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SERVICE MANUAL
My14 (and previous)
19-02-2014 HPB service manual MY14
1. INTRODUCTION

2. UPDATES

LATEST UPDATE: 19-02-2014

3. RIDE CONTROL

3.1 DISPLAY AND CONTROLLERS

3.2 DISPLAY IN WORKING ORDER
3.3 SET RIDECONTROL
3.4 RESET RIDE CONTROL
3.5 SELF-TEST MODUS
3.6 ERROR DIAGNOSTICS

4. PEDALPLUS

4.1 TORQUE SENSOR

4.1.1 Zero value torque sensor test
4.1.2 Rear torque sensor replacement
4.1.3 Chain wheel torque sensor replacement
4.2 SPEED SENSOR
4.3 CADENCE SENSOR
4.4 MOTOR ROTATION SENSOR

5. DRIVER

5.1 VOLTAGE DIFFERENCE

5.2 REPLACING DRIVER

6. ENERGYPAK

6.1 TEST FUNCTION ON ENERGYPAK

6.2 CAPACITY TESTER
6.2.1 Guidance
6.2.2 Discharge time table

7. SYNCDRIVE

7.1 SYNCDRIVE FRONT MOTOR REPLACEMENT

7.2 YAMAHA MOTOR REPLACEMENT
7.3 BOSCH MOTOR REPLACEMENT
7.4 SYNCDRIVE REAR MOTOR REPLACEMENT

8. WIRING SCHEMES

FRONT SYNCDRIVE
CENTRAL SYNCDRIVE
REAR SYNCDRIVE

9. VARIOUS ISSUES

9.1 LIGHTS
9.2 CHAIN TENSIONER

10. TOOLS, GIANT SPECIFIC

11. CONTACT

19-02-2014 HPB service manual MY14

1. Introduction
This manual is about Giant hybrid bikes. Along with explaining the parts, problem solving is being
handled. Specific tools are pointed out along with their Giant part codes. In case of an update, this
will be mentioned.

Step 1: Select the power mode and you’re ready to ride. Monitor riding information from the screen and adjust the tempo.
Giant designed all its controls so that you can operate them with your hands firmly on the grip. This gives you safe and
intuitive control to your bicycle.

Step 2: The Pedalplus sensor system precisely registers the amount of force you’re putting into the pedals and your moving
speed. This information is sent directly to the I² driver unit. Giant combines 4 sensors: human torque, motor speed, cadence
and bicycle speed.

Step 3: The I² driver unit receives the information from the PedalPlus sensors. Via its proprietary software, it is able to send
a smoothed-out power curve demand to the EnergyPak power source. Accurate computing allows to maintain an ideal
cadence, and makes power consumption more efficient.

Step 4: The high-capacity Lithium-ion battery pack produces more power and a longer riding range. The EnergyPak
communicates with the I² driver to deliver just the right amount of power to the SyncDrive motor.

Step 5: Thanks to Giants proprietary Sine Wave software and integrated motor sensors, Giant offers you a smooth and
quietly on your ride. Because of the wide range of motors, you can choose the most suitable version.

19-02-2014 HPB service manual MY14

2. Updates
In case of an update of this manual, you will receive pages to replace the expired ones in this manual.
An overview will be visible down here. This way, this manual will always be up-to-date.
Be sure to always remove old pages.

Latest update: 19-02-2014

Up Dates chapters
19-02-2014 HPB service manual (release date)

19-02-2014 HPB service manual MY14

 3. Ride Control
The Ride Control is the interface between user and driver. With these display and buttons, functions
can be selected and information can be shown.

3.1 Display and Controllers

LED MY14/13
A On/off button
B Light
D1 Power assist selector up
D2 Power assist selector down
E Power Assist indication
L Indicator energy level

In case of a double EnergyPak, a double

line of LED’s (L) is visible, representing the
second EnergyPak.

