ *

charging
Relative capacity 25 to 49 ● ■ ■ *
Relative capacity 50 to 74 ● ■ ■ ■ *
Relative capacity 75 to
● ■ ■ ■ ■ Turned off after the battery has been charged fully.
100

39

Model : 0S8E

Error diagnosis function of charger

y If an error is found when the battery is connected to the charger, faulty location can be
checked through the LED flashing status.
y Even though LEDs 1-3 or 2-4 on the battery do not flash alternately, the LED only on the
charger may be indicated.
LED Inspection/replacem
Indication Lit and flashing statuses Cause of error
color ent location
5 sec. before
lighting up

Lit (5 sec.)
Red + Battery voltage error Battery
Off (2 sec.)
2 sec. before turning off

0.2 sec. Fast flashing

Communication is
Fast
Red
flashing impossible due to Charging cord, plug
contact fault.
0.2 sec.

0.2 sec. Fast flashing continues for 5 sec.

Fast
flashing Communication is
Battery (BMC),
Red (5 sec.) impossible due to
+ charger
Off (2 sec.) circuit fault.
Turned off for 2 sec.

0.5 sec. Slow flashing/Lit once every 1 sec.

Slow Temperature inside
flashing
Red
(continuou
the charger Charger
sly) increases.
0.5 sec.

40

20
 <Reference> Lithium battery temperature standby during summer

Temperature
inside
Main charging
battery stop Main charging Charging
Main charging restart completion
Charging stop start
temperature

Charging start
temperature Main charging
standby Main Main charging Main Charging is
Approx. 5 hrs. in
environment at 30°C
charging standby charging completed.

Lamp is off. Lamp is lit in green. Lamp is off. Lamp is lit in green. Lamp is off.
{Green lamp is {Green lamp is {Green lamp is {Green lamp is {Green lamp is
lit./Charging lit./Charging lit./Charging lit./Charging lit./Charging
{Green lamp is flashing./ {Green lamp is flashing./ {Green lamp is flashing./ {Green lamp is flashing./ {Green lamp is flashing./
Charging standby Charging standby Charging standby Charging standby Charging standby
{Orange lamp is {Orange lamp is {Orange lamp is {Orange lamp is {Orange lamp is
lit./Refresh lit./Refresh lit./Refresh lit./Refresh lit./Refresh
{Red lamp is {Red lamp is {Red lamp is {Red lamp is {Red lamp is
lit/flashing./Error lit/flashing./Error lit/flashing./Error lit/flashing./Error lit/flashing./Error

41

Model : 0S8E

Items to be informed to sales shops and customers

42

21
 電動自転車をご愛用のお客様へ
For
Forcustomers
customersusing
usingpower
powerassist
assistbicycle
bicycle

Reference for battery charging and replacement (service life)

1 Charge the battery using specified special charger.

2 The battery has a service life.

(1) The service life may vary depending on the operating status, ambient
temperature, and/or charging method. If the travel distance per charge
becomes 1/2 of that of a new battery, this shows the battery replacement
timing.

(2) Reference service life of battery (This service life is not the guaranteed
value.)

cNumber of repeatedly charging/discharging cycles:

The travel distance per charge becomes approx. 50% of that of a new
battery after the battery has been charged and discharged repeatedly 700
to 900 times.
(General road riding pattern under conditions with a temperature of 25°C)

dReference operation period until the battery replacement is 1.5 to 2

years.

* The total operation-hour of the battery may vary depending the storage
condition, charging environment temperature, riding conditions,43 and
atmospheric temperature.

For
Forcustomers
customersusing
usingpower
powerassist
assistbicycle
bicycle

Reference for travel distance

As a guide, the reference travel distance per charge obtained from riding on general
road is described in the catalog.
(This value is not the guarantee value.)
(1) The riding conditions are as follows:
New battery, 25°C ambient temperature, 60 kg on-vehicle weight (total weight of
rider and luggage), flat and dry road surface, no wind, no lights, and Auto Eco
mode plus switch set at OFF.

(2) The riding courses and patterns conform to the JIS standards established in 2000.
General road riding patterns
Gradient, 3.5% Flat Gradient, 3.5%
(2-degree) (2-degree)
Flat Flat

* Value in ( ) shows the traveling speed of the

PAS wagon lithium.

