Segway VILLAIN SX10 Owner's Manual
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Segway VILLAIN SX10 Owner's Manual

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  • Page 3 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING Operating, servicing, and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer...
  • Page 4 WELCOME IMPORTANT NOTICE segwaypowersports.us Visit http:// for a list of dealers and service locations.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SAFETY INTRODUCTION VEHICLE DEVICE OPERATION MAINTENANCE SPECIFICATIONS TROUBLESHOOTING EMISSION CONTROL SYSTEM WARRANTY...
  • Page 6 INTRODUCTION BEFORE YOU RIDE SEGWAY WARNING...
  • Page 7 The meaning of these signs： WARNING WARNING CAUTION CAUTION NOTICE NOTICE IMPORTANT IMPORTANT The Mandatory The Prohibition Safety Sign Action Sign indicates an indicates an action action NOT to that NEEDS to be take in order to taken to avoid a hazard.

  • Page 8: Safety Introduction

    SAFETY INTRODUCTION IMPORTANT ON-PRODUCT LABELS ..........1-1 Hang Tag ..................1-1 WARNING LABELS ................1-2 SEVERE INJURY OR DEATH ............1-7 IMPORTANT SAFETY INFORMATION ..........1-9 Reading the manual..............1-9 Safe driving age ................1-9 Riding equipment .................1-9 Vehicle modification ..............1-10 Passengers ................1-10 Contact exhaust .................1-10 Fuel safety ................. 1-11 Safety belt ..................

  • Page 9: Important On-Product Labels

    IMPORTANT ON-PRODUCT LABELS Hang Tag This hang tag is not to be removed before sale.

  • Page 10: Warning Labels

    WARNING LABELS www. rohva.org . For more information about recreational off-road vehicle safety in the United States, visit www.rohva.org, call the Consumer Product Safety Commission at 866- 267-2751.
  • Page 14 FOR CANADA...

  • Page 15: Severe Injury Or Death

    SEVERE INJURY OR DEATH Can result if you do not follow these instructions:...

  • Page 17: Important Safety Information

    IMPORTANT SAFETY INFORMATION Reading the manual Safe driving age Riding equipment Helmet...

  • Page 18: Vehicle Modification

    Using alcohol or drugs Vehicle modification Passengers 1-10...

  • Page 19: Contact Exhaust

    Contact exhaust Fuel safety Gasoline is very flammable under certain conditions Safety belt Cab door 1-11...

  • Page 20: Loading On The Vehicle

    Loading the vehicle Always follow the following guidelines: ： ： Passengers in the cargo compartment Operating on pavement 1-12...

  • Page 21: Public Road Operation

    Public road operation Overspeed Turning 。 Jumping and Stunts ， ， Incorrect mountain climbing Down the hill Side hill 1-13...

  • Page 22: Vehicle Device

    VEHICLE DEVICE VEHICLE ACTIVATION ..............2-1 Unlock Vehicle ................2-1 App function .................2-2 PARTS AND CONTROL ..............2-3 FRONT PANEL ..................2-4 Ignition lock/Start button ..............2-4 Switchs 1 ..................2-4 Switchs 2 ..................2-5 Switchs 3 ..................2-6 Toggle switch for Two-wheel drive or Four-wheel drive ....2-6 VEHICLE EQUIPMENT...............2-7 The Power socket ................2-7 Electronic Power Steering（EPS）...

  • Page 23: Vehicle Activation

    Please download the APP from the “APP STORE” in your mobile phone before you try to activate the SSV by the APP in the fi rst time. Please search “Segway powersports” in the “APP STORE” in your mobile phone then download the APP as usual.

  • Page 24: App Function

    NOTICE App Function...

  • Page 25: Parts And Control

    PARTS AND CONTROL Safety Belt Seat Packing Shock Absorber Cab Door Refueling Gearshift parking Armrest Brake Pedal Accelerator Pedal...