LCD MY14/13
A on/off + EnergyPak selector
B Lighting (B1 Lighting indication)
C Mode
D Power assist button (D1 up D2 down)
E Power assist indication
F Speed
G Average speed
I Odo (total distance)
J Trip time
K Time (MY14, no info)
L EnergyPak indicator
(L1 battery 1, L2 battery 2)
M Energy select indicator (Left or Right)
N No info
O Ridecontrol plug socket
P Ridecontrol communication cable plug
Q Motion assist
R Power assist level indication bar

19-02-2014 HPB service manual MY14

LCD MY10/12
A On/off +EnergyPak selector
B Lighting
C Mode
D Power assist button
E Power assist indication
F Speed
G Average speed
H Trip distance
I Total distance
J Trip time
K Time
L EnergyPak charge indicator
M EnergyPak select indicator (left/right)

3.2 Display in working order

When you see no figures displayed on the Ride Control;
Step 1: Make sure the battery is charged, and not in an idle state.
Step 2: Make sure the display is connected correctly and the bike is switched on.
Step 3: Check the connections between RideControl bracket and buttons. Sometimes the connector
is not connected firmly.
Step 4: Check the contact points on the RideControl bracket. They sometimes are crooked by misuse.
(MY13 and older)
Step 5: Check the connections between the driver and RideControl.
Do not use contact spray. A degreaser-spray is advised.
Step 6: If previous steps are OK, replace RideControl display.
Step 7: If RideControl display still does not switch on, replace the driver.

3.3 Set Ridecontrol

Display settings:
Press button (C) to select the following display; Speed, trip distance / Average speed, ODO (total
distance) & trip time.

Power assist setting

Press button (D1) to choose a higher Power assist level (E).
Press button (D2) to choose a lower Power assist level (E).
SPORT: High power assist. Gives the smallest range
NORMAL: Normal power assist.
ECO: Low power assist. Gives the maximum range.
OFF: For riding without power assist but with cycle computer and light functions.

19-02-2014 HPB service manual MY14

Time setting (not available for MY14)
Step 1: Press ‘light’ (B) until minutes (J) start blinking.
Step 2: Adjust with + and – (D1 +D2).
Step 3: Confirm with mode (C) and pass on to hours.
Step 4: Repeat steps 2 and 3 for hours and date.
Step 5: Confirm all by pressing ‘light’ (B) until all stops blinking.

The maximum of ODO distance shown is 9999km. Please reset ODO when this distance has been
reached.

3.4 Reset Ride Control

MY14
Reset trip data:
To reset the values of trip distance, trip time and
average speed;
Press and hold the ‘M’ button (C) for 5 seconds.

Reset all data:

To reset the values of all trip data, including
ODD;
Press and hold the ‘-’ and ‘+’ buttons (D1+D2)
simultaneously for 5 seconds.

MY13
Reset trip data:
To reset the values of trip distance, trip time and
average speed;
Press and hold the ‘+’ button (D1) for 5 seconds.

Reset all data:

To reset the values of all trip data, including
ODD;
Press and hold the ‘-’ button (D2) for 5 seconds.

19-02-2014 HPB service manual MY14

MY10/12
20V series (mentioned on backside)
Step 1: Press ’level’ and ‘light’ buttons
simultaneously, until ‘00’ is blinking in the
display.
Step 2: To reset trip time, press ‘level’ button
once, and ‘light’ button twice.
Step 2a: To do a complete reset, press ‘level’
button twice, and ‘light’ button twice.

30V series (mentioned on backside)

To reset the display, press ‘mode’ until values
switch to zero.

3.5 Self-test modus

In self-test modus, several key components of the bike can be tested.
For example the motor, torque sensor and speed sensor etcetera. See Chapter 3.6 for error
diagnostics.
Note: make sure that the bike is turned off. Otherwise it is not possible to get in self-test mode.

MY14/13
Step 1: Press the ‘light’ button and then the
‘on/off’ (A) button for a few seconds.