„ The battery of a new bicycle does not show the performance at its optimal level.
In this case, charge the battery twice or three times to check the status.
44

22
 For
Forcustomers
customersusing
usingpower
powerassist
assistbicycle
bicycle

Difference in travel distance per charge by pedaling method

1 Even though the rider rides the bicycle on the same road at a similar speed, smooth pedaling at
a constant speed makes the travel distance per charge longer while powerful pedaling makes
this distance shorter.
2 If there are many obstacles, such as people, bicycles, and cars even on the flat sidewalk and
the rider rides the bicycle under riding conditions needing repeated acceleration and
deceleration, the possible travel distance becomes short excessively.
3 The possible travel distance becomes short according to the effects of customer’s riding,
ambient environment, such as road, wind, and temperature, vehicle maintenance status, and
deterioration of the battery.

Changes in travel distance caused by differences in road gradient (uphill)

Travel distance per charge is changed due to differences in road gradient.
The following shows the approximate travel distance assuming that the general road riding pattern is determined to 100%.
Riding method Travel distance Riding conditions

Flat The rider continuously runs on the flat road at 15

Approx. km/h. without startup and stop.
road 120% * Running with 3rd gear

The rider continuously runs on the uphill with a

Uphill Approx.
gradient of 3.5% (2-degree) at 10 km/h.
50%
* Riding with 2nd gear

Steep The rider continuously runs on the uphill with a

Approx.
uphill gradient of 7% (4-degree) at 7 km/h.
25%
* Riding with 1st gear
* Measurement conditions: New battery at normal temperature of 25°C, carrying a weight (weight of rider and luggage) of 60 kg, on a dry, flat road without light and without wind.
* If the ambient temperature decreases (battery temperature decreases), the possible travel distance becomes short or the assist power may drop due to the battery characteristics. In this case, as the ambient temperature increases, the performance of the battery is
recovered.
* The travel distance per charge becomes short as the number of charging cycles increases.
* Even though the number of charging cycles is small, the travel distance per charge becomes a half of that of a new battery as it is used for an extended period of time (1.5 to 2 years). 45
* When pedaling powerfully, the battery is consumed early.
* The travel distance with light becomes shorter than that without light.

For
Forcustomers
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bicycle

Operation of main switch

1 How to turn ON the main switch

c Do not put your foot on the pedal.

d Press the main switch [ON/OFF] button once.
e Wait for a while (approx. 2 sec.).
f Start riding.

{ The system is checked for 1.5 sec. after the main switch has been turned ON. If your foot is put
on the pedal or the pedal effort is applied during this period, the leg-power cannot be detected
correctly.

2 The assist mode can be changed ([High]←→[Low]) at any time, during stopping or
riding.

3 If the main switch is not operated correctly, the assist power becomes weak and the
pedal becomes heavy.
→ The system automatically corrects the assist power to recover it.

* Slow flashing indication has been made obsolete since 46

the production in July, ’05.

23
For
Forcustomers
customersusing
usingpower
powerassist
assistbicycle
bicycle

Auto power-OFF function

If any pedal effort is not applied to the pedal for 5 min. even though the main switch is
turned ON ([ECO]y[HIGH]), the circuit of the power assist system is automatically
turned OFF to protect the battery.
The battery remaining capacity lamps on the main switch panel and the battery lamp
are also turned off.
Turn OFF the main switch once, and then turn it ON again.

* A slight current flows from the battery in the auto power OFF mode. Therefore,
when the auto power OFF function is used frequently, the battery remaining
capacity indications may be skipped.
Therefore, keep the main switch turned OFF, where possible.

47

For
Forcustomers
customersusing
usingpower
powerassist
assistbicycle
bicycle

To use the bicycle for an extended period of time

1 The customer practices enough in a safe place and rides on general road after the customer has
become accustomed with the features of the power assist.
2 To operate the main switch, remove your foot from the pedal and turn ON the switch. After that, wait
for 2 sec. and start riding.
3 Start in the [Low] mode until the customer becomes accustomed with the power assist mode.
4 Check the bicycle before riding. The air pressure of the tire is important.
5 Receive the periodic inspection suitable for the customer’s usage.
6 Avoid charging the battery immediately after riding. Start charging the battery after the battery
temperature has become proper.
7 Sub-charging of the battery is possible. However, the battery can be used for a long time when
charging the battery after it has been exhausted.
9 Store the battery in a cool place during the summer or in a warm place during the winter.
10 If the battery is stored for an extended period of time (1 month or longer), check the battery
remaining capacity once a month. (If the battery is left in the empty status, the deterioration may be
promoted.)
11 Pay special attention so that the charger for electronics devices, does not get wet or is not fallen
down, or a vibration is not applied to it repeatedly in a basket.
12 If the battery gets wet by rain, dry it sufficiently before charging the battery.
Failure to do so may cause the charging terminal of the battery to corrode or the charger to
malfunction.
13 Always write the key No. in the key No. description area in the instruction manual (back cover).