  • Page 26: Front Panel

    FRONT PANEL Ignition Lock/Start Button The ignition Lock Start Button Switchs 1 Position Light Switch High Beam Switch Turn Signal Switch (if equipped) Emergency Light Switch (if equipped)

  • Page 27: Switchs 2

    Highlight Switch High Beam Switch Turn Signal Switch (if equipped) Emergency Sight Switch(if equipped) ： ： Use this switch in case of vehicle emergency • Temporary stop of vehicle • Vehicle failure • The vehicle encountered other emergencies Switchs 2 Horn Switch Mode Switch Horn Switch...

  • Page 28: Switchs 3

    Switchs 3 Emergency Stop Switch Torque Switch Emergency Stop Switch Toggle Switch for Two-Wheel Drive or Four-Wheel Drive Handle Switch 2 x 4 patterns 4 x 4 patterns 4×4 locking mode...

  • Page 29: Vehicle Equipment

    VEHICLE EQUIPMENT The Power Socket Output power: 12V/120W(MIX) 1: USB port 2: DC port Electronic Power Steering（EPS） Seat Seat Adjustment...

  • Page 30: Seat Removal/Installation

    Seat Removal/Installation Removal Bolts 、 、 、 、 Installation 、 、 、 、 Steering Wheel Adjustment Adjust Angle of steering wheel up and down:...

  • Page 31: Four-Point Safety Belt

    Four-Point Safety Belt Driver's seat belt correct Too high above unlocked lower unlocked Passenger Seat Belt...

  • Page 32: Cab Door

    CAUTION CAB DOOR 2-10...

  • Page 33: Refueling Cover

    Refueling Cover WARNING Passenger rail 2-11...

  • Page 34: Gearshift

    Gearshift Low speed High speed Neutral Reverse Parking CAUTION Brake pedal and accelerator pedal Brake Pedal Gas Pedal 2-12...

  • Page 35: Parking Brake

    Brake pedal Accelerator pedal CAUTION Parking Brake Turn on parking brake: Release the parking brake: WARNING 2-13...

  • Page 36: Roll-Overprotective Structures(Rops)

    Roll-Overprotective Structures (ROPS) WARNING Lifting and supporting the vehicle ： 2-14...

  • Page 37: Instrument Panel

    INSTRUMENT PANEL NOTICE Instrument Indicator Light/Warning Light ， The Engine Tachometer Shows 。 → → → → → The Speedometer Fuel Quantity Indicator ： ： 2-15...

  • Page 38: Indicator Light/Warning Indication

    Engine Water Temperature ： ： Time Display Subtotal Mileage Engine Running Time Dynamic Residual Mileage Fault Code Display Battery Voltage Total Mileage Four-Wheel Drive Full Differential Lock Indicator light/warning indication 2-16...
  • Page 39 2-17...

  • Page 40: Diagnostic Displays Code Definitions

    Diagnostic displays code definitions Fault Code Display Area 2-18...
  • Page 41 2-19...
  • Page 42 No midpoint of torque is written No end point of rotor angle is written Memory read write failure The main torque sensor is disconnected Abnormal output of main torque sensor The secondary torque sensor is disconnected 2-20...
  • Page 43 Abnormal output of secondary torque sensor The diff erence between main and secondary torques is too large The diff erence between the main torque before and after amplifi cation is too large Electrical machinery unassisted Over electric current Abnormal busbar electric current CAN communication abnormal (Output abnormally) Rotor Angle jump The rotor Angle sensor is disconnected...

  • Page 44: Operation

    OPERATION BASIC DRVING GUIDE ..............3-1 Trail Etiquette ................3-1 Know your riding area/tread lightly ...........3-1 Vehicle Run–in period ..............3-1 Brake system run-in ..............3-2 Clutch/belt ..................3-2 New operator driving procedures ..........3-2 Driving With Passengers ............3-3 Starting the vehicle ..............3-3 Park the vehicle ................3-3 Braking..................3-4 Parking the vehicle ..............3-4 Driving on slippery surfaces............3-4...