Step 2: One or two of indicators 2, 3 and 4 will Examples

light up, being the motor sensor. You are in test
modus.
Now test the various components;

19-02-2014 HPB service manual MY14

Step 3: Speed sensor:
Rotate rear wheel forwards.
Check if indicator 1 blinks when the magnet
passes the speed sensor.
(only when rear speed sensor is used)

Step 4: Motor sensor:

Rotate the wheel backwards.
Check if indicators 2, 3 and 4 light up alternately.
(applies to hub motors)

Step 5: Torque sensor:

Block the rear wheel.
Press the pedal with increasing force. Indicators
1,2,3,4,5 should light up according to the
exercised force.
(applies to all motors)
Step 6: Cadence sensor:
Rotate the cranks forwards. Indicator 5 should
blink.
(applies only to bikes with cadence sensor)

Step 7: To leave self-test modus press the

‘on/off’ (A) button until the display turns off.

MY10/12
Press the ‘on/off’ (A) button and the ‘light’
button(B) simultaneously for 5 seconds.

To leave the test modus press the ‘on/off’ (A)

button.

OLDER MODELS, MY 2007/2010

Switch on the bike, while holding the circled
button for 3 seconds.
The bike will go into Self-test mode now.

19-02-2014 HPB service manual MY14

3.6 Error diagnostics
In case of an error, all battery indicators will blink three times. After that, the issue indicating battery
indicators will continue blinking while all other battery indicators light up continuously. In this
chapter it’s clarified what’s the cause and what’s the solution.

Be clear in the communication towards your client and Giant;

the bottom battery indicator is number 1, the top battery
indicator is number 5.

If there are any problems with a MY13 display, be sure to work with the updated version of display,
RideControl bracket and buttons. The updated version has a green ‘G’, marked on the back of the
display, RideControl bracket and buttons. When you work with a non-updated version, contact your
local Giant service dealer for a replacement.

Quick summary:
Number Cause Solution
#5 EnergyPak signal problem * If connections are not ok, replace
cable or connections.
* If connections are ok, replace battery
connector (male side).
* If indicators still blink, replace driver.
#4 Motor signal error * If indicators light up alternately,
replace driver.
* If indicators do not light up
alternately, replace motor.
#3 A: Speed sensor malfunction * Adjust sensor magnet position.

B: Cadence sensor malfunction Replace cadence sensor.

#2 Torque sensor signal error Reset power
Replace torque sensor
#1 The EnergyPak is completely empty Charge EnergyPak

Comprehensive explanation
Indicator #1
Cause:
Battery current is low.

Step 1: Check the remaining energy level in the

EnergyPak. See chapter 6.1 for help.

Step 2: When level is low, charge battery.

19-02-2014 HPB service manual MY14

Indicator #2
Cause:
Torque sensor signal error

Step 1: Access self-test mode (chapter3.5).

Step 2: Block the rear wheel. Press the pedal firm and
continuously. #1,2,3,4,5 should light up proportionally.

Step 3: Check the connections between torque sensor

and driver.

Step 4: If connections are OK, but # 1/5 do not light up,

replace torque sensor. See chapter 4.1 for help.

Indicator #3
Causes:
A: Speed sensor malfunction
B: Cadence sensor malfunction, for front and rear motors
MY14 and MY13 only.
Step 1: Access self-test mode (chapter3.5).
Step 2a: Rotate rear wheel forwards.

Step 3a: Check if #1 blinks when the magnet passes the

speed sensor.

Step 4a: If #1 does not blink, adjust speed magnet

conform chapter 4.2.
Step 5a: When #1 still doesn’t blink, replace speed
sensor.
Next steps apply to front and rear motors MY14 and
MY13 only.
Step 6b: Rotate crank forwards.
Step 7b: If indicator 5 does not blink, replace cadence
sensor.

19-02-2014 HPB service manual MY14

Indicator #4
Cause: Motor signal error

Step 1: Check the cable and connections between motor

and driver.
Step 2: Access self-test mode (chapter3.5).
Step 3: Rotate the motor wheel backwards.

Step 4: Check if #2, 3 and 4 light up alternately.

Step 5: If #2/4 light up alternately, replace driver.
Step 6: If #2/4 do not light up alternately, replace motor.

Indicator #5
Cause: Battery signal error

Step 1: Check the connections between EnergyPak and

driver.
Step 2: If head- and rear lights glow, the wires are
connected in the wrong way. Energypak and lighting
system have the same connectors. Reconnect them the
right way.
Step 3: If connections are ok, replace battery connector
(male side).

