Yamaha CrossCore RC Series - User Manual

Dear New Yamaha CrossCore® RC or Wabash® RT e-Bike Owner,
-—and
extra 

Your new 
s:


 

 :
 
  
 3 
 3 Hex- 
 1 Hex-
TIP: 
Yamaha dealer or -800-962-
  with the orange-and-down

  hex-head 

 and ) 

, 
 

WARNING LABEL
ON BOTTOM


Summary

Battery Assembly and Activation

Important Safety Warning

Warning against dropping or impacting the battery pack to prevent fire or injury.

Required Components and Tools

Lists the battery, end cap, washers, and hex-head screws needed for assembly.

Battery Activation Procedure

Instructions to activate the new battery by connecting it to the charger.

Battery Usage Guidelines

Storage for Future Use

Guidance on storing the battery for extended periods, including charge level recommendations.

Regular Use or Backup

Advice for using the battery for regular rides or as a backup, including transport precautions.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

This document serves as a guide for new owners of Yamaha CrossCore® RC or Wabash® RT e-Bikes who have received a free extra battery as part of a promotion. It outlines the necessary steps for assembling, activating, and properly using or storing the new battery.

Function Description

The primary function of this document is to provide instructions for the assembly and activation of a new Yamaha e-Bike battery, which is essential for powering the e-Bike. The battery, once assembled and activated, serves as an additional power source, either for regular use, as a backup for extended rides, or for future storage. It is designed to integrate with the e-Bike's existing power system, providing the necessary energy for the electric assist features. The document also emphasizes safety precautions related to handling the battery, particularly regarding impact and potential fire hazards.

Usage Features

The document details several key usage features for the new battery:

• Assembly: The initial usage involves assembling the battery with an enclosed end cap. This requires a 3 mm hex wrench (Allen® key) and careful handling of components such as the battery pack, composite end cap, cylindrical washers (collars), and hex-head screws (both long and shorter). The instructions guide the user through positioning the battery with the warning label facing down, aligning the end cap, placing washers on screws, and inserting screws into the battery holes. Emphasis is placed on correctly locating the shorter screw and finger-tightening all screws initially. A cross-pattern tightening method is recommended for the final securement to ensure even pressure and prevent damage to the composite material of the end cap. The document specifies a proper tightness of 1.5 lb-ft (2.0 Nm) and advises against overtightening. After tightening, users are instructed to double-check that all fasteners are secure and that the end cap is firmly attached without gaps or loose parts.
• Activation: Before the battery can be used, it must be activated from its "sleep" mode. This process involves connecting the battery to its charger. Activation is confirmed when the LED lamp on the battery illuminates. Users are directed to their e-Bike's Owner's Manual (CrossCore RC, page 54; Wabash RT, page 56) for detailed instructions on charging a battery removed from the bicycle.
• Flexible Use Options: The document presents two main ways to use the extra battery:
  • Storage for Future Use: If the battery is not intended for immediate use, it does not need to be fully charged. Users are advised to follow the "Storage" procedure in their Owner's Manual (CrossCore RC, page 64; Wabash RT, page 66). For storage lasting a month or more, the battery should have only one or two battery capacity indicator LED lamps lit. Storing the battery either completely empty or fully charged is discouraged as it can negatively affect service life. Regular monthly checks of the battery capacity are recommended, with a brief 10-minute charge if the indicator lamp is flashing.
  • Regular Use or Backup for Long Rides: For users who plan to alternate between batteries or carry the extra battery as a backup on long rides, specific precautions are necessary. To transport the battery in a backpack or other bag, the open contacts on the battery should be masked or taped off. The battery must be packed carefully to prevent movement or damage from impacts. Users are directed to the "Transport" procedure in their Owner's Manual (CrossCore RC, page 64; Wabash RT, page 66) for more information on safe transportation.

Maintenance Features

While the document primarily focuses on initial setup and usage, it implicitly includes maintenance-related advice:

• Safety Precautions: A critical maintenance feature is the explicit warning against dropping the battery pack or subjecting it to impact. This is a preventative measure to avoid the battery becoming hot or catching fire, which could lead to serious injury or property damage. Adhering to this warning is crucial for the longevity and safe operation of the battery.
• Proper Tightening: During assembly, the instruction to tighten screws securely but not overtighten, and to use a cross-pattern, contributes to the long-term integrity of the battery's casing and connections. This prevents damage to the composite material and ensures the end cap remains firmly attached, which is vital for protecting the internal components.
• Storage Guidelines: The detailed instructions for storing the battery (not fully charged or completely empty, and regular capacity checks with brief charges) are essential maintenance practices. These guidelines are designed to preserve the battery's service life and ensure it remains in good condition for future use, preventing degradation that could occur from improper storage.
• Contact Protection During Transport: The recommendation to mask or tape off open contacts when transporting the battery is a maintenance-related precaution. It prevents potential short circuits or damage to the contacts, which could impair the battery's functionality or create a safety hazard.
• Professional Assistance: The document offers a valuable maintenance feature by advising users who are uncomfortable with assembly or lack the proper tools to visit a Yamaha dealer or contact Yamaha Power Assist Bicycles Customer Relations. This ensures that the battery is assembled correctly, preventing potential damage or safety issues that could arise from improper self-assembly. This professional support acts as a safeguard for the battery's integrity and the user's safety.

In summary, this document provides comprehensive instructions for the safe and effective integration of a new Yamaha e-Bike battery into the user's cycling experience, covering everything from initial assembly and activation to proper usage and storage, with an underlying emphasis on safety and battery longevity.

Yamaha CrossCore RC Series Specifications