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Segway 450 ATV 2023 Series Service Manual

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450 ATV

SERIES ModELS

SERVICE MANUAL

2023/9/12 V0

Table of Contents

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Summary of Contents for Segway 450 ATV 2023 Series

Page 1 450 ATV SERIES ModELS SERVICE MANUAL 2023/9/12 V0...
Page 2 INDEX GENERAL INFORMATION REGULAR MAINTENANCE ENGINE FRONT AND REAR AXLE FUEL SYSTEM COOLING SYSTEM INTAKE SYSTEM DRIVE CHAIN SYSTEM FRONT AND REAR SUSPENSION 9-1 WHEEL AND TIRE 10-1 BRAKE SYSTEM 11-1 STEERING SYSTEM 12-1 FRAME/BODY AND TRIM 13-1 ELECTRICAL SYSTEM 14-1...
Page 3 If you need to replace a part, please use the same part or the part specified by Segway, do not use parts that are not recognized by Segway. Do not use parts not approved by Segway for replacement.
Page 4 Kilograms per square centimeter watt(s) hour(s) Ω ohm(s) liter(s) This manual is applicable to the following vehicle models:： SGW500F-A1\SGW500F-A3\SGW500F-A5\SGW500F-A7 Segway AT5 \Segway AT5 S \Segway AT5 EPS SGW500F-A2\SGW500F-A4\SGW500F-A6\SGW500F-A8 Segway AT5 L\Segway AT5 Touring EPS...
Page 5 Parts When parts are damaged and need to be replaced, use parts approved or recommended by Segway. Replacements All components should be assembled with strict adherence to standard values such as torque and indeed adjustment values.
Page 6: General Information
GENERAL INFORMATION SEGWAY AT5 GENERAL INFoRMATIoN VEHICLE IdENTIFICATIoN NUMBER/ENGINE SERIAL CodE .........1-2 TECHNICAL PARAMETERS oF VEHICLE ..............1-3 UNIT CoNVERSIoN TABLE ..................1-6 ToRqUE ........................1-7 http://www.segwaypowersports.com 1 - 1...
Page 7: Vehicle Identification Number/Engine Serial Code
GENERAL INFORMATION SEGWAY AT5 VEHICLE IdENTIFICATIoN NUMBER/ENGINE SERIAL CodE VEHICLE IdENTIFI CATIoN NUMBER The vehicle identification number is located on the frame cross tube under the seat cushion and the engine number is embossed on the engine. It is used to assist the customer when ordering spare parts from the dealer or as a reference in case the vehicle is stolen.
Page 8: Technical Parameters Of Vehicle
GENERAL INFORMATION SEGWAY AT5 TECHNICAL PARAMETERS oF VEHICLE Item SGW500F-A1/A3/A5/A7 SGW500F-A2/A4/A6/A8 Vehicle Length 2160mm 2300mm Width 1180mm 1180mm Height 1230mm 1350mm Wheel base 1305mm 1455mm Ground clearance Front：235/Rear245 Turning diameter 5900 mm 6400mm Curb weight（no oil and gasoline） 372kg 389kg...
Page 9 GENERAL INFORMATION SEGWAY AT5 Item SGW500F-A1/A3/A5/A7 SGW500F-A2/A4/A6/A8 Fuel tank capacity Reserve fuel capacity 4.5L Throttle type 42mm mechanical throttle body Spark plug type CPR7EA/B7RTC Spark plug gap 0.7~0.9mm Transmission Shift sequence L-H-N-R-P Transmission gear ratio 0.6-2.97 L Gear Ratio 11.8-58.3 H Gear Ratio 6.8-33.6...
Page 10 GENERAL INFORMATION SEGWAY AT5 Item SGW500F-A1/A3/A5/A7 SGW500F-A2/A4/A6/A8 Electrical System Ignition mode Electric(ECU） Recharge batteries 450W / 5500 rpm Battery 12V 32Ah Proximity optical power 9.5(W) Remote Optical Power17(W) 32000cd Headlight Daytime running light power 20(W) Turn signal power 10 (W) Front position lamp power2.7(W)
Page 11: Unit Conversion Table
GENERAL INFORMATION SEGWAY AT5 UNIT CoNVERSIoN TABLE TORQUE Unit coefficient Convert to N·m × 0.1020 kg·m N·m ×0.7376 ft·lbs N·m ×8.851 in·lbs kg·m ×9.807 N·m kg·m ×7.233 ft·lbs kg·m ×86.80 in·lbs in·lbs ×0.833 ft·lbs in·lbs ×0.116 kg·m PRESSURE × 0.01020 kg/cm²...
Page 12 GENERAL INFORMATION SEGWAY AT5 ToRqUE The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent.
Page 13 GENERAL INFORMATION SEGWAY AT5 Torque Item Fastener Designator Grade Remark (N•m) Wheel side caliper body mounting GB/T 5789 M10×1.25×25 40 ～ 50 bolts Brake master cylinder mounting bolts GB/T5789 M8×25 30 ～ 40 Brake disc mounting bolts （Thread M8） 25 ～ 28 Center Axle Brake Disc Bolt GB/T 70.1 M10×1.25×20...
Page 14 GENERAL INFORMATION SEGWAY AT5 Torque Item Fastener Designator Grade Remark (N•m) cylinder head spark plugs 13±2 Hexagon socket cheese head Magneto Overrunning Clutches 18±2 screws M6×16 Hexagonal flange face nuts Crankshaft magneto rotor 180±8 M18×1.5 Crankshaft magneto rotor peephole cover 12±2...
Page 15: Table Of Contents
MAINTENANCE SEGWAY AT5 MAINTENANCE TECHNICAL SPECIFICATIONS .................. 2-3 VEHICLE LIFTING SUPPORT POSITION ..............2-4 MAINTENANCE CYCLE TABLE ................. 2-5 BREAK-IN MAINTENANCE ..................2-6 PERIODIC MAINTENANCE ..................2-6 REMAINING LUBRICATION FILLING ..............2-10 ENGINE MAINTENANCE .................... 2-12 ENGINE OIL LEVEL CHECK .................. 2-12 ENGINE OIL EMISSIONS ..................
Page 16 MAINTENANCE SEGWAY AT5 FUEL FILTER ......................2-27 FUEL LINE ......................2-28 CVT ..........................2-29 CVT INTAKE SCREEN CHECK ................2-29 CVT BELT ........................ 2-29 DRY CVT ......................... 2-30 INSTALLATION OF DRIVE BELTS ................. 2-30 DRIVE SHAFT DUST SLEEVE INSPECTION ............. 2-31 WHEEL PARTS REMOVAL ..................
Page 17: Maintenance
MAINTENANCE SEGWAY AT5 TECHNICAL SPECIFICATIONS General specifications Item standard usage limit Cylinder leakage —— Intake valve clearance (cold) 0.1 ~ 0.15mm (0.0039" ~ 0.0059") —— Exhaust valve clearance (cold) 0.2 ~ 0.25mm (0.0079" ~ 0.0098") —— Front Tire Pressure 7 psi ( 48 kPa) ——...
Page 18: Vehicle Lifting Support Position
MAINTENANCE SEGWAY AT5 VEHICLE LIFTING SUPPORT POSITION Park the vehicle on a flat, non-slip surface. Make sure the vehicle shift lever is set to Park. To lift the front or rear of the vehicle, place the jacks at the left and right centers of the front or rear of...
Page 19: Maintenance Cycle Table
The periodic maintenance table describes the inspection, adjustment and lubrication of important parts. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspections indicate the need for replacement parts, use genuine Segway parts from your Segway dealer. SYMBOL DESCRIPTION ►...
Page 20: Break-In Maintenance
MAINTENANCE SEGWAY AT5 BREAK-IN MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS HOURS CALENDAR MILES（KM） Break-in check: cycle key to Fuel System 25 H 200 (320) pressurize fuel pump. check lines and fittings for leaks and abrasion Engine oil change...
Page 21 MAINTENANCE SEGWAY AT5 MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS HOURS CALENDAR MILES（KM） ► Oil lines and 100 H 12 M 1000 (1600) Inspect for leaks and loose fittings fasteners ► Front gearcase oil 100 H 12 M 1000 (1600) Change fluid.
Page 22 MAINTENANCE SEGWAY AT5 Maintenance Reference Item Recommended Model Capacity Inspection Method Schedule SAE10W-40/SN Maintain level in safe Refer to Maintenance Engine 2200 mL range on dipstick Schedule or higher M a i n t a i n t h e l e v e l...
Page 23 MAINTENANCE SEGWAY AT5 Recommended Item Capacity Inspection Method Schedule Model Maintain the level Refer to Maintenance Brake fluid DOT4 between the fill —— Schedule lines. Maintain the fluid Front axle Refer to Maintenance SAE 80W-90 GL5 170 mL to the Fill Plug...
Page 24: Remaining Lubrication Filling
MAINTENANCE SEGWAY AT5 Grease The front and rear suspension arms, balance rods and driving shafts of the vehicle are designed with fueling nozzles. Grease these parts with lubricating oil regularly, make sure these parts are dry before filling. Item Recommended Model...
Page 25: General Vehicle Inspection And Maintenance
MAINTENANCE SEGWAY AT5 GENERAL VEHICLE INSPECTION AND MAINTENANCE Pre-Ride / Daily Inspection Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. ◆ Engine Oil - Check for proper level on dipstick located in oil tank (refer to “Engine Oil Level”...
Page 26: Engine Maintenance
MAINTENANCE SEGWAY AT5 ENGINE MAINTENANCE ENGINE OIL LEVEL CHECK IMPORTANT GASOLINE ENGINES USE THESE SAE VISCOSITY GRADES Running the engine with an incorrect oil level may result in serious engine damage. 20W-20, 20W-40, 20W-50 15W-40 10W-30, 10W-40 Oil type: 5W-30°...
Page 27: Engine Oil Emissions
MAINTENANCE SEGWAY AT5 ENGINE OIL EMISSIONS Always change the engine oil and oil filter at regular intervals. Replacement intervals or replacement mileage are available in the Weekly Maintenance Schedule. Change the oil and oil filter at the times given in the Periodic Maintenance Chart.