Step 4: If #5 still blinks, replace driver.

See ‘various issues’ for further problem solving.

19-02-2014 HPB service manual MY14

 4. Pedalplus
Giant is using a 4 sensor technology for torque, cadence, motor rotation and speed sensor. These
sensors give information to the driver. With this info the driver can decide what support is necessary.

4.1 Torque sensor

The Pedalplus is a ‘torque sensor’ that generates the signal of power given by the rider. The amount
of power assistance from the motor depends partially on how much signal is generated by the torque
sensor. Central motor systems have this sensor built in.
If there are problems with inconsistent assistance and insufficient range, it is advised to test the
torque sensor.

4.1.1 Zero value torque sensor test

To make sure the torque sensor is ok, a test can be done. It can be done with three different tools.

1: The E-lab (Part# 9500000V) is a Giant multi-usable device. The value of

the measurement has to be between 1V and 2V. If the value is not between
the 1,0V and 2,0V replace the complete torque sensor assembly.

The E-lab is a multi-purpose tool for Giant E-bikes. Contact your Giant
contact person for further information.

2: Use the pedalplus voltage tester (Part# 5481-GITS-

01V). The value of the measurement has to be between
1V and 2V. If the value is not between the 1,0V and 2,0V
replace the complete torque sensor assembly.

19-02-2014 HPB service manual MY14

3: You can also use cable
assembly (part# 147L-
HCtes-01V) between the
connection of the torque
sensor and the driver. It
will only fit one way. The
white plug is used for
measurement.
Use a multi-meter in DC
setting for this measurement, place the probes of the meter against the contacts of the white plug.
The value of the measurement has to be between 1V and 2V.
If the meter gives a minus (-) in front of the numbers you have to switch the red and black probes
because this is a polarity warning.
If the value is not between the 1,0V and 2,0V replace the complete torque sensor assembly.

4.1.2 Rear torque sensor replacement

Step 1: If in order, remove the cover of the torque sensor unit and the bolts of the pannier-rack.
Step 2: Disconnect the cable of the torque sensor unit completely.
Step 3: Release the nut and ring of the rear axle.
Step 4: Unscrew the bolts of the torque sensor unit and take the
unit out.
Place the new torque sensor unit. Make sure the sensor cable
does not get stuck.

Step 5: Replace the bolts. Tighten them with a torque wrench

[10Nm]. Use the correct sequence, being; center, right, left
(1,2,3).

Step 6: Replace the axle nut and ring, and tighten them with a torque wrench [40Nm].
Step 7: Realign the cable and do the ‘Zero value torque sensor test’ as previously described. If the
test is ok, replace the covers and rear rack. The bike is ready for use.

4.1.3 Chain wheel torque sensor replacement

In older model years (MY07-MY12) bottom bracket torque sensors were used.
Step 1: Remove the crank with a regular extractor. The
Pedalplus chain wheel unit stays on the axle.

19-02-2014 HPB service manual MY14

Step 2: Remove the lock-ring with 4 pin socket (turn
clockwise). (part# 2520-FY06-03V)

Step 3: Remove the chain wheel unit. The torque

sensor can be removed by loosening the 3 screws and
disconnecting the connector.

Step 4: Follow the procedure in reversed order (with a new sensor) to reassemble.

4.2 Speed sensor

As of MY14, front hub motors have an internal speed sensor. In case of an external speed sensor,
actions as written below should be followed.
Step 1: For proper function, the center of the
magnet must be aligned with one of the ends
of the speed sensor(S-Marks) and point in the
direction of the sensor. If you listen very
close, you can hear the relais ‘click’ inside the
speed sensor.
If this doesn’t work, try step2.

Step 2: Switch the multi-meter in Ω position.

Measure at the plug of the speed sensor. Turn
the wheel. Every time the magnet passes the
sensor, the indication on the multi meter
should jump from “OL” to a value.
If this doesn’t work, try step 3.

Step 3: Switch the multi-meter in DC position.

