YAMAHA PW V2 VOLspeed E-Bike Tuning Instruction Manual

YAMAHA PW V2 VOLspeed E-Bike Tuning

Product Information

General Information

The Yamaha PW V2 is an electric bike tuning module that allows  you to increase the motor support speed of your e-bike. Byinstalling the tuning module, you can achieve speeds of up to 45km/h (28mph) with electric motor support. The product comes with safety instructions and warranty information.

Requirements for Safe Use

Intended Use
The tuning module is designed to shift the cut-off threshold ofthe motor support of your e-bike. It is intended for use in compliance with the following:

• Restrictions on use
• Installation requirements
• Obligations of the owner and the user

Restrictions on Use
The following restrictions are associated with the installation of the tuning module:

• Do not use in public areas: E-bikes with a permitted speed of  > 25 km/h are subject to regulation in the EU. The tuning moduledoes not provide approval for operation in public areas, therefore, participation in public road traffic and driving on public roads is prohibited after installation.
• Prevent misuse and abuse: Only use your tuned e-bike on private, secured property or race tracks. Do not ride on public paths or areas that you have not securely blocked off against entry by other persons. Always lock your tuned e-bike when parking to prevent misuse and abuse.

General information

• Be sure to take the time to read these operating instructions carefully before starting to install the tuning module.
• Keep these operating instructions in a safe place, yet within easy reach, so that you always have access to the important and safety-relevant information for use, even after installation.
• Make these operating instructions available for reading to any other person who may ride your tuned e-bike.
• Ensure that every person who is allowed to ride your tuned e-bike has read and understood these operating instructions before any use.
• Instruct the user in the safe use of the tuned e-bike with the aid of these operating instructions before leaving your tuned e-bike to other persons.
• Be sure to pass this manual on to the future owner if you ever want to sell the tuning module or your tuned e-bike.

Safety instructions
The warnings used in these instructions draw your attention to possible dangers. You endanger yourself and others if you do not follow these instructions. Serious injuries or considerable damage to property may result.

Warning notices are available in the following categories:

• WARNING : Warns you of hazards that could result in fatal or serious injury to persons if you do not follow these instructions.
• CAUTION : Warns you of hazards that may result in minor, usually reversible injury to persons if you do not follow these instructions.
• ATTENTION : Warns you of situations that can lead to property damage and malfunctions during use if you do not follow these instructions.
• IMPORTANT : Identifies safety-relevant descriptions and instruction parts

Requirements for safe use

Intended use
The tuning module shifts the cut-off threshold of the motor support of your e-bike. Thus, with the installation of the tuning module, speeds of up to 45km/h (28mph) can be achieved with electric motor support. Intended use also includes compliance with all of the following without exception

• Restrictions on use and
• Installation requirements and the
• Obligations of the owner and the user.

Restrictions on use
The following restrictions of use are associated with the installation of the tuning module in your e- bike. Do not use in public areas E-bikes for use on public roads or public ways with a permitted speed of > 25 km/h are subject in the EU to Regulation 168/2013/EU, the Vehicle Regulation. Further approval requirements in non- European countries may apply. The purchase of the Tuning Module does not entail any approval for operation in public areas. Therefore, participation in public road traffic and driving on public roads is prohibited after installation of the tuning module.

IMPORTANT: Prevent misuse and abuse

• Only use your tuned e-bike on private, secured property or race tracks.
• Never ride on public paths or areas that you have not previously been able to securely block off against entry by other persons.
• Also prevent another person from using your tuned e-bike in public traffic or on public roads.
• Always lock your tuned e-bike when you park it. This will prevent misuse and abuse, even by other people.

Restricting the circle of users
Reaching higher speeds can lead to the permissible group of users determined by the e-bike manufacturer having to be further restricted. Such a restriction must be determined by the owner of the tuned e-bike on his own responsibility, taking into account the physical and mental fitness of the persons to whom the tuned e-bike is made available for use.

IMPORTANT : Prevent misuse and abuse

• Clearly define the permission for use before each transfer to other persons.
• Also clearly define the terrain to be covered.
• Always lock your tuned e-bike when you park it. This will prevent misuse and abuse by other people.

Observe shortened maintenance and inspection intervals
Due to the higher speeds with electric motor assistance, higher loads and forces will act on all vehicle parts. Reaching higher speeds increases wear on all vehicle parts, especially the brake system and all parts of the drive system, even with suitable strength and design of the vehicle.

IMPORTANT : Define shortened maintenance and inspection intervals

Shortened inspection and maintenance cycles must be determined by the owner of the tuned e- bike on his own responsibility, taking into account the conditions of use.