Page 28: Cleaning The Filters
MAINTENANCE SEGWAY AT5 CLEANING THE FILTERS IMPORTANT Clean the filter at every oil change. Clean the oil filter before changing the engine's oil, which is located behind the filter cover. 【A】Screw M6*25 【B】Strainer cover 【C】Sealing ring 【D】Screen spring 【E】Oil filter screen...
Page 29: Filling The Engine Oil
MAINTENANCE SEGWAY AT5 FILLING THE ENGINE OIL Engine oil can be filled from the dipstick. Add the proper amount of recommended engine oil, do not overfill. Oil type: SAE10W-40/SN or higher grade Oil capacity: 2200mL 1. Unscrew the dipstick and fill with the proper amount of the recommended type of oil.
Page 30: Engine/Fuel Tank Hose Inspection
MAINTENANCE SEGWAY AT5 ENGINE/FUEL TANK HOSE INSPECTION The engine and fuel tank are equipped with vent hoses. Check for possible kinks or damaged, cracked air hoses. The hose is molded for proper installation. 【A】 Engine 【B】Air filter 【C】Engine exhaust pipe 【D】Fuel tank...
Page 31: Valve Lash Check
MAINTENANCE SEGWAY AT5 VALVE LASH CHECK CAUTION Valve lash should be done at room temperature on a cold engine. 1. 1. Remove the seat cushion and disconnect the negative (-) battery cable. 2. 2. Remove the air filter cover and air filter.
Page 32: Front Gearbox And Rear Gearbox
MAINTENANCE SEGWAY AT5 8. Rotate the engine crankshaft with the socket until the cam above the valve to be measured is facing the correct direction. The tip of the peach wheel is facing the correct direction. 9. Measure the valve lash 【A】 and 【B】 with a thickness gauge (plug gauge).
Page 33: Front Reduction Gearbox Oil Drain
MAINTENANCE SEGWAY AT5 FRONT REDUCTION GEARBOX OIL DRAIN The front reduction gearbox oil drain plug is located at the very bottom of the front reduction gearbox. 【A】Oil drain plug 【B】 O-ring ◆ Place a container under the drain plug of the front reduction gearbox to collect the discharged waste oil.
Page 34: Rear Reduction Gearbox Drain
MAINTENANCE SEGWAY AT5 REAR REDUCTION GEARBOX DRAIN The rear reduction gearbox oil drain plug is located at the very bottom of the rear reduction gearbox. 【A】Oil drain plug 【B】O-ring ◆ Place a container under the rear gearbox drain plug to collect the discharged waste oil.
Page 35: Shift Lever Inspection/Adjustment
MAINTENANCE SEGWAY AT5 SHIFT LEVER INSPECTION/ADJUSTMENT Adjustment of the shift lever may be required if the following conditions included: ◆ No gear on the combination meter ◆ Gear noise during acceleration and deceleration ◆ Cannot put into gear ◆ Excessive gear clearance (noise) ◆...
Page 36: Cooling System
MAINTENANCE SEGWAY AT5 COOLING SYSTEM COOLING SYSTEM OVERVIEW The engine coolant level is controlled or maintained by the cooling system. The cooling system components are the sub-tank, radiator, radiator pressure cap and connecting hoses. As the operating temperature of the coolant rises, it...
Page 37: Radiator Check
MAINTENANCE SEGWAY AT5 RADIATOR CHECK ◆ Check the radiator air passages for blockage or damage or obstructions. ◆ If the corrugated fins 【A】 are deformed, carefully straighten them. 【A】Radiator 【B】 Corrugated fins ◆ Remove obstructions with low-pressure compressed air or low-pressure water.
Page 38: Coolant Replacement
MAINTENANCE SEGWAY AT5 COOLANT REPLACEMENT To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be system be completely drained and a new antifreeze 50/50 premix added every two (2) years. CAUTION Steam spillage can burn the skin. Do not remove the pressure cover when the engine is warm.
Page 39: Ntake And Exhaust Maintenance
MAINTENANCE SEGWAY AT5 INTAKE AND EXHAUST MAINTENANCE AIR FILTER The air filter element is a paper air filter element. The air filter needs to be replaced after a certain period of time. In extremely dusty conditions, the air filter needs to be changed more frequently.
Page 40: Spark Arrestor
MAINTENANCE SEGWAY AT5 SPARK ARRESTOR Spark arrestors prevent random sparks from igniting other combustibles. Regular maintenance can prevent carbon buildup. deferred maintenance can reduce engine performance. WARNING ◆ Make sure the exhaust pipe is cool. The engine has just stopped working and can burn your skin due to overheating of the exhaust pipe.
Page 41: Fuel System And Air Intake
MAINTENANCE SEGWAY AT5 FUEL SYSTEM AND AIR INTAKE FUEL SYSTEM WARNING Gasoline burns easily under certain conditions ◆ You must be extremely careful when dealing with gasoline. ◆ When refueling, the engine must be shut off and must be done outdoors or in a well-ventilated area.
Page 42: Fuel Line
MAINTENANCE SEGWAY AT5 FUEL LINE 【A】Fuel tank 4 joints 【B】Throttle disconnect fitting 【C】Injector end high-pressure fuel hose connector First check the piping connections on the tank for leaks, wear wear, deterioration, damage, etc. Replace fuel lines if necessary.Inspect the fuel lines connecting the engine to the fuel tank for signs of wiring and quick connects for signs of failure wear, deterioration, damage or leaks.
Page 43: Cvt
MAINTENANCE SEGWAY AT5 CVT INTAKE SCREEN CHECK It is recommended that the CVT air intake filters be checked periodically and the following procedure should be followed: There are 2 CVT air intakes, both located under the seat cushion. 【A】 Air inlet 1 【B】...
Page 44: Dry Cvt
6. Allow the engine speed to remain at idle speed, apply the brake, and shift the transmission to the lowest available range. 7. Belt slip test, if belt slips, repeat process. 8. If the vehicle needs service, contact your Segway dealer to provide you with assistance. http://www.segwaypowersports.com 1 - 30...
Page 45: Drive Shaft Dust Sleeve Inspection
MAINTENANCE SEGWAY AT5 DRIVE SHAFT MAINTENANCE / TIRES DRIVE SHAFT DUST SLEEVE INSPECTION Inspect the front and rear driveshaft dust boots 【A】 for cuts, damage or grease leaks. If the dust boots show any of these symptoms, they should be replaced. Check dust boot clamps 【B】...
Page 46: Tire Tread Depth
MAINTENANCE SEGWAY AT5 TIRE TREAD DEPTH Check the tire tread block wear, when the tire tread block wear is at least 1.6mm above the tread, the tire should be replaced. WARNING Operating with worn tires increases the likelihood of vehicle skidding and possible loss of control. Worn tires can cause accidents.
Page 47: Steering Maintenance
MAINTENANCE SEGWAY AT5 STEERING MAINTENANCE STEERING SYSTEM CHECK Steering system components should be checked periodically for loose fasteners, worn tie rod ends/ transverse tie rod fasteners, loose steering shaft universal joints, and tie rod ball wear. Replace any worn or damaged steering parts. The steering should travel the full range of travel of free movement with no sticking.
Page 48: Transverse Tie Rod Inspection
MAINTENANCE SEGWAY AT5 TRANSVERSE TIE ROD INSPECTION NOTE Whenever you replace a steering component, check the front beam for alignment ◆ To check the clearance of the transverse tie rod 【A】, grasp the transverse tie rod and pull it in all directions to feel if there is any movement.
Page 49: Front Beam Adjustment
MAINTENANCE SEGWAY AT5 ◆ Apply a thick line of chalk or paint near the center of the front tire. ◆ As you turn the wheel, use a needle tip plotter to make a small mark near the center of the chalk coating.
Page 50: Shock Absorber
MAINTENANCE SEGWAY AT5 SHOCK ABSORBER SHOCK ABSORBER INSPECTION Since the front shock absorbers are sealed units, they cannot be disassembled and only require external inspection. If one unit is damaged, replace both shock absorbers as a set. If only one unit is replaced and both are not balanced, it may cause the vehicle to become unstable at high speeds or the overall comfort deterioration of the vehicle at high speeds.
Page 51: Oil Shock Absorber Adjustment
MAINTENANCE SEGWAY AT5 OIL SHOCK ABSORBER ADJUSTMENT The damping has 5 positions for different loads or driving conditions. position sprung environment load topography speed ↑ soft soft Light smooth ↑ ↑ ↑ ↑ ↑ standard position ↓ ↓ ↓ ↓...
Page 52: Braking System
MAINTENANCE SEGWAY AT5 BRAKING SYSTEM Front and rear brakes are hydraulic disc brakes, activated by the brake pedal Brake liquid cup Front left Front right WARNING brake brake The brake fluid level must be checked periodically: An overfilled brake cylinder may cause brake resistance or brake lock-up, which could result in serious serious injury or death.
Page 53: Brake Fluid Cup Level Check
MAINTENANCE SEGWAY AT5 CAUTION Brake fluid can damage plastic and painted surfaces, use caution when adding. If brake fluid comes into contact with skin or eyes, flush immediately with plenty of water. If there is any further discomfort, please consult a doctor immediately.
Page 54: Brake Pedal Air Travel Check
MAINTENANCE SEGWAY AT5 BRAKE PEDAL AIR TRAVEL CHECK 【A】 Brake pedal travel ◆ Check the empty travel of the brake pedal 【A】. ◆ Depress the brake pedal gently with your foot until the brake pedal is depressed. If the rear brake pedal has too much air travel, adjust it, (see chapter "Braking").
Page 55: Electrical And Ignition Systems
MAINTENANCE SEGWAY AT5 ELECTRICAL AND IGNITION SYSTEMS BATTERY MAINTENANCE Keep battery terminals and connections free of corrosion, if cleaning is required, use a stiff wire If cleaning is required, remove corrosion with a stiff wire brush, clean with a solution of one tablespoon of baking soda and one cup of water, rinse well with tap water, dry with a clean towel, lubricate with dielectric grease or vanadium.