Switch on the bike. Measure at the plug of the
speed sensor from the driver. The voltage
should be approx 5 Volt.
If this doesn’t work, replace speed sensor.

19-02-2014 HPB service manual MY14

4.3 Cadence sensor
As of MY14, a cadence sensor is mounted in all bikes. The response of this sensor smoothens the
ride, especially after every stop. This sensor is inside the motor of central Syncdrives (Yamaha and
Bosch). In all front and rear Syncdrives, this sensor is mounted (under a cover) at the bottom bracket.

MY14/13
Step 1: Remove the cover of the driver.

Step 2: The cadence sensor is mounted on the bottom

bracket.

Step 3: Remove the sensor.

Step 4: Follow the procedure in reversed order (with a new sensor) to reassemble.

To measure the cadence sensor, you can also use cable assembly (part# 147L-HCtes-01V) between
the connection of the cadence sensor and the driver. It will only fit one way. The white plug is used
for measurement. Use a multi-meter in DC setting for this measurement, place the probes of the
meter against the contacts of the white plug. The value of the measurement has to be +/- 5V.

19-02-2014 HPB service manual MY14

4.4 Motor rotation sensor
Every motor has 3 sensors for rotation detection. The position of the sensors regulates the current
that is sent to the coils of the motor to make it run smoothly.

If the speed sensor is malfunctioning, the motor rotation sensor will generate a speed signal until
approximately 12 Km/h. This means that despite a malfunctioning speed sensor, a speed indication
will still show. Above approximately 12km/h, “OL” will appear in the screen. If only a LED screen is
used, LED 4 will blink.

19-02-2014 HPB service manual MY14

 5. Driver
The driver collects all info and controls the motor. It’s ‘the brain’ of the bike. Driver failures should be
solved by the dealer by replacement of the complete driver. Malfunctioning drivers should be
returned to your Giant representative. Different sorts of bikes and EnergyPaks use different drivers.

5.1 Voltage difference

Different voltage drivers have been used. From MY11 on, 36V drivers have been in use. There is an
obvious visual distinction between the 26V and 36V versions, being the connectors and the (color of
the) Voltage decal.

5.2 Replacing driver

When replacing a driver, unplug the EnergyPak first.
Loosening cables of drivers
Note: Do not damage the plug and cable. Never pull the cable directly. Always remove the plugs
using your fingers or long nose pliers.
Step 1: Unplug the battery cables first. The connector
to the battery has a locking hook. Press it off by a small
screwdriver.

Step 2: Unplug bus connectors. Green and blue cables

can be hard to distinguish in dark areas.

Step 3: Unplug the other cables. The connectors have a

locking hook. Unlock this.

Step 4: Follow the procedure in reversed order (with a new sensor) to reassemble.
Note: Avoid stressing the connectors when mounting the driver back into the driver compartment.

MY 14 models with driver in down tube

19-02-2014 HPB service manual MY14

Step 1: Loosen the 3 Philips screws.

Step 2: Remove the cover.

Step 3: Remove (the screws that fixes) the cadence

sensor.

Step 4: Pull the driver out of the tube. Disconnect all

cables.

Step 5: Follow the procedure in reversed order (with a new driver) to reassemble.

MY 13 models with driver in down tube

Step 1: Loosen the 3 Philips screws.

19-02-2014 HPB service manual MY14

Step 2: Remove the cover.

Step 3: Remove the screw that fixes the driver. Pull the
driver out of the tube.

Step 4: Follow the procedure in reversed order (with a new driver) to reassemble.

MY 13 models with horizontal EnergyPak

Step 1: Loosen the two hex bolts.

Step 2: Slide the cover backwards in between pannier

rack and driver housing.

Step 3: Loosen the screws of the driver.

Step 4: Follow the procedure in reversed order (with a new sensor) to reassemble.

19-02-2014 HPB service manual MY14

MY10 and later models with vertical EnergyPaks
Step 1: Loosen the two hex bolts.

Step 2: Pull the cover up and pull of forward.

Loosen the screws to release the driver.

Step 3: Follow the procedure in reversed order (with a new sensor) to reassemble.