• Before each use of your tuned e-bike, perform a comprehensive inspection of the vehicle. It is imperative that you check the condition and function of the
  • brakes and their functional components,
  • vehicle frame,
  • steering system and its functional components,
  • drive system and its functional components as well as components,
  • saddle and its functional components,
• In addition, observe all inspections not mentioned here that are prescribed by the manufacturer of your e-bike before each use. This list does not replace the original operating instructions of the e-bike manufacturer.
• Establish further inspection and maintenance cycles according to the manufacturer’s instructions for your e-bike.
• Shorten them according to your operating conditions.
• If necessary, coordinate this with your specialist company, which will carry out the inspection and maintenance work.
• This ensures that the shortened inspection and maintenance intervals are adhered to.

Know and comply with installation requirements
For safe use of the tuning module in your e-bike, your e-bike must also meet some requirements.

Requirements for the strength and construction of the e-bike
Strength and construction requirements are regulated by EN 15194 and EN ISO 4210-2 and must be confirmed as applied by the manufacturer of your e-bike.

WARNING: Prevent increased accident risks due to insufficient strength

• Due to the higher speeds with electric motor assistance, higher loads and forces will act on all vehicle parts. Increased accident risks due to part breakage and part failure can only be largely ruled out with e-bikes that are demonstrably designed and built in accordance with both product standards.
• Check the EC declaration of conformity of the manufacturer of your e-bike.
• Only install the tuning module in your e-bike if the manufacturer of your e-bike states the two product standards EN 15194 and EN ISO 4210-2 as applied in its EC declaration of conformity.
• Only if both standards are mentioned as applied, it can be assumed that the requirements for strength and design are fulfilled.
• Never use the tuning module in vehicles for which you cannot clearly establish these requirements and prove them by means of the EC declaration of conformity from the e-bike manufacturer.

IMPORTANT: Racing e-bikes, city e-bikes or trekking e-bikes are usually not equipable

Racing e-bikes, city e-bikes or trekking e-bikes often do not meet the requirements for strength and construction, as lower requirements apply to these types of e-bikes. Furthermore, it cannot be assumed that these e-bikes are actually only used on private, secured properties or race tracks.

• Check and confirm drive system and display requirements
• The tuning module is adapted to specific drive systems and display types.
• Check the equipment of your e-bike.
• The tuning module only works with e-bikes that have an electric motor support of up to 25km/h ex works. Children’s e-bikes with a support up to 20km/h and Speed-e-bikes with a support up to 45km/h are not supported.
• Only install the tuning module into your e-bike if you can determine that your e-bike equipment matches the drive systems and display types listed below.
  Drive system:| Display type:| Control Unit:
  ---|---|---
  Yamaha PW| LCD, LED| –

Compatibility

The tuning is NOT compatible with the following motors:

–  All newer Yamaha motors (PW-X, PW-X2, PW-X3, PW-SE, PW-TE, PW-ST)

–  Giant Syncdrive Sport and Pro motors.

Prevent damage and malfunctions

Use in vehicles with unsuitable drive systems and/or display types will lead to malfunctions or damage to the e-bike or the tuning module.

Obligation of the owner
Any user of the tuned e-bike must be instructed accordingly by the owner of the tuned e-bike on the basis of these operating instructions, as well as being informed about the special restrictions on use and increased risks due to the increased speed. The owner of the tuned e-bike ensures that all requirements for safe use

• all requirements for safe use
• and for the intended use are complied with, and
• these operating instructions are always available to every user.

The owner of the tuned e-bike undertakes to only make the tuned e-bike available to persons who have read and understood these operating instructions and

• have been instructed in the safe and proper use of the tuned e-bike.
• have been instructed in the safe and proper use of the tuned e-bike.

Obligation of each user

Every user is obliged,

• to read and observe these operating instructions in full, and
• to follow all safety and warning instructions without exception,
• to use the tuned E-bike only in technically perfect condition and in accordance with its intended purpose, in a safety-conscious and hazard-conscious manner and in compliance with these operating instructions and
• to remedy immediately any damage or malfunctions detected which could impair safety, or, if necessary,
• to have them remedied.

Warranty and liability

Warranty and liability of the tuning module manufacturer

• Increased wear or breakage of components of the e-bike, especially parts of the brake system and/or the drive system,
• non-observance of these operating instructions,
• improper use of the tuning module or the e-bike with integrated tuning module,
• non-observance of the operating restrictions of these operating instructions,
• use or operation with operating conditions that do not comply with these operating instructions, improper installation, commissioning, maintenance or repair not specified in these operating instructions,
• after unauthorised structural, hardware or software modifications to the tuning module itself or to the e-bike approved for the tuning module or its equipment.