Page 56: Battery Installation
MAINTENANCE SEGWAY AT5 6. Remove the positive battery screw and disconnect the red (positive) battery cable. 7. Remove the battery from the vehicle BATTERY INSTALLATION CAUTION To reduce the possibility of sparking: each time the battery is removed, disconnect the black (negative) cable to reconnect.
Page 57: Spark Plugs
MAINTENANCE SEGWAY AT5 SPARK PLUGS Refer to the recommended spark plug type and gap specifications. Spark Plug Torque Specifications. CAUTION Using non-recommended spark plugs can cause serious engine damage. 0.6~0.8mm Always use recommended spark plugs or their equivalent. model number spark plug gap Spark Plug Torque spark 12 N.m (1.2 kgf·m，...
Page 58: Throttle Cable Free Travel Check And Adjustment
MAINTENANCE SEGWAY AT5 THROTTLE CABLE FREE TRAVEL CHECK AND ADJUSTMENT THROTTLE LEVER FREE PLAY CHECK 【A】Throttle lever 【B】Free clearance 【C】Adjuster 【D】Lock nut 【E】Adjusting screw 【F】Lock nut 1. Check that the throttle lever moves smoothly from the fully open position to the closed position. and quickly and completely closes the throttle in all steering positions by means of the return spring door.
Page 59: Engine Lubrication System
ENGINE LUBRICATION SYSTEM SEGWAY AT5 ENGINE LUBRICATION SYSTEM ExpLOdEd vIEw ..................... 3-1-2 TEChNICAL pARAMETER ..................3-1-4 SpECIAL TOOLS ANd SEALANTS ................ 3-1-5 ENGINE OIL FLOw ChART ..................3-1-6 ENGINE OIL ANd OIL FILTER ................. 3-1-7 Oil level inspectiOn ..................3-1-7 engine Oil change ..................
Page 60: Exploded View
ENGINE LUBRICATION SYSTEM SEGWAY AT5 ExpLOdEd vIEw http://www.segwaypowersports.com 3 - 1 - 2...
Page 61 ENGINE LUBRICATION SYSTEM SEGWAY AT5 tOrque name remarks n·m kgF·m Ft·lb Oil pump Drive gear Flat key spacer bolt m10×1.25×25 Oil pump idler gear shaft circlip 15 spacer 15×28×1 Oil pump idler gear e-ring 9 spacer12×20×1 Oil pump Driven gear Oil pump shaft bolt m6×20...
Page 62: Technical Parameter
ENGINE LUBRICATION SYSTEM SEGWAY AT5 TEChNICAL pARAMETER item standard ENGINE OIL: grade api sn or higher viscosity sae 10W-40 capacity 2.0 L (2.11 US qt) (when filter is not removed) 2.2 L (2.32 US qt) (when filter is removed) 2.4 l (2.54 us qt) (when engine is completely dry)
Page 63: Special Tools And Sealants
ENGINE LUBRICATION SYSTEM SEGWAY AT5 SpECIAL TOOLS ANd SEALANTS SILICONE SEALANT: OIL pRESSURE GAUGE, 10 kGF/CM Oil pressure test hose, m10×1: e01gZ0040001 http://www.segwaypowersports.com 3 - 1 - 5...
Page 64: Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM SEGWAY AT5 ENGINE OIL FLOw ChART strainer Filter Oil nozzles 13 transmission countershaft assembly Oil pump piston 14 crankshaft Oil pressure valve unit 9 intake camshaft 15 starter One-Way gear Oil Filter exhaust camshaft 16 alternator stator and rotor...
Page 65: Engine Oil And Oil Filter
ENGINE LUBRICATION SYSTEM SEGWAY AT5 ENGINE OIL ANd OIL FILTER wARNING vehicle operation with insufficient,deteriorated,or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident,and injury. OIL LEvEL INSpECTION ◆ park the vehicle so that it is level, both side-to-side and front-to-rear.
Page 66: Engine Oil Change
ENGINE LUBRICATION SYSTEM SEGWAY AT5 ENGINE OIL ChANGE ◆ refer to the engine lubrication system in the periodic maintenance chapter. OIL FILTER ChANGE ◆ refer to the engine lubrication system in the Periodic Maintenance chapter to fill the oil filter.
Page 67: Oil Pressure
ENGINE LUBRICATION SYSTEM SEGWAY AT5 OIL pRESSURE OIL pRESSURE MEASUREMENT NOTE measure the oil pressure after the engine is warmed up. ◆ remove the oil pressure switch, and attach the oil pressure gauge【a】and adapter【b】. Tools: Oil Pressure Gauge,10 kgf/cm Oil Pressure Gauge Adapter Oil Pressure Standard: 400 kPa (4.1 kgf/cm...
Page 68: Oil Pressure Valve Removal
ENGINE LUBRICATION SYSTEM SEGWAY AT5 OIL pRESSURE vALvE REMOvAL ◆ split the crankcase (see crankshaft / transmission chapter). ◆ remove the oil pressure relief valve cover. ◆ remove the oil pressure relief valve【a】. OIL pRESSURE vALvE INSTALLATION ◆ see crankcase assembly (see crankshaft / transmission chapter).
Page 69: Oil Pump
ENGINE LUBRICATION SYSTEM SEGWAY AT5 OIL pUMp OIL pUMp REMOvAL ◆ remove: alternator rotor and starter clutch gear(see electrical system chapter). ◆ remove: 【a】e-ring 9 【b】Flat Washer 12×20×1 【c】Driven gear,Oil pump 【D】needle roller 4×15.8 ◆ remove: 【b】Oil pump bolts 【a】Oil pump cover 【e】shaft,Oil pump...
Page 70: Oil Pump Gear
ENGINE LUBRICATION SYSTEM SEGWAY AT5 OIL pUMp GEAR ◆ Check the flexibility of the Oil Pump Shaft rotation ◆ install the Oil pump Driven gear【a】 with the Oil pump【b】. OIL pUMp GEAR REMOvAL ◆ remove: Oil pump idler gear shaft【e】...
Page 71: Oil Cooler
ENGINE LUBRICATION SYSTEM SEGWAY AT5 OIL COOLER OIL COOLER REMOvAL ◆ remove: Drain the engine coolant and oil spring band hose clamps【a】 screw m6×16【b】 cooler【c】 O-ring 19×2.5【D】 OIL COOLER INSTALLATION ◆ install: 1. replace the O-ring 【D】 with new ones 2.
Page 72 CRANKSHAFT / TRANSMISSION SEGWAY AT5 CRANKSHAFT / TRANSMISSION ExplOdEd vIEw ..................... 3-2-2 TECHNICAl pARAMETER ..................3-2-8 SpECIAl TOOlS ANd SEAlANTS ................ 3-2-9 CRANKCASE ......................3-2-10 CrankCase Disassembly ................3-2-10 CrankCase assembly ................... 3-2-13 CRANKSHAFT ......................3-2-24 ConneCting roD big enD siDe ClearanCe ..........3-2-24 Crankshaft runout ..................
Page 73: Exploded View
CRANKSHAFT / TRANSMISSION SEGWAY AT5 ExplOdEd vIEw http://www.segwaypowersports.com 3 - 2 - 2...
Page 74 CRANKSHAFT / TRANSMISSION SEGWAY AT5 (lEFT) (RIgHT) s 20 s 20 http://www.segwaypowersports.com 3 - 2 - 3...
Page 75 CRANKSHAFT / TRANSMISSION SEGWAY AT5 torque name remarks n·m kgf·m ft·lb left Crankcase assembly ss,o right Crankcase & right Cover Combination ss,o isolator bolt m6×65 87 in•lb Dowel pin 6×10 bolt m8×40 needle roller bearing hk121612 bolt m8×70 Flow Orifice Φ1 0.25...
Page 76 CRANKSHAFT / TRANSMISSION SEGWAY AT5 http://www.segwaypowersports.com 3 - 2 - 5...
Page 77 CRANKSHAFT / TRANSMISSION SEGWAY AT5 torque name remarks n·m kgf·m ft·lb transmission main shaft idle shaft needle roller bearing k252913 r idle gear spacer 17×38×2 transmission Countershaft assembly reduction Driven gear Circlip 25×1.2 Drive bevel gear shaft Drive bevel gear housing bolt m8×30...
Page 78 CRANKSHAFT / TRANSMISSION SEGWAY AT5 torque name remarks n·m kgf·m ft·lb shiftshaft Cover gasket shiftshaft Cover oil seal 15×25×5 bolt m6×20 87 in•lb bolt m6×40 shift fork spring seat shoulder bolt Detent pawl Detent pawl torsion spring shift fork shift fork l...
Page 79: Technical Parameter
CRANKSHAFT / TRANSMISSION SEGWAY AT5 TECHNICAl pARAMETER item standard service limit Transmission: shift fork ear thickness: 5.8 ~ 5.9 mm 5.7 mm shifter groove width: 6.0 ~ 6.1 mm 6.2 mm http://www.segwaypowersports.com 3 - 2 - 8...
Page 80: Special Tools And Sealants
CRANKSHAFT / TRANSMISSION SEGWAY AT5 SpECIAl TOOlS ANd SEAlANTS outside Circlip pliers bearing Driver set sealant: 5699 http://www.segwaypowersports.com 3 - 2 - 9...
Page 81: Crankcase
CRANKSHAFT / TRANSMISSION SEGWAY AT5 CRANKCASE CRANKCASE dISASSEMBly ◆ remove: 1. engine (see engine removal/installation chapter) 2. starter motor (see electrical system chapter) 3. oil filter (see engine lubrication system chapter) 4. Cylinder blocks and pistons (see engine top end chapter) 5.
Page 82 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ Disassembly: bolt (m6×20)【b】. gear sensor【a】 bolt (m6×30)【C】. bolt (m6×60)【D】 right crankcase cover【e】 right crankcase cover gasket 【f】. ◆ Disassembly: 1. retaining ring【a】 2. respirator cover【b】 3. respirator cover【C】 4. Cylindrical pin 6×10【e】 ◆ Disassembly: left crankcase bolt m6(13)【a】...
Page 83 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ remove: 1. Wrap the teeth on the sprockets【b】by taping for protecting the bushing in the crankcase. 2. using the pry points【a】, split the crankcase halves. 3. Lift off the right crankcase half. http://www.segwaypowersports.com 3 - 2 - 12...