  • Page 45: Basic Drving Guide

    WARNING BASIC DRVING GUIDE Trail Etiquette Know your riding area/tread lightly Vehicle Run–in period...

  • Page 46: Brake System Run-In

    Brake System run-in Clutch/Belt New Operator Driving Procedures...

  • Page 47: Driving With Passengers

    Driving with Passengers Slow down. Always travel at a speed appropriate for your skills, your passengers’ skills and operating conditions. Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger. Vehicle handling may change with passengers and/or cargo on board. Allow more time and distance for braking.

  • Page 48: Braking

    Braking NOTICE Parking the vehicle Driving on Slippery Surfaces NOTICE Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.

  • Page 49: Driving Through Water

    Driving through water CAUTION...

  • Page 50: Driving In Reverse

    Driving in reverse Driving over obstacles Driving uphill...

  • Page 51: Driving Downhill

    Driving downhill...

  • Page 52: Driving On A Sidehill (Sidehilling)

    Driving on a sidehill (sidehilling) If crossing a sidehill is unavoidable, follow these precautions: Parking on an incline...

  • Page 53: Break-In Guidelines

    Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: Break-in Guidelines NOTICE...

  • Page 54: Pre-Ride Inspection

    PRE-RIDE INSPECTION Inspection Items 、 、 3-10...

  • Page 55: Hauling Cargo

    HAULING CARGO WARNING SECURE ALL LOADS BEFORE OPERATING. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. USE EXTREME CAUTION DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEED. 3-11...

  • Page 56: Maximum Loading Capacity

    Maximum loading capacity 。 Vehicle Model SGW1000F Horizontal Maximum traction Vertical Loading guidelines When transporting cargos, please follow these instructions: Trailer Where a designated attachment point is provided on the towbar: 3-12...
  • Page 57 WINCH OPERATION WARNING 3-13...
  • Page 58 3-14...
  • Page 59 WARNING WARNING 3-15...
  • Page 60 Winch Operation Manual Release switch of Winch Manual release switch of Winch Operation of control Switch OUT：Release the winch cable IN： Recoil the winch cable 3-16...
  • Page 61 Remote control operation Release the winch cable Reclaim the winch cable NOTICE 3-17...

  • Page 62: Maintenance

    MAINTENANCE...
  • Page 63 MAINTENANCE WINCH OPERATION ...............3-13 Winch Operation ...............3-16 PERIODIC MAINTENANCE ..............4-1 LUBRICATING OIL ................4-4 Front fl uid recharging cover and electrical maintenance cover ...4-4 Engine maintenance cover removal ...........4-5 Tool box removal................4-5 Ventilation cover removal.............4-6 ENGINE OIL MAINTENANCE PROGRAM ........4-7 Oil recommendation..............4-7 Engine Oil Level Check ...............4-8 Changing engine oil&fi...
  • Page 64 MAINTENANCE SHOCK ABOSRBER.................4-22 Shock abosrber preload adjustment..........4-22 Damping adjustment of shock absorber........4-23 SUSPENSION DRIVE LUBRICATION ..........4-24 Front/rear drive shaft dust cover ..........4-24 AIR FILTER ..................4-25 Replace the air fi lter ..............4-25 Replace primary air fi lter ............4-26 LAMP ....................4-27 Change the headlight..............4-27 High beam adjustment ...............4-28 SPARK PLUG ..................4-29 Spark plug inspection ..............4-30...