IMPORTANT: The installation and operation of the tuning module is at your own risk.

• The manufacturer of the tuning module does not accept any liability for damage related to the operation or installation of the tuning module.
• The technical and legal consequences mentioned may be incomplete.
• In addition to the technical and legal consequences mentioned in these operating instructions, further requirements may apply depending on the place of operation.
• Before installing the device, inform yourself about possible further technical and legal consequences and requirements that you must comply with in order to operate the tuned e-bike.

Warranty, guarantee and liability by the manufacturer of the e-bike

Due to the higher speeds with electric motor assistance, higher loads and forces will act on all bicycle parts. Reaching higher speeds increases wear on all bicycle parts, especially the braking system and all parts of the drive system, even if the vehicle is of suitable strength and design. For this reason, liability, warranty and guarantee claims against the dealer or manufacturer of the ebike will expire or be severely limited with the use of the tuning module.

Property damage and personal injury

Further exclusions of liability to be considered
An e-bike can reach electric motor-assisted speeds of up to 45 km/h after the tuning module has been installed. Reaching such speeds increases the risk of a fall and resulting injury, even with

ATTENTION: Reduce increased liability risks

• Precisely define your operating conditions and user groups to be insured.
• Take out li0ability insurance appropriate to the conditions of use and the user group for the use of your tuned e-bike.

WARNING: Reduce increased risk of hazards

• Always wear suitable protective clothing and a helmet while using your tuned e-bike to protect yourself from increased risk of accidents.
• Insist that every user of your tuned e-bike wears appropriate protective clothing and a helmet at all times during use.

ATTENTION: Reduce the risk of accidents monetarily

• Precisely define your operating conditions and user groups to be insured.
• Take out an insurance policy for the use of your tuned e-bike that is appropriate to the conditions of use and the user group.

Functional description
The tuning module provides the following functions after installation:

• Adjustable speed limit up to 45km/h (28mph) via the control unit on the e-bike
• Adjustable dynamic mode, reduced “wall effect”
• Correct display of speed and distance travelled
• Residual range calculation with consideration of the current riding style
• Correct total odometer reading after re-removal of the tuning module
• Wheel circumference adjustable

Setting options
All settings are made via the display on the e-bike or the RideControl App.

Protected electronics
The electronics are cast into the housing and thus safely protected from moisture.

Safety and protective devices
Safety and protection devices of the e-bike remain untouched by the installation of the tuning module.

Technical data

• Housing dimensions: 37mm x 19mm x 9mm (1.46” x 0.75” x 0.36”)
• Cable length: Approx. 140mm (5.5”)
• Weight: 0.025kg (0.9oz)
• Power consumption: 0.1W
• Supply voltage: 5VDC

Installation

IMPORTANT : Before you start the installation

Confirm that you have read and understood all previous chapters of these operating instructions carefully and completely before you start the installation. This is the only way to ensure that youuse the tuning module exclusively for the purpose described in these instructions and as intended.

The installation described below and all associated instructions for action refer to the installation example: Haibike SDURO Fullnine RX Other e-bike Models

For other e-bike models, the installation may differ slightly from the installation
example.

Required tools

• Allen key 3mm / 6mm
• Torque wrench

Other tools may be necessary
The lower and side motor covers may also be fastened with other screws, depending on the e-bike model. Additional tools may be required for this.

Note part number and serial number For support requests note

Make a note of the

• Part number (P/N) and
• Serial number (S/N) of the tuning module on the back of these operating instructions. This way, you always have the data at hand for possible support requests.

Remove covers

WARNING : Prevent unexpected startup

If the drive starts unexpectedly, hands and fingers may shear, crush or retract. Switch off the e-bike and remove the battery. This will prevent any movement assisted by the electric motor. Ensure that your e-bike stands firmly and securely.

• Remove the screws (1) and (2) from the stone guard. The screws behind the chainring do not need to be loosened.
• Loosen the screws (3), (4) and (5).
• Remove the screws (3) and (4) and fold down the motor. The screw (5) serves as a hinge.
• Trace the cables coming off the top of the motor and disconnect the 3-pin connector (speed sensor) and the 4-pin connector (display).

Check function

• Insert the battery pack back into the e-bike.
• Switch on the e-bike and perform the setup as described in chapter 7.
• When the setup has been performed successfully, switch the e-bike off again and remove the battery.