Page 84: Crankcase Assembly
CRANKSHAFT / TRANSMISSION SEGWAY AT5 CRANKCASE ASSEMBly NOTE ◆ be certain that all parts are cleaned thoroughly before assembly. ◆ blow through all oil passages with compressed air to clear any blockage in the crankcase halves and crankshaft. wARNINg Clean the engine parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area;...
Page 85 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ install: oil pressure relief valve【e】(see engine lubrication system chapter) ◆ install: Chain guide【a】 Chain tensioner【C】 ◆ tighten: Torque Chain guide bolts【b】 12 n·m (1.2 kgf·m, 8.7 ft·lb) apply a non-permanent locking agent to the bolts【b】.
Page 86 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ press in the new deep groove ball bearings until they bottom out. Special Tools - Bearing Mounting Kit: 【a】 Deep groove ball bearing: 6206 【b】 Deep groove ball bearing: 6203 【C】 Deep groove ball bearing: 6228 ◆...
Page 87 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ install: transmission shaft【a】and new bearing 6205【b】. ◆ press and insert the bearings until they are bottomed. Special Tool - Bearing driver Set: 【b】 ball bearing : 6205 ◆ install: 【C】nut m55×1.5×6-lh ◆ tighten: Torque nut【C】...
Page 88 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ press and insert the bearings until they are bottomed. Special Tool - Bearing driver Set 【a】ball bearing : 6305 【C】ball bearing : 6207 ◆ install: nut m65×1.5×8-lh【b】 (left-hand threads) ◆ tighten: Torque nut【b】 137 n·m (14 kgf·m, 106 ft·lb) ◆...
Page 89 CRANKSHAFT / TRANSMISSION SEGWAY AT5 CAUTION the Driving bevel gear【b】and Driven bevel gear 【a】are machined at the factory in the assembled state, so the Driving bevel gear and Driven bevel gear must be replaced as a set. ◆ install: 1. Driven bevel gear assembly【a】...
Page 90 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ be sure the following parts are in place in the left crankcase half. 1. Drive bevel gear shaft assembly【a】 2. parking brake arm【b】, snap ring 12【C】, parking brake shaft【D】 3. Countershaft assembly【e】,shift rail l【f】...
Page 91 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ apply engine oil to the needle roller bearing 【a】,Crankshaft rod【b】,Crankshaft Case oil passages ,main bearing bore【e】. CAUTION the Crankshaft and balance shaft gear mark points 【D】must be aligned. ◆ Apply liquid gasket【C】to mating surface of the right crankcase half.
Page 92 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ apply a non-permanent locking agent to the area 【a】(12 mm, 0.47 in.) except for the tip【b】(2 ~ 3 mm, 0.08 ~ 0.12 in.). right Crankcase bolt m6×40【13】 ◆ tighten the right crankcase bolts (m6) following the tightening sequence【1 ~ 13】...
Page 93 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ installation: 【a】shift positioning wheel 【b】 bushing 【C】 shift driven gear 【D】shift torsion spring 【e】 Washer 6.2×22×2 【f】 hexagon head bolt 【g】shift shaft assembly 【l】 Cylindrical pin 6×10 ◆ Tightening torque: hexagon head bolt m6×40【f】...
Page 94 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ install: 【a】Dowel pin 6×10 【b】Centrifugal oil-air separator 【C】Washer 【D】snap ring 25×1.2 ◆ install: oil seal 20×30×7【l】 oil seal 35×52×7【m】 ◆ apply engine oil to the main bearing bore【n】 ◆ apply grease the lip of the oil seal【l】and【m】...
Page 95: Crankshaft
CRANKSHAFT / TRANSMISSION SEGWAY AT5 CRANKSHAFT CAUTION the Crankshaft and Connecting rod are assembled at the factory , so the Crankshaft must be replaced as a set. CONNECTINg ROd BIg ENd SIdE ClEARANCE ◆ measure the side clearance of the connecting rod big end.
Page 96: Transmission
CRANKSHAFT / TRANSMISSION SEGWAY AT5 TRANSMISSION TRANSMISSION REMOvAl ◆ remove the shift lever (see shift lever removal). ◆ remove the shiftshaft (see Crankcase Disassembly). ◆ split the crankcase (see Crankcase Disassembly). ◆ remove: Drive bevel gear Component bolts【a】 Drive bevel gear Component【b】...
Page 97 CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ remove: main shaft【a】 ◆ remove: Countershaft assembly【b】,shift rail l【C】,shift rail h/r【D】,shift Drum【e】Component. http://www.segwaypowersports.com 3 - 2 - 26...
Page 98: Transmission Installation
CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ remove: parking brake arm shaft【a】and snap ring 12 【b】 spacer12×20×1【C】 parking brake arm【D】 TRANSMISSION INSTAllATION ◆ install: insert the parking brake arm assembly in the crankcase until it is bottomed ◆ install: Drive bevel gear assembly【a】...
Page 99: Shift Fork Bending
CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ install: shift rail fork assembly h/r【C】 shift rail fork assembly l 【D】 shift Drum【a】 Countershaft assembly【b】 insert the shift forks into the groove of the Countershaft assembly SHIFT FORK BENdINg ◆ visually inspect the shift fork.
Page 100: Transmission And Shift Mechanism Inspection
CRANKSHAFT / TRANSMISSION SEGWAY AT5 TRANSMISSION ANd SHIFT MECHANISM INSpECTION ◆ visually inspect: gears Dogs of gear and shifter if they are damaged or worn excessively, replace them ◆ install: 1. install the Countershaft assembly, shift rail l, shift rail h/r and shift Camshaft to C.
Page 101 CRANKSHAFT / TRANSMISSION SEGWAY AT5 Countershaft spacer 22×32×1.5 l gear driven gear shifter, h Washers 20×30×1.5 Washer 33×1.5 elastic retaining ring 25×1.2 reduction drive gear h gear driven gear spacer 28×36.5×1 h bushing gear r parking gear bushing r reverse gear intermediate wheel shaft...
Page 102: Ball Bearing, Needle Bearing, And Oil Seal
CRANKSHAFT / TRANSMISSION SEGWAY AT5 BAll BEARINg, NEEdlE BEARINg, ANd OIl SEAl BAll ANd NEEdlE BEARINg REplACEMENT CAUTION Do not remove the ball or needle bearings unless it is necessary. removal may damage them. ◆ using a press or puller, remove the ball bearing and/ or three needle bearings.
Page 103: Oil Seal Inspection
CRANKSHAFT / TRANSMISSION SEGWAY AT5 ◆ Check the needle bearings. the rollers in a needle bearing normally wear very little, and wear is difficult to measure. instead of measuring, inspect the bearing for abrasion, color change, or other damage.spin【a】the bearing by hand to check its condition.
Page 104: Engine-Electrical System
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 ENGINE-ELECTRICAL SYSTEM ExpLodEd vIEw ..................... 3-3-2 TEChNICAL pARAMETER ..................3-3-4 SpECIAL TooLS ..................... 3-3-5 ChARGING SYSTEM ....................3-3-6 AlternAtor Cover removAl ..............3-3-6 AlternAtor Cover InstAllAtIon .............. 3-3-6 AlternAtor rotor removAl ..............3-3-7 AlternAtor rotor InstAllAtIon .............. 3-3-8 AlternAtor stAtor removAl ..............
Page 105: Exploded View
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 ExpLodEd vIEw http://www.segwaypowersports.com 3 - 3 - 2...
Page 106 ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 torque name remarks n·m kgf·m ft·lb stator Cover plug 13.3 o-ring 35×3.5 left Crankcase Cover left Crankcase Cover gasket Alternator stator plate Bolt m6×16 87 in•lb Bolt m6×35 nut m18×1.5 18.4 Alternator rotor Double gear shaft one-Way Clutch spacer 12×18×12...
Page 107: Technical Parameter
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 TEChNICAL pARAMETER Item standard service limit Charging System: – – – Alternator type three-phase AC – – – Charging voltage 14 ~ 15v (Regulator/rectifier output voltage) – – – Alternator output voltage: 36 ~ 54V 3000r/min(rpm) –...
Page 108: Special Tools
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 SpECIAL TooLS Flywheel holder： Flywheel puller Assembly : e01gZ0010001 http://www.segwaypowersports.com 3 - 3 - 5...
Page 109: Charging System
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 ChARGING SYSTEM ALTERNAToR CovER REMovAL ◆ place an coolant pan under the engine left side. ◆ Drain the coolant (see Cooling System chapter). ◆ place an oil pan under the engine left side. ◆ Remove Water Pump (see Cooling System chapter).
Page 110: Alternator Rotor Removal
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 ALTERNAToR RoToR REMovAL ◆ remove: 1. Alternator Cover (see Alternator Cover Removal) 2. Alternator rotor nut m18×1.5【A】 3. thread the flywheel puller【B】onto the alternator rotor. Special Tool - Flywheel puller:E01GZ0010001 Flywheel holder ◆ holding the Flywheel holder【B】, turn the rotor puller【C】until the alternator rotor is forced off the...
Page 111: Alternator Rotor Installation
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 ALTERNAToR RoToR INSTALLATIoN ◆ Clean【A】the inside of the rotor and the end of the crankshaft. ◆ Fit the rotor onto the crankshaft so that woodruff key 【B】 fits in the groove【C】in the hub of the rotor.
Page 112: Alternator Stator Installation
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 ALTERNAToR STAToR INSTALLATIoN ◆ Apply a non-permanent locking agent to the area 【A】 (12 mm, 0.47 in.) except for the tip【B】(2 ~ 3 mm, 0.08 ~ 0.12 in.) ◆ tighten: Torque Bolts m6×35 9.8 N•m (1.0 kgf•m, 87in•lb) Bolts m6×16...
Page 113: Alternator Inspection
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 ALTERNAToR INSpECTIoN there are three types of alternator failures: short, open, or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.
Page 114: Stator Coil Resistance
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 STAToR CoIL RESISTANCE Connections tester reading range Tester (+) to Tester (–) to one yellow Another 0.33~0.49 Ω ×1Ω lead yellow lead If there is more resistance than shown in the table, or no reading (infinity) for any two leads, the stator has an open and must be replaced.