  • Page 65: Periodic Maintenance

    PERIODIC MAINTENANCE Severe use is defined as: • Frequent immersion in mud, water, or sand. • Frequent or prolonged operation in dusty environments. • Short trip cold weather operation. • Racing or racing-style high RPM use. • Prolonged low speed, heavy load operation. •...
  • Page 66 （ MI/KM ） ► ► ► Brake pad wear 10 H Monthly 100 (160) Inspect periodically Battery 20 H Monthly 200 (320) Check terminals. clean. test Inspect. cycle key to pressurize fuel pump. Fuel System 20 H Monthly check lines and fi ttings for leaks and abrasion ►...
  • Page 67 （ MI/KM ） Inspect coolant strength Cooling system 50 H 1000(1600) seasonally. pressure test system yearly ► Engine oil change 100 H 1000(1600) Change the oil and fi lter Oil lines and Inspect for leaks and loose ► 100 H 1000(1600) fasteners fi...

  • Page 68: Lubricating Oil

    LUBRICATING OIL Project Recommended model Capacity Inspection procedure Maintain level in safe Engine oil SAE10W-40/SJ or Higher 3.5 qts. (3800 m L ) range on dipstick Front SAE 75/80W-90 GL5 0.16 qts. (180 mL ) Diff erential Drive each 2000km Kilometers. Rear SAE 75/80W-90 GL5 1.36 qts.
  • Page 69 Rear Cargo Bed Rear Cargo Bed Rear Cargo Bed Lid Removal of rear cargo bed...
  • Page 70 Removal of Air filter housing assembly Remove the rear Cargo Bed...

  • Page 71: Engine Oil Maintenance Program

    ENGINE OIL MAINTENANCE PROGRAM WARNING Oil Recommendation CAUTION...

  • Page 72: Engine Oil Level Check

    Engine Oil Level Check NOTICE Daily Oil Level Check Upper Line Lower Line Oil Filler cap Oil Level Check After Oil Change NOTICE...

  • Page 73: Changing Engine Oil&Filter

    Changing Engine Oil&Filter NOTICE WARNING Drain the Engine Oil Oil Drain Plug O-ring Oil Filter Strainer O-ring Oil Drain Plug Oil drain position 1 Oil drain position 2...
  • Page 74 WARNING Oil Drain Plug: 16-20N.m(11.8-14.8ft·lb) Torque Replace Oil Filter/Oil Strainer IMPORTANT Change Oil Filter N.m） Bolt M12×1.25×65 81~88 ft·lb（110~120 4-10...

  • Page 75: Add Engine Oil

    Oil Strainer Cleaning Oil drain plug O-ring oil strainer Drain Plug: 16-20N.m(11.8-14.8ft·lb) Torque Add Engine Oil 4-11...

  • Page 76: Front/Rear Gearbox (Demand Drive) Fluid

    FRONT/REAR GEARBOX (DEMAND DRIVE) FLUID CAUTION Check the Rear Gear Box Oil Level 4-12...

  • Page 77: Add Gear Oil

    Front/Rear Gearbox Oil Change Torque Drain Plug: 16-20N.m(11.8-14.8ft·lb) Add gear oil Filling Plug O-ring Oil Dipstick O-ring Torque Filling Plug: 16-20N.m(11.8-14.8ft·lb) 4-13...

  • Page 78: Coolant

    COOLANT Cooling Bottle Coolant 4-14...

  • Page 79: Cvt Belt

    Radiator Coolant CAUTION CVT Belt WARNING CVT cover bolt CVT cover 　　 CVT cover seal CVT belt replacement tool 4-15...
  • Page 80 Install the drive belt CVT cover bolt Torque : 4.4 ft·lb. ( 6 N.m ) Drying the CVT 4-16...

  • Page 81: Brake System

    BRAKE SYSTEM WARNING Brake Fluid Brake Fluid DOT4 4-17...
  • Page 82 NOTICE Brake pads and brake discs 4-18...

  • Page 83: Tire

    TIRE Tire Pressure Tread Depth When to Replace a tire : 4-19...

  • Page 84: Replace The Tires

    Replace the Tires Wheel Removal Torque Specification： Torque Mounting nuts: 74-88 ft-lbs. (100~120N·m） 4-20...