Older models (MY 07 - MY10)

Step 1: Loosen the three screws.

Step 2: Remove the cover.

Step 3: Loosen the screws to release the driver.

Step 4: Follow the procedure in reversed order (with a new sensor) to reassemble.

19-02-2014 HPB service manual MY14

 6. EnergyPak
Giant hybrid powered bikes use various Energypaks. They vary in voltage, capacity and shape. The
type of Energypak can always be found on the Energypak itself, usually on the backside.

6.1 Test function on EnergyPak

The 36V EnergyPaks are equipped with an internal test function.
If you push the “push “button on the EnergyPak/battery pack for a few seconds, it will show the
remaining amount of energy left in the battery pack.
If you encounter issues with charging an EnergyPak, check all connectors on both EnergyPak and
charger.

19-02-2014 HPB service manual MY14

6.2 Capacity tester

6.2.1 Guidance
The capacity tester is used to determine the discharge time of the EnergyPak.
Important: This measurement is only reliable when started with a fully charged EnergyPak.

Usage
Step 1: Use the correct position of the ‘Volts’ indicator
(depending on the type of battery).

Step 2: Connect a fully charged EnergyPak to the tester

(check polarity).

Step 3: Switch on the tester (at the back of the machine). The
display indicates the voltage of the battery. The ‘voltage’ LED
lights up.
for a 36V battery the ideal voltage is 41,5 V +/-0.2V
for a 26V battery the ideal voltage is 29,5V +/-0.2V
Step 4: Press one of the yellow buttons until ‘time’ LED lights
up.
(during testing, you can switch at any time between Voltage,
Current and Time).

Step 5: Now press the green start button. The tester will start
with the discharge of the battery. The ‘discharge’ LED lights
up.

Step 6: The ‘finish’ LED will light up when the test is

completed. Compare this value with the correct table on the
next page.

19-02-2014 HPB service manual MY14

 6.2.2 Discharge time table
If the discharge is below given values for given time and temperature, contact your Giant
representative for possible warranty claim (regarding the applicable conditions for warranty).

36V EnergyPak discharge time (LI-ION 10AH)

Ambient Indication for discharge time in minutes
temperature New battery 0/6 Months 7/12 months 13/18 months 19/24 months
35 ͦC +/- 5 ͦ C 113 110 101 90 79
25 ͦC +/- 5 ͦ C 113 110 101 90 79
15 ͦC +/- 5 ͦ C 106 105 96 86 75
5 ͦ C +/- 5 ͦ C 101 99 90 80 71
-5 ͦ C +/- 5 ͦ C 95 94 86 76 68
Below -10 ͦ C Use and discharge of the battery is not recommended

36V EnergyPak discharge time (LI-ION 8AH)

Ambient Indication for discharge time in minutes
temperature New battery 0/6 Months 7/12 months 13/18 months 19/24 months
35 ͦC +/- 5 ͦ C 90 85 75 65 60
25 ͦC +/- 5 ͦ C 90 85 75 65 60
15 ͦC +/- 5 ͦ C 85 85 75 65 60
5 ͦ C +/- 5 ͦ C 80 80 65 60 55
-5 ͦ C +/- 5 ͦ C 75 75 60 55 50
Below -10 ͦ C Use and discharge of the battery is not recommended

26V EnergyPak discharge time (LI-ION)

Ambient Indication for discharge time in minutes
temperature New battery 0/6 Months 7/12 months 13/18 months 19/24 months
35 ͦC +/- 5 ͦ C 75 75 65 55 50
25 ͦC +/- 5 ͦ C 75 75 65 55 50
15 ͦC +/- 5 ͦ C 75 75 65 55 50
5 ͦ C +/- 5 ͦ C 65 65 60 50 45
-5 ͦ C +/- 5 ͦ C 60 60 55 45 40
Below -10 ͦ C Use and discharge of the battery is not recommended

24V EnergyPak discharge time (NiMh)