Page 115: Electric Starter System
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 ELECTRIC STARTER SYSTEM STARTER MoToR REMovAL ◆ remove starter motor Cable【A】 starter motor mounting Bolts【B】 starter motor【C】 CAUTIoN Do not tap the end of the starter motor shaft or the motor may be damaged. STARTER MoToR INSTALLATIoN ◆...
Page 116: One-Way Clutch Removal
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 oNE-wAY CLUTCh REMovAL ◆ remove the Alternator rotor (see Alternator rotor Removal). ◆ hold the rotor with the Flywheel holder and take out the one-Way Clutch Bolts 【A】. ◆ take out the one-Way Clutch 【B】. oNE-wAY CLUTCh INSTALLATIoN ◆...
Page 117: Starter Gear Removal
ENGINE-ELECTRICAL SYSTEM SEGWAY AT5 STARTER GEAR REMovAL ◆ remove 1. Alternator Rotor (see Alternator Rotor Removal) 2. spacer【e】 3. Washer【D】 4. Double gear shaft【C】 5. needle roller Bearing【B】 6. remove the starter gear Assembly【A】 visually inspect the starter gear If the gear does not operate correctly, or if it makes noise, disassemble it and examine each part visually.
Page 118: Engine Cooling System
CRANKSHAFT / TRANSMISSION SEGWAY AT5 ENGINE-COOLING SYSTEM ExpLOdEd vIEw ..................... 3-4-2 TEChNICaL paraMETEr ..................3-4-4 waTEr puMp ......................3-4-5 Water PumP removal ................... 3-4-5 Water PumP InstallatIon ................3-4-5 ThErMOSTaT ......................3-4-6 thermostat removal ................... 3-4-6 thermostat InstallatIon ................3-4-6 thermostat InsPectIon ................
Page 119: Exploded View
CRANKSHAFT / TRANSMISSION SEGWAY AT5 ExpLOdEd vIEw http://www.segwaypowersports.com 3 - 4 - 2...
Page 120 CRANKSHAFT / TRANSMISSION SEGWAY AT5 torque Fastener remarks n·m kgf·m ft·lb thermostat assembly thermostat cover Bolt m6×20 87 in•lb Water temperature sensor aluminum washer 14×21×1.5 coupling Plumbing Fittings steel band elastic hose clamp hoop 22 Water pipe 12×20×147 Plastic-coated wire clips (10x95) hose clamp Water pipe 12×20×455...
Page 121: Technical Parameter
CRANKSHAFT / TRANSMISSION SEGWAY AT5 TEChNICaL paraMETEr Item standard service limit coolant provided when – – – shipping: Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust type inhibitor chemicals for aluminum engines and radiators) – – –...
Page 122: Water Pump
CRANKSHAFT / TRANSMISSION SEGWAY AT5 waTEr puMp waTEr puMp rEMOvaL ◆ Drain the engine coolant and oil ◆ remove: clamp【a】 cooling hoses【B】 Water Pump Bolts【c】 Water Pump【D】 Water Pump Gasket【e】 waTEr puMp INSTaLLaTION ◆ apply engine oil to the oil Pump o-ring【a】...
Page 123: Thermostat
CRANKSHAFT / TRANSMISSION SEGWAY AT5 ThErMOSTaT ThErMOSTaT rEMOvaL ◆ Drain the coolant (see cooling system in Periodic maintenance chapter). ◆ remove: thermostat housing cover Bolts【B】 thermostat housing cover【c】 thermostat【a】 ThErMOSTaT INSTaLLaTION ◆ Be sure to install the o-ring【D】on the thermostat ◆...
Page 124: Thermostat Inspection
CRANKSHAFT / TRANSMISSION SEGWAY AT5 ThErMOSTaT INSpECTION ◆ remove the thermostat, and inspect the thermostat valve【a】at room temperature. If the valve is open, replace the valve with a new one. ◆ to check valve opening temperature, suspend the thermostat【a】and an accurate thermometer 【B】in a container of water with the heat-sensitive...
Page 125: Coolant Temperature Sensor
CRANKSHAFT / TRANSMISSION SEGWAY AT5 COOLaNT TEMpEraTurE SENSOr COOLaNT TEMpEraTurE SENSOr rEMOvaL CauTION the coolant temperature sensor should never be allowed to fall on a hard surface. such a shock to the part can damage it. ◆ Drain the coolant (see cooling system in Periodic maintenance chapter).
Page 126: Engine Top End
ENGINE TOP END SEGWAY AT5 ENGINE TOP END TEchNIcal ParamETEr ..................3-5-6 SPEcIal TOOlS ..................... 3-5-8 SPark PluG / ValVE cOVEr / ThrOTTlE BODy / camShafT ...... 3-5-9 ThrOTTlE BODy ....................3-5-10 ThroTTle Body removal ................3-5-10 ThroTTle Body InsTallaTIon ..............3-5-10 aIr InTake PIPe removal: ................
Page 127 ENGINE TOP END SEGWAY AT5 cylInder head dIsassemBly ..............3-5-21 valve guIde / valve InsPecTIon ..............3-5-22 comBusTIon chamBer cleanIng ............... 3-5-23 valve seaT recondITIonIng ................ 3-5-24 valve seaT InsPecTIon: ................3-5-24 valve seaT rePaIr (valve laPPIng) ............3-5-25 cylINDEr aND PISTON ..................3-5-28 cylInder removal ..................
Page 128: Exploded View
ENGINE TOP END SEGWAY AT5 ExPlODED VIEw http://www.segwaypowersports.com 3 - 5 - 3...
Page 129 ENGINE TOP END SEGWAY AT5 Torque name remarks n·m kgf·m ft·lb 87 in•lb Bolt m6×20 chain guard shoulder Bolt 87 in•lb chain Tensioner chain guide Plate Timing chain Pipe/line Fixing Plate 87 in•lb Bolt m6×25 Tensioner gasket Tensioner Base gasket...
Page 130 ENGINE TOP END SEGWAY AT5 Torque name remarks n·m kgf·m ft·lb valve Bucket split keeper valve retainer valve spring valve stem seal valve seat Intake valve exhaust valve Piston Piston Pin retaining ring Top ring second conpression ring oil ring combination Piston Pin g: apply grease for oil seal and o-ring.
Page 131: Technical Parameter
ENGINE TOP END SEGWAY AT5 TEchNIcal ParamETEr Item standard service limit cylinder head: 450 ~700 kPa (4.7 ~ 7.2 kgf/cm²,65 ~ 102 cylinder compression(usable range) psi) @ 300 r/min (rpm) – – – electric starter – – – 0.05 mm (0.002 in.) 120.5 ±...
Page 132 ENGINE TOP END SEGWAY AT5 Item standard service limit Piston Pin: Piston Pin o.d. 20.000 ~ 20.005 mm(0.7873" ~ 0.7875") 19.98 mm (0.7866") Piston ring: Installed gap: 0.5 mm (0.0197") Top ring 0.20 ~ 0.35 mm (0.0079" ~ 0.0138") 0.7 mm (0.0276") second ring 0.35 ~ 0.55 mm (0.0138"...
Page 133: Special Tools
ENGINE TOP END SEGWAY AT5 SPEcIal TOOlS valve spring compressor assembly compression gauge compression gauge adapter, m10×1.0 http://www.segwaypowersports.com 3 - 5 - 8...
Page 134: Spark Plug / Valve Cover / Throttle Body / Camshaft
ENGINE TOP END SEGWAY AT5 SPark PluG / ValVE cOVEr / ThrOTTlE BODy / camShafT http://www.segwaypowersports.com 3 - 5 - 9...
Page 135: Throttle Body
ENGINE TOP END SEGWAY AT5 ThrOTTlE BODy ThrOTTlE BODy rEmOVal ◆ remove clamp 70【a】 Throttle Body【B】 ThrOTTlE BODy INSTallaTION ◆ Install Throttle Body clamp 70 aIr INTakE PIPE rEmOVal: ◆ remove: Bolts m8×25【 a】 air Intake Pipe removal【B】 aIr INTakE PIPE INSTallaTION: ◆...
Page 136: Fuel Injector / Thermostat
ENGINE TOP END SEGWAY AT5 fuEl INjEcTOr / ThErmOSTaT fuEl INjEcTOr rEmOVal ◆ disconnect the Fuel Injector lead. ◆ remove: Fuel Injector Bolts【a】 Fixed Plate【B】 Fuel Injector Press Plate【c】 Fuel Injector adapter【d】 Fuel Injector【e】 fuEl INjEcTOr INSTallaTION Fuel Injector【e】 Fuel Injector adapter【d】...
Page 137: Ignition Coil / Spark Plug
ENGINE TOP END SEGWAY AT5 IGNITION cOIl / SPark PluG SPark PluG rEmOVal ◆ disconnect the Ignition coil lead. ◆ remove: Bolt m6×20【a】 Ignition coil【B】 spark Plug【c】 cauTION The spark Plug should never be allowed to fall on a hard surface. such a shock to the part can damage it.
Page 138: Valve Cover
ENGINE TOP END SEGWAY AT5 ValVE cOVEr ValVE cOVEr rEmOVal ◆ remove: shoulder Bolts 【B】 (using a T40 driver) Isolators【a】 valve cover【c】 valve cover seal【d】 dowel Pin 10×14【e】 ValVE cOVEr INSTallaTION: ◆ replace isolators【B】and valve cover seal【c】if oil leaks are evident.
Page 139: Crank Position Sensor
ENGINE TOP END SEGWAY AT5 craNk POSITION SENSOr craNk POSITION SENSOr rEmOVal ◆ disconnect the crank Position sensor lead. ◆ remove: Bolt m6×16【a】 crank Position sensor【B】 o-ring 17×2【c】 ◆ remove: stator cover Plug【e】 o-ring 35×3.5【d】 ◆ using a wrench on the alternator nut【a】,rotate counterclockwise the crankshaft until the flywheel Tdc mark【B】is aligned or centered in the...
