Yamaha CROSS CORE 2018, Assembly Manual

Page 1: ...2018 ASSEMBLY MANUAL CROSS CORE PW70CRL PW70CRM PW70CRS LIT 15666 00 03 X1M 28107 12 ...

Page 2: ...l 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 th...

Page 3: ...N 1 Part box 1 2 Front wheel 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 NOTICE 1 2 ...

Page 4: ...s subject to change without notice No Part names Q ty Remarks 1 Front wheel 1 2 Part box 1 1 3 Part box 2 1 2 in part box 1 4 Part box 3 1 2 in part box 1 5 Part box 4 1 2 in part box 1 6 Saddle and seat post assembly 1 7 Front axle 1 8 Pedals 2 1 each for left and right 9 Bell 1 0 Front reflector 1 q Rear reflector 1 w Owner s manual 1 e Button cell battery 1 w in owner s manual pouch Standard CR...

Page 5: ...INCLUDED PARTS 3 7 9 1 2 0 q w 6 7 8 9 3 4 5 r t e ...

Page 6: ...rom the front disc cali per a Give the removed spacer b to the customer explaining how it is used 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 left side of the bicycle Tighten the bolts and nuts to the specified torq...

Page 7: ...ndlebar 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 e d d d 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 result ing in an accident with severe injury or death 8 Fasten the lever d at po...

Page 8: ...der shown in the illustration 8 Tighten in such a way that the gaps f above and below the handlebar holder c are equal 4 Installing the headlight Install the headlight a to the bracket b as shown then tighten the bolt c to 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 a b d d c Tighten...

Page 9: ... illustration then tighten it together with the stay 2 and screw 3 TIP Adjust so that the front reflector 1 faces straight ahead then tighten the screw 6 Installing the bell Install the bell 1 in the position a shown then tighten it with the screw 2 1 2 3 a 1 Front reflector 1 B 2 Stay 1 B 3 Screw 1 B a 1 2 1 Bell 1 B 2 Screw 1 B ...

Page 10: ... the position shown in the illustration Clamp the rear brake wire 2 rear shift wire 3 and display unit lead 7 with the plastic locking ties 0 at the position shown in the illustration Clamp the front shift wire 4 and switch unit lead 6 with the wire clip q at 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 lockin...

Page 11: ...king ties 0 are placed as shown in the illustration Check that the rear brake wire 2 rear shift wire 3 and speed sensor lead w are routed as shown in the illustration 8 Tightening the seat pin Insert the saddle and seat post 1 then tighten the bolt a to the specified torque 7 0 3 4 1 8 2 3 2 w a b 1 Tightening torque 4 0 N m 0 40 kgf m 3 0 lb ft 1 Saddle and seat post 1 A ...

Page 12: ...he seat post clamp or even frame may break which could cause the rider to lose control and fall 8 Always tighten fasteners to the correct torque Bolts that are too tight can stretch and deform Bolts that are too loose can move and fatigue Either mistake can lead to a sudden failure of the bolt causing the rider to lose control and fall Do not insert the seat post completely when lowering the saddl...

Page 13: ...cell battery cover d on the back of the display unit b in direction e remove it then install the button cell battery 1 Mount the button cell battery cover d then turn it in direction f until it locks After installing the button cell battery install the display unit onto the bracket following the removal procedure in reverse order Peel off the protective film after installing 1 a Tightening torque ...

Page 14: ...itch f is pressed while the Min ute section of the clock e is flashing The minutes value decreases when the assist mode switch d is pressed Press the function select switch b to set the minutes F The time is set and the mode returns to the nor mal mode TIP If you make a mistake adjusting the time start over from step B G Press the power switch a to complete adjust ment of the time 14 Checking the ...

Page 15: ...witch a to quit TIP Turn the rear wheel at least 3 revolutions and check that the display reads 3 15 Adjusting the opening of the front and rear brake levers Turn the adjusting screw 1 to adjust the open ing of the tip of the brake lever a from the tip of the grip TIP Adjust to a position at which it is easy for the cus tomer to operate the front and rear brake levers and within the range of play ...

Page 16: ...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 Light brightness and angle of the headlight Check that the headlight shines on the road approximately 33 ft 10 m ahead 8 Installation state of the reflectors 8 Maximum tire air pres...

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