yamaha pw-x removal from Haibike Allmtn 2.0

[davebarras]

Hi,
Having trouble getting at the wiring.
Seem to have all the right bolts removed but won't even wiggle. What am I missing ?

 

[Nova Haibike]

What am I missing ?

A hammer (such as the Park Tool Shop Hammer, or a plastic mallet.)

Here are service instructions for Yamaha motors. See page 2-4 and the accompanying illustration. Read the tip for removing the motor from the frame mount.

 

[davebarras]

A hammer (such as the Park Tool Shop Hammer, or a plastic mallet.)

Here are service instructions for Yamaha motors. See page 2-4 and the accompanying illustration. Read the tip for removing the motor from the frame mount.

That worked perfect...thank you so much !!

 

[FlatSix911]

A hammer (such as the Park Tool Shop Hammer, or a plastic mallet.)

Here are service instructions for Yamaha motors. See page 2-4 and the accompanying illustration. Read the tip for removing the motor from the frame mount.

Well done... thanks for sharing the Yamaha Service manual.

 

[bikero]

Hi Dave!
I'm also struggling to remove the drive unit assy. I tapped the bolt with a plastic hammer but nothing seems to happen.
How hard did you tap it? Does it have to be a "manly" tap or really a light tap like the instructions say?
What happened in your case when you tap it? Did the [a] move?

 

[davebarras]

I have removed mine twice now.....not much of a tap does not take much !
Make sure it is not hitting the frame slightly when trying to get out, mine was had to wiggle it.

 

[bikero]

Do I have to re-insert the long screws (M8) and torque them to 22 Nm in order for the tapping on the M6 screws to work?
Because I initially removed all the screws and only after I read the instructions from the service manual.
Also, I don't understand what happens when I tap the M6 screw, how does it have any effect whatsoever.. from what I see, there is nothing it pushes against inside.

 

[davebarras]

Do I have to re-insert the long screws (M8) and torque them to 22 Nm in order for the tapping on the M6 screws to work?
Because I initially removed all the screws and only after I read the instructions from the service manual.
Also, I don't understand what happens when I tap the M6 screw, how does it have any effect whatsoever.. from what I see, there is nothing it pushes against inside.

I put them all M8 and M6 back in, did not torque it just tightened it and then did exactly like the directions said. I have never cared to research what holds it inside and why it requires a " tap " but did not care once it worked
Once I got it to wiggle a little I realized it was hitting frame ever so slightly so keep an eye on that also.

 

[bikero]

I got it to wiggle a bit but not that much, tapping on the screw doesn't seem to work. The reason why I asked you how the tapping works is that in my case it might be stuck for some reason so I needed a workaround. Really don't understand why a PW-SE is so easy to remove yet a PW-X is so difficult.
Btw, how did you put it back on? The instructions state
"lightly tap the protruding portion [a] of the Drive Unit assy. plug with a plastic hammer to push it in"
Where exactly do you tap? And is it really "in" or actually out? Because you already pushed it in when you initially removed the motor, right?

 

[bikero]

Too long just give me the short answer version: don't gently tap the M6 screw with a plastic hammer, use a normal hammer and apply moderate force until there is no space between the plug (see picture below) and the motor - it helps if you put the bike upside down to see when this happens but you can feel it as well i.e. motor starts to wiggle after this happens. Don't forget to do this for both M6 screws.

To anyone else facing this issue, today I had to (again) remove my motor (PW-X, the first one) in order to replace the sensor cable.
The "gentle" tap mentioned in the Yamaha service manual is an absolute joke. I went to a car mechanic to show him and he bet this couldn't be done with a plastic mallet to begin with.
The plug mechanism (sorry for the photo, it's not from my PW-X but it's very similar) works like this:
When the motor is out of the bike,the plug is near the motor (there is no space); when you put the screws in, this plug goes away (like half of a millimeter) from the motor and this is what it makes it "stuck", what the original poster of this thread mentioned
The only trick left is to get it close to the motor again while inside the frame. This is done via what the manual says, gently tapping the end of the small M6 screw with a hammer.
However, this indication is awfully misleading because you can gently tap the end of the M6 screw all day long, the plug won't budge!

My car mechanic then used a normal hammer and applied 2-3 short but relatively powerful hits. The plug moved next to the motor and the motor was free!!
I followed the Yamaha indications by heart and couldn't move the damn plug even after 100 gentle taps with the plastic hammer.

Conclusion: sometimes it is better to use force. Not sure why in my case the manual indications don't work but keep in mind this is my second Yamaha PW-X motor with this problem.