Page 140: Camshaft Chain Tensioner
ENGINE TOP END SEGWAY AT5 camShafT chaIN TENSIONEr camShafT chaIN TENSIONEr rEmOVal cauTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. observe all the rules...
Page 141: Camshaft Carrier / Camshaft
ENGINE TOP END SEGWAY AT5 camShafT carrIEr / camShafT camShafT carrIEr rEmOVal ◆ remove the bolts m6×65 【 a】retaining the fixed cam chain guide【B】and remove the assembly from the engine. ◆ remove Bolts m6×35【c】 camshaft carrier【d】 dowel Pin 8×14【e】 NOTE evenly loosen the bolts retaining camshaft carrier carefully lift the camshaft carrier off the camshafts.
Page 142: Camshaft Inspection
ENGINE TOP END SEGWAY AT5 camShafT INSPEcTION auTOmaTIc cOmPrESSION rElEaSE The automatic compression release momentarily opens the exhaust valves on the compression stroke at very low speeds. This allows some of the compression pressure to escape, making it easy to turn over the engine during starting.
Page 143: Automatic Compression Release Removal
ENGINE TOP END SEGWAY AT5 auTOmaTIc cOmPrESSION rElEaSE rEmOVal ◆ remove: camshaft (see camshaft removal) circlip【c】 automatic compression release unit【d】 dowel Pin【e】 auTOmaTIc cOmPrESSION rElEaSE INSTallaTION ◆ Install: dowel Pin【e】 automatic compression release unit【d】 circlip【c】 camShafT SPrOckET INSTallaTION ◆ Install the sprockets on the intake and exhaust camshafts.
Page 144: Camshaft / Camshaft Bore Inspection
ENGINE TOP END SEGWAY AT5 camShafT / camShafT BOrE INSPEcTION cam wEar ◆ visually inspect each cam lobe for wear or damage. ◆ measure the height【d】of the cam with a micrometer. If the cams are worn past the service limit, replace the camshaft.
Page 145: Cylinder Head
ENGINE TOP END SEGWAY AT5 cylINDEr hEaD cylINDEr hEaD rEmOVal NOTE The cylinder head can be serviced with the engine installed in the chassis. ◆ remove the (2) outer m6 bolts【a】that retain the cylinder head【B】to the cylinder. ◆ loosen the (4) cylinder head bolts【c】evenly 1/8 turn at a time until all are loose.
Page 146: Cylinder Head Disassembly
ENGINE TOP END SEGWAY AT5 cylINDEr hEaD DISaSSEmBly warNING Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs. ImPOrTaNT keep mated parts together and in order with respect to their location in the cylinder head for assembly purposes.
Page 147: Valve Guide / Valve Inspection
ENGINE TOP END SEGWAY AT5 ◆ measure the free length of each valve spring with a Vernier caliper and compare to specification. ◆ valve spring Free length: standard: 1.726" (43.85 mm)service limit: 1.683" (42.75 mm) standard service limit 42.5 mm (1.6732") 41.4mm (1.6299")
Page 148: Combustion Chamber Cleaning
ENGINE TOP END SEGWAY AT5 NOTE The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent or damaged. ◆ measure diameter of valve stem with a micrometer in three places, then rotate 90° and measure again (take six measurements total).
Page 149: Valve Seat Reconditioning
ENGINE TOP END SEGWAY AT5 ValVE SEaT rEcONDITIONING ◆ valve seat reconditioning should be performed by a technician proficient in cylinder head reconditioning techniques. reconditioning techniques vary, so follow the instructions provided by the valve reconditioning equipment manufacturer. do not grind seats more than necessary to provide proper seat surface, width, and contact point on valve face.
Page 150: Valve Seat Repair (Valve Lapping)
ENGINE TOP END SEGWAY AT5 ValVE SEaT rEPaIr (ValVE laPPING) ◆ Install pilot into valve guide. ◆ apply cutting oil to valve seat and cutter. ◆ Place 46° cutter on the pilot and make a light cut. ◆ Inspect the cut area of the seat: If the contact area is less than 75% of the circumference of the seat, rotate the pilot 180°...
Page 151 ENGINE TOP END SEGWAY AT5 NOTE When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. look for an even and continuous contact point all the way around the valve face【a】.
Page 152 ENGINE TOP END SEGWAY AT5 ◆ rotate the valve rapidly back and forth until the cut sounds smooth. Lift the valve slightly off of the seat, rotate 1/4 turn, and repeat the lapping process. do this four to five times until the valve is fully seated, and the seating surface is smooth, Then repeat process for the other valve(s).
Page 153: Cylinder And Piston
ENGINE TOP END SEGWAY AT5 cylINDEr aND PISTON cylINDEr rEmOVal ◆ remove: cylinder head (see cylinder head removal) cylinder Bolt【a】 cylinder【B】 cylinder Base gasket【c】 PISTON rEmOVal ◆ remove the cylinder block (see cylinder removal). ◆ Place a piece of clean cloth under the piston and remove the piston pin snap rings【a】from the...
Page 154: Cylinder, Piston Installation
ENGINE TOP END SEGWAY AT5 cylINDEr, PISTON INSTallaTION NOTE If a new piston or cylinder is used, check piston to cylinder clearance (see Piston/cylinder clearance), and use new piston rings. The oil ring rails have no “top” or “bottom”. ◆ Install the oil ring expander【a】in the bottom piston ring groove so the ends【B】butt together.
Page 155: Cylinder Wear
ENGINE TOP END SEGWAY AT5 ◆ Install: dowel Pins【a】 new cylinder Base gasket【B】 cylinder【c】 Bolt【d】 ◆ Tighten: Torque Bolt【d】 9.8 n·m (1.0 kgf·m, 87 in·lb) cauTION Base gasket and surfaces must be dry and oil free. use care upon assembly to keep oil away.
Page 156: Piston/Cylinder Clearance
ENGINE TOP END SEGWAY AT5 PISTON/cylINDEr clEaraNcE ◆ subtract the piston diameter from the cylinder inside diameter to get the piston/cylinder clearance. Piston/Cylinder Clearance Standard: 0.051 ~ 0.069 mm (0.0020" ~ 0.0027".) PISTON rING, PISTON rING GrOOVE wEar ◆ check for uneven groove wear by inspecting the ring seating.
Page 157: Piston Ring End Gap
ENGINE TOP END SEGWAY AT5 If any of the measurements is less than the service limit on either of the rings, replace all the rings. cauTION When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides.
Page 158: Cylinder Head Installation
ENGINE TOP END SEGWAY AT5 cylINDEr hEaD INSTallaTION cylINDEr hEaD INSTallaTION ◆ Install: dowel Pins【a】 new cylinder head gasket【B】 camshaft chain guide【c】 camshaft chain guide【d】 shoulder Bolts【e】(using a T40 driver) ◆ Tighten: Torque shoulder Bolts 9.8 n·m (1.0 kgf·m, 87 in·lb) ◆...
Page 159: Camshaft Installation / Timing
ENGINE TOP END SEGWAY AT5 camShafT INSTallaTION / TImING cauTION If any valve train components were replaced, refer to valve clearance adjustmentpage procedure. camShafT INSTallaTION / TImING ◆ Rotate the engine until the flywheel Top Dead Center (Tdc) mark is aligned or centered in the crankshaft Position sensor (cPs) mounting hole.
Page 160: Camshaft Chain Tensioner Installation
ENGINE TOP END SEGWAY AT5 ◆ Tighten the camshaft carrier bolts (m6)【d】and 【e】following the tightening sequence as shown. Torque Bolts m6 9.8 N•m (1.0kgf•m, 87in•lb) ◆ Install chain guard【a】 Bolts m6×20【B】 ◆ Tighten: Torque Bolts m6×20【B】 9.8 N•m (1.0kgf•m, 87in•lb) camShafT chaIN TENSIONEr INSTallaTION ◆...
Page 161: Valve Clearance Adjustment
ENGINE TOP END SEGWAY AT5 ValVE clEaraNcE aDjuSTmENT Timing view For camshafts ImPOrTaNT always inspect valve clearance prior to camshaft installation or final engine assembly. ◆ camshaft installation (see the camshaft Installation / Timing) ◆ camshaft carrier installation (see the camshaft...
Page 162 ENGINE TOP END SEGWAY AT5 ◆ record the 3 digit number on the bottom of the tappet【a】. ◆ reference the valve clearance measurement recorded for that valve, along with the 3 digit tappet number. ◆ refer to the appropriate tappet selection matrix (Intake or exhaust) on the following pages and select the proper tappet.
Page 163: Valve Lash - Tappet Selection
ENGINE TOP END SEGWAY AT5 ValVE laSh - TaPPET SElEcTION ImPOrTaNT The Valve Lash Specification and Measured Valve lash must be calculated in millimeters (mm), A 480 tappet means the thickness of the tappet is 4.80 mm. ◆ The proper valve tappet may be obtained by completing these steps: 1.
Page 164: Valve Cover Installation
ENGINE TOP END SEGWAY AT5 ValVE cOVEr INSTallaTION ValVE cOVEr INSTallaTION ◆ Install: spark Plug【a】 dowel Pin 10×14【B】 valve cover seal【c】 valve cover【d】 new Isolators【e】 shoulder Bolts【F】 (using a T40 driver) oil Fill cap seal【g】 o-ring 22×3【h】 oil Fill cap【j】...
Page 165: Cylinder Compression
ENGINE TOP END SEGWAY AT5 cylINDEr cOmPrESSION ◆ The following table should be consulted if the obtainable compression reading is not within the usable range. Problem diagnosis remedy (action) carbon accumulation on piston, cylinder remove the carbon deposits head, and in combustion chamber possibly...
Page 166: Cvt System
CVT SYSTEM SEGWAY AT5 CVT sysTem CVT sysTem explosion diagram ..............3-6-2 speCial Tools ...................... 3-6-4 CVT CoVer remoVal/insTallaTion ..............3-6-5 CVT CoVer remoVal ..................3-6-5 CVT CoVer lining insTallaTion ..............3-6-5 CVT CoVer insTallaTion ................3-6-5 CVT inner CoVer remoVal ................3-6-6 CVT inner CoVer remoVal: .................