48

24
Model : 0S8E

Troubleshooting

49

Battery
Batterytroubleshooting examplec
troubleshootingexample c

„ Symptom
y The assist power becomes insufficient in a high-temperature
environment during the summer.
y The assist power becomes insufficient when riding
on the steep uphill continuously.

„ If the battery temperature becomes high, the high temperature control is activated to
suppress the discharge current so as to prevent the battery from deteriorating.

When riding in a high-temperature environment during the summer or when riding on

the steep slope continuously, the battery temperature increases and it may reach a
temperature level, at which these controls are activated.

If this trouble occurs, decrease the battery temperature once, check the assist power
again, and give an explanation to the customer.

50

25
Battery
Batterytroubleshooting exampled
troubleshootingexample d

„ Symptom
y The assist power becomes insufficient in a low-temperature
environment during the winter.
y The assist power becomes insufficient when riding
on the steep slope continuously.

„ If the battery temperature becomes low, the low temperature control is activated to
suppress the discharge current so as to prevent the battery from deteriorating.

When the battery is stored outdoors during the night in the winter that the temperature
is low, the battery temperature decreases and these controls may be activated.

Store the battery in an indoor place at normal temperature (0 to 30°C) during the winter,
where possible and mount the battery on the vehicle before use. This ensures that the
battery becomes beyond the low-temperature control conditions.

Additionally, as the battery temperature rises when riding for a while even though the
low-temperature control is activated, the control is cancelled and the normal assist
power is recovered.

51

Battery
Batterytroubleshooting examplee
troubleshootingexample e

„ Symptom
y The battery remaining capacity lamp indications
are skipped during riding.
(3 LEDs are lit. → 1 LED is flashing.)
„ If the battery remaining capacity lamp indications are skipped, it is thought that the following may be the cause.
(1) Caused by low temperature
When the temperature is low during the winter (reference: 10°C or less), the resistance inside the battery
increases and the voltage drop may occur easily. Therefore, the remaining capacity indication skip may occur
easily.
In particular, this trouble occurs easily if a large current is required, such as riding on steep uphill.
→ When the temperature becomes high, this trouble symptom is difficult to occur.

(2) Caused by error of remaining capacity meter

This trouble occurs if the actual capacity is insufficient when compared to the capacity recognized by the
battery.

1) If the sub-charging is performed frequently, slight errors are integrated inside the remaining capacity
meter. If this error becomes large, this trouble occurs.
→ It is preferable to charge the battery after it has been exhausted, where possible.

2) Auto power OFF function is used frequently.

If the battery is left with the auto power OFF function activated, a slight current leaks and an error may
occur between the capacity learned from the battery and the actual capacity.
⇒ Instruct the customer not to always use the auto power OFF function. 　

(3) Caused by deterioration of battery

The internal resistance of the deteriorated battery becomes large, causing voltage drop to occur easily.
52

26
Charging
Chargingtroubleshooting example①
troubleshootingexample ①

„ Symptom
When the battery is connected to the charger, the lit battery remaining capacity
lamps 1 and 3 and lamps 2 and 4 flash alternately.

„ First, it is thought that the charging terminal has faulty contact.

y Insert the battery into the charger firmly. dIncline the
Battery
y Check the terminal for contamination. battery and
insert the
y Check the battery terminal voltage. cConnect to battery so that ePush the top
the power the hooks slide
y If possible, perform the cross-check of supply. along the
of the battery
toward the
the battery. guides. orientation A.
Hook Guide
　　　　　　↓ Power plug Charger

If the symptom is not improved, replace the battery.

* If the lamps flash alternately during charging, leave the battery for a while (1 min. or longer) and
attempt to charge the battery again.
* Keep the [PUSH] button pressed for 10 sec. while the lamps are flashing, the contents of the error
are shown. 53

27