Ambient Indication for discharge time in minutes
temperature New battery 0/6 Months 7/12 months 13/18 months 19/24 months
35 ͦC +/- 5 ͦ C 55 55 50 40 35
25 ͦC +/- 5 ͦ C 55 55 50 40 35
15 ͦC +/- 5 ͦ C 55 55 50 40 35
5 ͦ C +/- 5 ͦ C 50 50 40 35 30
-5 ͦ C +/- 5 ͦ C 45 45 40 35 30
Below -10 ͦ C Use and discharge of the battery is not recommended

19-02-2014 HPB service manual MY14

 7. Syncdrive
Be sure to detach the EnergyPak while working on a Syncdrive.

7.1 Syncdrive Front motor replacement

This motor can only be serviced by the manufacturer or its authorized service center.
Contact your Giant representative or service center, to determine whether the motor should be
returned for service, or shall be replaced completely.
Step 1: Loosen the 3 screws from the
cover. Disconnect the motor cable (and
brake wires).

Step 2: Loosen the nuts from the axle

and the fender.

Step 3: Take out the wheel and motor.

Step 4: Follow the procedure in reversed order to reassemble.
Make sure the anti-rotation plate is correctly placed in the right side drop-out.
Tighten the axle nuts at 40 Nm.

19-02-2014 HPB service manual MY14

7.2 Yamaha motor replacement

This motor can only be serviced by the manufacturer or its authorized service center.
Contact your Giant representative or service center, to determine whether the motor should be
returned for service, or shall be replaced completely.
Step 1: Remove the cover and the
crank bolt. Both cranks can be removed
with a regular pulley.

Step 2: Remove the big nut at the chain

ringside. Beware; opens clockwise.
Blocking the rear wheel can be useful.
The chain ring can be taken of the axle
together with the chain now.
Remove the motor covers now.

Step 3: Untighten the three frame

bolts. The rear bolt should remain in
the frame. The two front bolts can be
removed. The motor now can twist, but
will not fall out.

Step 4: Disconnect all the wires and

take out the motor.

Step 5: Follow the procedure in reversed order to reassemble.

The frame bolts should be tightened with 40Nm. The big nut for the chain ring tightens with 40Nm.

19-02-2014 HPB service manual MY14

7.3 Bosch motor replacement

This motor can only be serviced by the manufacturer or its authorized service center. Motor failures
should be solved by the dealer by replacement of the complete motor unit. Malfunctioning motors
should be returned to a Bosch authorized Service Center.

Removing the chain wheel

Step 1: Remove the crank arms(allen key size 8 ISIS crank puller)
Step 2: Block the rear wheel
Step 3: Unscrew the lock ring(2) with the spider tool (1) Be aware left hand thread !
Step 4: Remove the chain
Step 5: Remove the chain wheel crank(spider3) together with the chain wheel(take the chain wheel
with both hands and pull it out by moving back and forth.Prise off the spider with a long lever from
the housing. DO NOT use a hammer, the torque sensor can be destroyed).

Removing the stone chip protection

Step 1: Remove 3 screws (1)(Torx T20). (Ensure that you do not inadvertently remove the screws of
the motor casing.
Step 2: Pull the stone chip protection (2) forwards.

19-02-2014 HPB service manual MY14

Disconnecting the cable connections on the drive unit.
Step 1: Unplug all cables (the connector to the battery has a locking hook (1). Prize it off by 1-2 mm
with a screwdriver. Damage is possible if the locking hook is not disengaged before dismounting.

Do not damage the plug and cable, always remove the plugs using your fingers or long nose pliers.
Never pull the cable directly!!

Remove the drive unit

Step 1: Loosen and remove the fixing screws(1-Torx T30, 2-Torx T40) and mounting plate(3).
Step 2: Pull the drive in the direction of motion to the right from the frame.
Step 3: Dispose of the 3 expansion sleeves (2)(The expansion sleeves cannot be reused, new
expansion sleeves are supplied with each new motor.
Step 4: Retain all the rest of the components!