Page 167: Cvt System Explosion Diagram
CVT SYSTEM SEGWAY AT5 CVT sysTem explosion diagram http://www.segwaypowersports.com 3 - 6 - 2...
Page 168 CVT SYSTEM SEGWAY AT5 Torque fastener remarks n·m kgf·m ft·lb CVT adjustment spacer CVT driven wheel CVT driving wheel CVT belt flanged bushing 12×28×6 CVT driving wheel bolt m12×1.25×142 12.2 r,lh flanged bushing 10.5×36×8 CVT driven wheel bolts CVT inner cover sealing ring Ⅰ...
Page 169: Special Tools
CVT SYSTEM SEGWAY AT5 speCial Tools Drive pulley tightening bolt: back-up ring pliers: e01gZ0060001 e01gZ0000008 retaining tool: Driven wheel jack bolt: E01-E200001-000-00 Drive pulley retainer: alignement Tool e01gZ0000012 assembly-Disassembly Tool Vise http://www.segwaypowersports.com 3 - 6 - 4...
Page 170: Cvt Cover Removal/Installation
CVT SYSTEM SEGWAY AT5 CVT CoVer remoVal/insTallaTion warning excessive imbalance or excessive operating speed may cause the continuously variable transmission master and slave to fail, resulting in serious injury or death. The main and driven wheels of a continuously variable transmission are precision balanced components designed to operate within certain speed limits.
Page 171: Cvt Inner Cover Removal
CVT SYSTEM SEGWAY AT5 CVT inner CoVer remoVal ◆ Remove the driving wheel and driven wheel (see Disassembling the driving wheel) ◆ removal: bolt m8×28【a】 remove the CVT inner cover assembly CVT inner CoVer remoVal: ◆ removal: CVT outer cover seal 【b】...
Page 172: Drive Belt Removal/Installation
CVT SYSTEM SEGWAY AT5 driVe belT remoVal/insTallaTion driVe belT remoVal ◆ remove the drive pulley 【a】 (see drive pulley removal). CauTion before disassembling the transmission belt, please pay attention to the direction of the 【a】 printed on the transmission belt (such as manufacturer name, arrow mark, etc.) so that the transmission belt can be...
Page 173: Drivie And Driven Pulley Removed From The Vehicle
CVT SYSTEM SEGWAY AT5 driVie and driVen pulley remoVed from The VehiCle ◆ Disassembly: Remove the CVT outer cover (see CVT outer cover removal) loosen the drive pulley bolt 【e】 (left-hand thread) CauTion The drive wheel bolt is left-hand threaded. Turn the wrench clockwise to loosen.
Page 174: Exploded Diagram Of Drive Assembly
CVT SYSTEM SEGWAY AT5 exploded diagram of driVe assembly Torque fastener remarks n·m kgf·m ft·lb fixed sheave freewheel or idle bearing spring seat Shim (if applicable) shim stroke limiter spring sliding sheave Centrifugal mass block mass Cap shoe Washer (If applicable) Washer (If applicable) http://www.segwaypowersports.com...
Page 175: Drive Assembly Disassembly And Installation
CVT SYSTEM SEGWAY AT5 driVe assembly disassembly and insTallaTion pulley remoVal from The VehiCle removing the drive pulley: ◆ Remove the fixation bolt from the drive pulley (you will need to use the retaining tool to prevent the retaining tool pulley from rotating).
Page 176: Drive Pulley Disassembly
CVT SYSTEM SEGWAY AT5 driVe pulley disassembly new block recommended inspection and replacement 1. Check for wear marks on the blocks 1.1. Change the blocks when the wear marks exceed the wear limit. admissible wear limit of the block is less than 14mm.
Page 177: Drive Pulley Re-Assembly
CVT SYSTEM SEGWAY AT5 driVe pulley re-assembly Part number square notch Alignment of fixed sheave ①, sliding sheave ⑩ and cap ◆ align the 2 notches on the sheaves ① and ⑩ and also the square shape notch or point or part number...
Page 178: Pulley Tightening
CVT SYSTEM SEGWAY AT5 pulley TighTening ◆ once the pulley is properly installed, use a torque wrench to tighten the fixation bolt. ◆ To tighten the drive pulley, use the retaining tool 【a】 to lock the rotation. warning Do not forget to remove the tools from the drive pulley.
Page 179: Cvt Driven Pulley Assembly Exploded View
CVT SYSTEM SEGWAY AT5 CVT driVen pulley assembly exploded View Torque fastener remarks n·m kgf·m ft·lb fixed sheave Washer sliding sheave Cam shoe Cam shoe screw 0.36 spring external retaining ring g:apply grease for oil seal and o-ring. l:apply a non-permanent locking agent.
Page 180: Pulley Disassembly
CVT SYSTEM SEGWAY AT5 pulley disassembly remoVing The driVen pulley ◆ make sure you take note of the position of the spring ⑥in the sliding sheave ③ and cam ⑧ holes, as well as the aligment of the cam ⑧ versure the cam shoe support.
Page 181: Spring Disassembly
CVT SYSTEM SEGWAY AT5 spring disassembly ◆ using a vise, mount the disassembly tool as shown . ◆ install the pulley on the disassembly tool as shown .use thelock srrew to prevent the rotation of the pulley on the disassembly.
Page 182: Recommended Inspection
CVT SYSTEM SEGWAY AT5 reCommended inspeCTion ◆ Check for wear marks on the cam ⑧. ◆ Check for wear marks on the spring ⑥. ◆ Perform a visual inspection of the compone. ◆ C h e c k t h e w e a r o f t h e s l i d i n g s h e a v e ③...
Page 183: Sliding Flange Mainten
CVT SYSTEM SEGWAY AT5 sliding flange mainTen reCommended inspeCTion ◆ if the cam shoes ④ are worn down to about 1 mm before making contact with the cam shoe support, they must be replaced. ◆ after removing the cam shoe screws ⑤with a no. 20 torx screwdriver, the camshoes ④...
Page 184: Pulley Re-Assembly
CVT SYSTEM SEGWAY AT5 pulley re-assembly The use of the disassembly tool is required in order ◆ to re‐assemble the pulley pulley re-assembly Install the fixed sheave ① on the disasse ◆ ◆ Put the washer ② (if applicable) on the fixed sheave ①then put the sliding sheave ③...
Page 185: Rollers ③ Re-Assembly
CVT SYSTEM SEGWAY AT5 rollers ③ re‐assembly Place the spring ⑥ lugs into the proper cam ⑧ hole ◆ and the proper sliding sheave ③ hole at the same positions noted during the disassembly steps . ◆ iPress down the cam ⑧ onto the fixed sheave ①shaft with the disassembly tool.
Page 186 FRONT AND REAR DIFFERENTIAL SEGWAY AT5 FRONT AND REAR DIFFERENTIAL TECHNICAL SPECIFICATIONS ..................4-2 SPECIAL TOOLS ......................4-3 EXPLODED VIEW OF FRONT AXLE ................4-5 REAR AXLE WITH DIFFERENTIAL EXPLOSION DIAgRAm ........4-7 DIAgRAm OF REAR AXLE EXPLOSION WITHOuT DIFFERENTIAL ......4-9 FRONT AXLE gEAR OIL REPLACEmENT ..............4-11 Drain front axle oil ..................4-11...
Page 187: Technical Specifications
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 TECHNICAL SPECIFICATIONS item standard service limit front axle assembly: sae 80W/90 api Gl-5 model gas station side (m18 screw plug) oil drain port bottom (m14 screw plug) volume 190 mL (first refill) 170 ml (replace oil) bevel gear backlash 0.15~0.25 mm(0.06~0.10 in.)
Page 188: Special Tools
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 SPECIAL TOOLS allen wrench 8mm / 12mm: Silicone rubber flat sealant： screwdriver external circlip pliers http://www.segwaypowersports.com 4 - 3...
Page 189 FRONT AND REAR DIFFERENTIAL SEGWAY AT5 Work fixture： Work fixture： name: oil seal 48×65×9 tooling name: oil seal 24×38×8 tooling Work fixture： Work fixture： name: oil seal 30×45×6.5 tooling name: oil seal 35×56×8 tooling http://www.segwaypowersports.com 4 - 4...
Page 190: Exploded View Of Front Axle
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 EXPLODED VIEW OF FRONT AXLE torque fastener remarks n·m kgf·m ft·lb bolt m8×30 2.55 18.5 oil seal 24×38×8 front axle box cover Hexagonal flange bolts M8×12 fork shaft o front axle shift motor assembly bolts m6×16...
Page 191 FRONT AND REAR DIFFERENTIAL SEGWAY AT5 torque fastener remarks n·m kgf·m ft·lb washers Deep groove ball bearing 61912 o hexagon socket head screws m8×20 (black zinc) 2.55 18.5 differential cover left side gear spacer left side bevel gear planetary gear spacer...
Page 192: Rear Axle With Differential Explosion Diagram
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 REAR AXLE WITH DIFFERENTIAL EXPLOSION DIAgRAm torque fastener remarks n·m kgf·m ft·lb Hexagonal flange bolt M8×25 2.55 18.5 oil seal 30×45×6.5 screw plug m18×1.5 o-ring seal 16.4×2.5 rear axle box cover O-ring seal φ153×φ2.5 Deep groove ball bearing 6011 Adjusting shim φ55×φ65×...
Page 193 FRONT AND REAR DIFFERENTIAL SEGWAY AT5 torque fastener remarks n·m kgf·m ft·lb return spring shift fork support frame U-shaped spring shift fork bushing shift fork cylindrical pin sealing ring shift fork cylindrical pin solenoid valve assembly retaining ring for 30 holes55 Deep groove ball bearing 16006 o-ring seal 13×1.5...
Page 194: Diagram Of Rear Axle Explosion Without Differential
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 DIAgRAm OF REAR AXLE EXPLOSION WITHOuT DIFFERENTIAL torque fastener remarks n·m kgf·m ft·lb Hexagonal flange bolt M8×25 2.55 18.5 oil seal 35×56×8 screw plug m18×1.5 o-ring seal 16.4×2.5 rear axle box cover breather pipe connector...