Finalize installation

• Place the tuning module and the connectors in a suitable location, for example in the down tube.
• Make sure to route the cables so that the motor can be folded back up completely.
• Fold the motor back up and reinstall the screws (3) and 4). Do not crush any cables in the process.

ATTENTION : Protect speed sensor cable

On full suspension bikes, make sure that the cable to the speed sensor has enough room to move at the transition to the chainstay, otherwise it could tear off during compression.

• Tighten the screws (3), (4) and (5) to 22Nm.
• Reattach the stone guard with the screws (1) and (2).

Setup
Before using the tuning module for the first time or after conversion to another bike, the setup must always be executed first. Even in the event of malfunctions, a defined state of the module can be restored by running the setup

• Switch on the e-bike
• Press “Arrow up” and “Arrow down” simultaneously for 3 seconds
• Speed 11.1 km/h is displayed for 10 seconds.
• The wheel circumference stored in the motor is displayed for 5 seconds. The value can be adjusted with the “Arrow up” and “Arrow down” keys. However, a correction is normally not required.
• As soon as 0.0km/h is displayed again, the setup is complete.

Speed Mode
When Speed mode is activated, the speed limit for motor assistance is raised. The limit can be freely set in the range 25 to 45km/h. When the e-bike is switched off, the speed mode is automatically switched off and must therefore be reactivated when the e-bike is switched on again.

Activate

• Press the “Arrow up” key for 2 seconds.
• The speed limit is displayed for 5 seconds. If desired, use the “Arrow up” or “Arrow down” keys to adjust the value. The set value is saved. Possible values: 25..45 km/h. Default value: 32 km/h.
• The display shows the normal speed again. The speed mode is active.

Deactivate

• Press the “Arrow down” key for 2 seconds.
• The display shows 25.0km/h for 2 seconds. The speed mode is off.

Dynamic Mode
If the speed limit is exceeded, the motor power is reduced very strongly by default. A higher pedal force then initially no longer results in a higher speed, but in a lower motor support. For a more natural riding experience, the dynamic mode spreads the downshift over a wider speed range, the so-called “wall effect” is significantly reduced and it is possible to ride with much more constant pedal force. Dynamic mode can only be activated when Speed mode is active.

• While riding (> 10km/h), press the walk button for 2 seconds.
• Dynamic mode off: 50.0 km/h is displayed for 2 seconds.
• Dynamic mode on: 50.1 km/h is displayed for 2 seconds.

Range calculation
Speed mode can significantly reduce the range of the e-bike. In the original state of the bike, the range is only calculated from the current charge level of the battery and the selected support level. When Speed mode is activated, the current power consumption also flows into the range calculation, making the displayed remaining range more accurate.

Speed-Modus aus

Speed Modus ein

FAQ

At speeds above 25 km/h, it takes a bit longer until the motor assistance kicks in. Why is that?
If you don’t pedal at higher speeds, the time is used to adjust the mileage in the motor control unit to the actual kilometers driven by simulating a high wheel speed. If the pedal is then pressed again, it takes a little longer for the motor to provide support again.

However, the time is significantly less than one second.

Is the total mileage correct even after removing the module?
Yes, the total kilometers measured by the motor control unit are not changed by the tuning. This is ensured by a compensation function in the tuning module that works continuously in the background. However, before removing the module, the bike should be left at a standstill with Speed Mode switched on until it switches itself off. This ensures that the compensation function has adjusted the mileage correctly.

However, any wheel circumference adjusted during setup does not affect the odometer reading of the motor control unit. When the circumference is adjusted, deviations therefore occur in principle.

The displayed speed or the total mileage is not correct. What can I do?
Run the setup again. This will transfer the current mileage from the motor control unit to the tuning module and you will have the option to readjust the wheel circumference if necessary.

Technical support
If you have any questions or problems, please contact us by e-mail or telephone at: TLI Elektronik GmbH St.-Martin-Str. 11 D-86676 Ehekirchen [email protected] Tel.: +49 (0) 8253 / 9279902

In addition to your request, please provide the following information:

• Article number and serial number of the unit (S/N, P/N)
• Bicycle manufacturer, type and year of construction
• Display type (e.g. LCD)
• Motor type (e.g. Yamaha PW)

To ensure that you always have the unit data at hand, you can enter it here before installing the unit:

• Part number (P/N):
• Serial number (S/N):

Disposal
Electronic devices are recyclable materials and do not belong in household waste. At the end of its service life, dispose of the product in accordance with the applicable legal requirements.
0036089 631057 >
1273_BA_E_Rev0 – VOLspeed Yamaha PW
© TLI Elektronik GmbH

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