  • Page 85: Tire Replacement

    CAUTION ） Tire Replacement Size WARNING 4-21...

  • Page 86: Shock Abosrber

    SHOCK ABOSRBER Shock abosrber preload adjustment Gear Spring Environment Load Terrain Speed Soft Flexible Light Flat ↑ ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ ↓ Hard Solid Heavy Bump High Locknut Adjusting Nut Crescent wrench Spring preload position Item Factory setting Available range Front shock absorber:...

  • Page 87: Damping Adjustment Of Shock Absorber

    Damping adjustment of shock absorber Compression damping adjustment Restoration damping adjustment 4-23...

  • Page 88: Front/Rear Drive Shaft Dust Cover

    LUBRICATION Front/Rear Drive Shaft Dust cover 4-24...

  • Page 89: Air Filter

    AIR FILTER WARNING Replacing the Secondary Air Filter Removal of the air filter cover Air filter cover snap Air filter cover Air Filter element 4-25...
  • Page 90 Air filter inlet cap and CVT inlet mesh fabric Air filter inlet cap CVT inlet mesh fabric WARNING 4-26...

  • Page 91: Lamp

    LAMP CAUTION Change the Headlight LED Lights CAUTION Removal of the Headlight: Expansion screw Headlight bolts Headlight Shield 4-27...

  • Page 92: High Beam Adjustment

    High beam adjustment CAUTION Adjust the headlight beam upwards and downwards Light adjusting screw 4-28...

  • Page 93: Spark Plug

    Adjust the headlight beam left and right Light adjusting screw SPARK PLUG CAUTION 4-29...

  • Page 94: Spark Plug Inspection

    Spark Plug Inspection CAUTION Bolt Ignition coil Spark plug Spark plug sleeve 4-30...

  • Page 95: Spark Arrester

    SPARK ARRESTER WARNING Pan head screw M6×12 Muffler spark arrester 4-31...

  • Page 96: Battery

    BATTERY WARNING Battery Removal NOTICE 4-32...

  • Page 97: Battery Charging

    Battery Guard Battery pull strap Protective rubber sleeve Positive and negative anchor bolts for cable Positive and negative anchor nuts for cable Battery Charging CAUTION 4-33...

  • Page 98: Battery Installation

    Measures to be taken in an emergency Battery Installation NOTICE 4-34...

  • Page 99: Fuse

    FUSE NOTICE Fuse Box NOTICE Normal fuse Blow fuse 4-35...

  • Page 100: Fuse/Relay Distribution And Rated Amperage

    Fuse/Relay Distribution and Rated Amperage Rated amperage of fuse/relay and distribution Fuse/Relay Power 12V,USB,Trailer LAMP Brake,Trailer,Speed,EPS 2-4WD Flameout 7.5A TBOX,IVI 7.5A ICU,LOCK,OBD,Buzzer FUEL PUMP MAIN FUSE TBOX,IVI,ICU 7.5A IGNITION COIL,INJECTOR EVAP 7.5A High/Low LAMP FAN2 4-36...

  • Page 101: Fuse Box Replacement

    Remote power-on relay 12V 20A IG1 relay 12V 20A Auxiliary start relay 12V 20A Main relay 12V 20A High light relay 12V 20A Low light relay 12V 20A Day light relay 12V 20A Fuel pump relay 12V 20A FAN relay 12V 20A 2-4 Wheel drive relay 12V 20A...
  • Page 102 APPEARANCE CARE Vehicle Washing Vehicle Storage 4-38...