19-02-2014 HPB service manual MY14

Installing the drive unit
Step 1: Lightly grease the attachment points on the bicycle frame(the threads of the stub bolts(4 not
visible in the drawing)must be kept free of grease).
Step 2: Install the motor on the right of the frame in the direction of motion.
Step 3: Insert the fixing screws: First all the M6 screws(1) then screw on the expansion sleeves(2)
together with the mounting plate(3).(Always use new expansion sleeves and install them free of
grease!)
Step 4: Tighten the M6 bolts (1) first. Use a torque wrench and tighten them with 8-10 Nm.
Step 5: Tighten the expansion sleeves (2). Use a torque wrench and tighten them with 25-30 Nm.

For further details regarding the Bosch system use the Bosch training.

19-02-2014 HPB service manual MY14

7.4 Syncdrive rear motor replacement

This motor can only be serviced by the manufacturer or its authorized service center. Contact your
Giant representative or service center, to determine whether the motor should be returned for
service, or shall be replaced completely.
Step 1: Disconnect the motor cable.

Step 2: Loosen the axle nuts or quick-release.

Step 3: Remove the rear wheel.

Step 4: Follow the procedure in reversed order
to remount the Syncdrive.
Make sure the anti-rotation plate is correctly
placed. Make sure the wire outlet faces
downwards.
Tighten the axle nuts at 40 Nm.

19-02-2014 HPB service manual MY14

8. Wiring schemes

Front Syncdrive

Central Syncdrive

Rear Syncdrive

19-02-2014 HPB service manual MY14

9. Various issues

9.1 Lights
Step 1: Check for faulty connectors on the lightning wiring.
Step 2: Check with the special tool (part#2520-SY06-13V) if the
front or tail light is OK. The tool can be connected to the lights
directly.
Make sure the (AA) batteries are full.

Step 3: Replace the light if not functioning. If the light is

working correctly with the battery set attached, reconnect
the lights to the system to see if the problem is solved. If not,
follow the next steps.
Step 4: Switch on the bike, then switch on the lights. The
backlight of the RideControl should switch on. If the backlight
does not function, replace the RideControl display.
Step 5: Use the multi-meter in DC mode. If the voltage on the
light plugs near the headlight is not approximately 6V, check
at the driver directly.

Step 6: Use the multi-meter in DC mode. If the voltage on the

light plugs near driver is approximately 6V, replace the cable
assembly.

19-02-2014 HPB service manual MY14

9.2 Chain tensioner
Front wheel hub motored bikes are equipped with a chain tensioner. If mounted, the derailleur is
being used as such. Otherwise, a separate chain tensioner is mounted. Its running smooth is of big
influence on the Pedalplus sensor, and therefore on the range and performance of the bike. To
check;
Step 1: Remove the chain covers.

Step 2: Check the position and

direction of the chain tensioner. The
chain has to run straight and clear on
both sides of the flanks. If it’s faulty,
continue the steps.

Step 3: The chain tensioner can be

slid sideways to get in line with the
chain. To do this the Allen bolts have
to be loosened.

Step 4: Now the horizontal axle from

the chain tensioner can be aligned.

Step 5: By moving the chain, it can be

determinated which way the chain
tensioner should slide.
Step 6: With some pliers the wheel
can be adjusted to make it run
parallel with the chain.

19-02-2014 HPB service manual MY14

Step 7: When the chain runs smooth,
clear and straight, the Allen bolt can
be secured.

Step 8: Check the chain tensioner. It

should effectively tension the chain.

Step 9: Replace the covers.

19-02-2014 HPB service manual MY14

10. Tools, Giant specific

Pedalplus voltage tester

Gits voltage tester
(Part# 147L-HCTEST-01V)
(Part# 5481-GITS-01V)

Capacity tester
(Part# 5481-test-06V)

E-lab
(Part# 95200000V)

4pin socket for central Syncdrive MY07/MY12

Light tester (part# 2520-FY06-03V)
(Part# 2520-sy06-13V)

19-02-2014 HPB service manual MY14

11. Contact
Gathering information

If this manual doesn’t help out, you can contact your Giant service manager.
Make sure to have at hand;
- Energypak charged completely
- A clear explanation of the customer’s complaint
- Frame number
- Model and version of the bike
- Any measurement data
- List of actions taken / parts replaced
- Other relevant data

19-02-2014 HPB service manual MY14