  • Page 103: Specifications

    SPECIFICATIONS APPEARANCE CARE ..............4-38 Vehicle washing .................4-38 Vehicle storage ................4-38 4-39...
  • Page 104 SPECIFICATIONS OF THE VEHICLE PARAMETERS ITEM SGW1000F-S1 SGW1000F-S2 133 in × 64 in × 71 in 133.1 in × 73 in × 73 in Length×width×height (3375mm×1630mm×1800mm) (3380mm×1850mm×1850mm) Wheelbase 2590mm) 102 in ( Front wheelbase 53 in ( 1340mm) 62 in ( 1570mm) Rear wheelbase 1350mm)
  • Page 105 Double wishbone independent Front Suspension suspension type Rear Multi-link independent suspension Front Hydraulic spring-external airbag Shock absorber type Rear Hydraulic spring-external airbag Air fi lter type Paper fi lter type Muffl er type Impedance Parallel double cylinder, water Engine type cooling, four stroke Engine model 293MY...
  • Page 106 Rear brake light color/ Red/12.78 W specifi cation Rear position light color/ Rear light Red/2.1 W specifi cation Rear turn signal color/ Amber/2.32W specifi cation Battery capacity 12V/32Ah Shift operation mode Mechanical Auxiliary DC Outlet Instrument Central control screen (inch) (optional) 10.6 Driver Four-point roll-up...
  • Page 107 VEHICLE IDENTIFICATION NUMBER(VIN) The engine number is stamped on the engine.

  • Page 108: Troubleshooting

    TROUBLESHOOTING SPECIFICATIONS OF VEHICLE ............5-1 THE FRAME NAMEPLATE ...............5-3 VEHICLE IDENTIFICATION NUMBER ..........5-4 Drive belt and cover problems .............6-1 Engine doesn’t turn over ..............6-2 Engine pings or knocks..............6-2 Engine stops or loses power............6-3 Engine turns over, fails to start ............6-3 Engine backfi...

  • Page 109: Drive Belt And Cover Problems

    Drive Belt and cover problems Possible Cause Solution...

  • Page 110: Engine Doesn't Turn Over

    Possible Cause Solution ， Engine doesn’t turn over Possible Cause Solution Engine pings or knocks Possible Cause Solution...

  • Page 111: Engine Stops Or Loses Power

    Engine stops or loses power Possible Cause Solution Engine turns over, fails to start Possible Cause Solution Engine backfires Possible Cause Solution...
  • Page 112 Engine runs irregularly, stalls or misfires Possible Cause Solution Engine runs irregularly, stalls or misfires Possible Cause Solution...
  • Page 113 Engine stops or loses power Possible Cause Solution...

  • Page 114: Emission Control System

    EMISSION CONTROL SYSTEM Engine runs irregularly, stalls or misfi res ........6-4 Engine runs irregularly, stalls or misfi res ........6-4 Engine stops or loses power............6-5 SOURCE OF EXHAUST EMISSIONS ..........7-1...
  • Page 115 SOURCE OF EXHAUST EMISSIONS EXHAUST EMISSION CONTROL SYSTEM CRANKCASE EMISSION CONTROL SYSTEM NOISE CONTROL SYSTEM...

  • Page 116: Warranty

    WARRANTY EXHAUST EMISSION CONTROL SYSTEM ........7-1 CRANKCASE EMISSION CONTROL SYSTEM .......7-1 NOISE CONTROL SYSTEM ..............7-1 EMISSION CONTROL SYSTEM WARRANTY ........8-1 LIMITED WARRANTY POLICY ............8-2...
  • Page 117 EMISSION CONTROL SYSTEM WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS OWNER'S WARRANTY RESPONSIBILITIES Segway Segway Segway Segway WARRANTY COVERAGE Segway Segway Segway Segway...
  • Page 118 LIMITED WARRANTY POLICY Segway SEGWAY SEGWAY SEGWAY SEGWAY SEGWAY SEGWAY’ SEGWAY SEGWAY WARRANTY REQUIREMENTS Segway LIMITATIONS OF WARRANTY SEGWAY SEGWAY SEGWAY SEGWAY SEGWAY’s SEGWAY SEGWAY...
  • Page 119 EXCLUSIONS OF WARRANTY SEGWAY SEGWAY SEGWAY SEGWAY...

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