Page 195 FRONT AND REAR DIFFERENTIAL SEGWAY AT5 torque fastener remarks n·m kgf·m ft·lb hexagon socket head screw m8×35 (black zinc) thread sleeve m30×1.5 O-ring seal φ1.9×φ23.5 oil seal 48×65×9 hole retaining ring 22 universal joint fork (disc brake disc) flat pad φ14.5×φ35.2×4 Hexagonal flange bolt M14×1.5×30...
Page 196: Front Axle Gear Oil Replacement
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 FRONT AXLE gEAR OIL REPLACEmENT WARNINg operating a vehicle with insufficient or contaminated front axle oil will cause excessive wear of the front axle, resulting in damage to the front axle, which may cause an accident and cause injury.
Page 197: Disassemble And Replace Oil Seal
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 DISASSEmbLE AND REPLACE OIL SEAL ◆ Disassembly 【a】 oil seal 24×38×8 ◆ Tools: Slotted screwdriver, oil seal 24×38×8 tooling ◆ Use a flat-blade screwdriver to remove [A], clean the oil stains on the casing, and then use tooling to replace the new [A] in place.
Page 198: Disassemble And Replace Oil Seal
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 DISASSEmbLE AND REPLACE OIL SEAL ◆ Disassembly 【a】Universal joint fork assembly 【b】 Hexagonal flange bolt M14×1.5×30 【c】 Flat pad φ14.5×φ35.2×4 【D】 front axle universal joint fork 【e】 oil seal 48×65×9 ◆ Tools: 18mm socket, slotted screwdriver, oil seal 48×65×9 tooling...
Page 199: Differential Rear Axle Gear Oil Replacement
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 DIFFERENTIAL REAR AXLE gEAR OIL REPLACEmENT WARNINg running a vehicle with insufficient or contaminated transmission fluid can cause excessive transmission wear, resulting in transmission damage that could cause an accident and result in injury.
Page 200: Disassemble And Replace Oil Seal
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 DISASSEmbLE AND REPLACE OIL SEAL ◆ Disassembly 【a】 oil seal 30×45×6.5 ◆ Tools: Slotted screwdriver, oil seal 30×45×6.5 tooling ◆ Use a flat-blade screwdriver to remove [A], clean the oil stains on the casing, and then use tooling to replace the new [A] in place.
Page 201: Disassemble And Replace Oil Seal
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 DISASSEmbLE AND REPLACE OIL SEAL ◆ Disassembly 【a】 oil seal 48×65×9 【b】 Universal joint fork 【c】 Flat pad φ14.5×φ35.2×4 【D】 Hexagonal flange bolt M14×1.5×30 【e】Universal joint fork assembly ◆ Tools: 18mm socket, slotted screwdriver, oil seal 48×65×9 tooling...
Page 202: Non-Differential Rear Axle Gear Oil Replacement
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 NON-DIFFERENTIAL REAR AXLE gEAR OIL REPLACEmENT WARNINg operating a vehicle with insufficient or contaminated transmission fluid can cause excessive wear and tear on the transmission, leading to transmission damage and possible accidents and injuries.
Page 203: Oil Seal Replacement And Assembly
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 OIL SEAL REPLACEmENT AND ASSEmbLy DISASSEmbLE AND REPLACE OIL SEAL ◆ Disassembly 【a】 oil seal 35×56×8 ◆ Tools: Slotted screwdriver, oil seal 35×56×8 tooling ◆ Use a flat-blade screwdriver to remove [A], clean the oil stains on the casing, and then use tooling to replace the new [A] in place.
Page 204: Disassemble And Replace Oil Seal
FRONT AND REAR DIFFERENTIAL SEGWAY AT5 DISASSEmbLE AND REPLACE OIL SEAL ◆ Disassembly 【a】 oil seal 48×65×9 【b】 Universal joint fork (disc brake disc) 【c】 Flat pad φ14.5×φ35.2×4 【D】 Hexagonal flange bolt M14×1.5×30 【e】Universal joint fork assembly ◆ Tools: 18mm socket, slotted screwdriver, oil seal 48×65×9 tooling...
Page 205: Fuel System
FUEL SYSTEM SEGWAY AT5 FUEL SYSTEM FUEL Tank ExpLodEd viEw oF FUEL SYSTEM ............4-2 FUEL Tank rEMovaL/inSTaLLaTion ..............4-3 Disassembly ......................4-3 installation ......................4-3 FUEL FiLTEr rEMovaL / inSTaLLaTion ..............4-4 Removal .........................4-4 installation ......................4-5 Carbon CaniSTEr aSSEMbLY rEMovaL / inSTaLLaTion ........4-6 Disassembly ......................4-6 installation ......................4-7...
Page 206: Fuel Tank Exploded View Of Fuel System
FUEL SYSTEM SEGWAY AT5 FUEL Tank ExpLodEd viEw oF FUEL SYSTEM torque Fastener Remarks n·m kgf·m ft·lb Center shield front heat shield large Gasket a Class 5 Cross recessed pan head tapping screws st4.2×16 steel band elastic hose clamp 9...
Page 207: Fuel Tank Removal/Installation
FUEL SYSTEM SEGWAY AT5 FUEL Tank rEMovaL/inSTaLLaTion warninG ◆ Whenever the gasoline line is removed, the battery connection must be disconnected to prevent the accidental startup of the fuel pump. ◆ Whenever any repairs or inspections are made to the fuel system, there is a possibility that a fuel leaks may occur.
Page 208: Fuel Filter Removal / Installation
FUEL SYSTEM SEGWAY AT5 FUEL FiLTEr rEMovaL / inSTaLLaTion warninG ◆ Whenever the gasoline line is removed, the battery must be disconnected to prevent the accidental startup of the fuel pump. ◆ Whenever any repairs or inspections are made to the fuel system, fuel leaks may occur.
Page 209: Installation
FUEL SYSTEM SEGWAY AT5 FUEL FiLTEr rEMovaL / inSTaLLaTion inSTaLLaTion 【F】single ear stepless clamp bracket 16.5 【e】 Fuel filter ◆ When assembling the fuel filter, make sure that the arrow is pointing (as shown in the left figure) in the fuel ◆...
Page 210: Carbon Canister Assembly Removal / Installation
FUEL SYSTEM SEGWAY AT5 Carbon CaniSTEr aSSEMbLY rEMovaL / inSTaLLaTion warninG ◆ Whenever the gasoline line is removed, the battery must be disconnected to prevent the accidental startup of the fuel pump. ◆ Whenever any repairs or inspections are made to the fuel system, fuel leaks may occur.
Page 211: Installation
FUEL SYSTEM SEGWAY AT5 Carbon CaniSTEr aSSEMbLY rEMovaL / inSTaLLaTion inSTaLLaTion When assembling, reverse the order of disassembly; When assembling tubing and clamps, make sure they are assembled correctly and reliably. CaUTion When replacing or assembling the carbon canister assembly, please carefully check whether the oil pipe is intact.
Page 212: Cooling System
COOLING SYSTEM SEGWAY AT5 COOLING SYSTEM EXPLODED VIEW OF COOLING SYSTEM ..............6-2 COOLANT FLOW ......................6-3 TECHNICAL PARAMETER ..................6-5 Cooling system pressure test ..............6-6 radiator Cap pressure test ................6-7 radiator CheCk ....................6-8 radiator removal / installation ..............6-8 radiator Fan removal/installation ............6-9 http://www.segwaypowersports.com...
Page 213: Exploded View Of Cooling System
COOLING SYSTEM SEGWAY AT5 EXPLODED VIEW OF COOLING SYSTEM torque Fastener remarks n·m kgf·m ft·lb Buffer rubber engine radiator body tank lid assy v Hexagon flange bolt m6×25 8 ～ 12 0.8~1.2 t-sleeve i-shaped rubber parts Bolt m6×16 8 ～ 12 0.8~1.2...
Page 214: Coolant Flow
COOLING SYSTEM SEGWAY AT5 COOLANT FLOW Permanent antifreeze is selected for use as coolant to prevent rust and corrosion in the cooling system. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax particle type that opens or closes as the coolant temperature changes.
Page 215 COOLING SYSTEM SEGWAY AT5 COOLANT FLOW Red arrow: Hot coolant Blue arrow: cold coolant 1.radiator 2.engine radiator vent pipe 3.Water pump cover 4.sub-tank 5.Water filler cap assembly 6.Sub-tank cover 7.Thermostat cover 8.Water temperature sensor assembly http://www.segwaypowersports.com 6 - 4...
Page 216: Technical Parameter
COOLING SYSTEM SEGWAY AT5 TECHNICAL PARAMETER serviCe item standard limit Coolant provided during transportation： Type Permanent antifreeze (soft water and glycol for – – – aluminum engines and radiators plus corrosion inhibitors and rust inhibitor chemicals) – – – green Color –...
Page 217: Cooling System Pressure Test
COOLING SYSTEM SEGWAY AT5 COOLING SYSTEM PRESSURE TEST A. Fill port B. Fill port cover C. Front service cover D. Front shelf ◆ Remove front shelf D, front access cover C and radiator cap B, then install a cooling system pressure tester on radiator filler port A.
Page 218: Radiator Cap Pressure Test
COOLING SYSTEM SEGWAY AT5 RADIATOR CAP PRESSURE TEST ◆ Check the condition of the radiator cap top and bottom seals. ◆ Replace the radiator cap if either of them appears damaged. 【a】 Bottom seal 【B】 top seal 【C】 pressure valve spring ◆...
Page 219: Radiator Check
COOLING SYSTEM SEGWAY AT5 RADIATOR CHECk ◆ Check the radiator core. ◆ If there is an obstruction to air flow, remove the radiator and clear the obstruction. ◆ If the corrugated fins 【a】 are deformed, carefully straighten them. ◆ If the air path of the radiator core is blocked more...
Page 220: Radiator Fan Removal/Installation
COOLING SYSTEM SEGWAY AT5 RadiatoR Fan Removal/installation radiator (see radiator removal) radiator fan assembly bolts 【a】 ◆ ◆ Fan assembly 【B】 WARNING 1. the opening and stopping of the radiator fan is controlled by the ECU of the whole vehicle, when the...
Page 221: Intake / Exhaust System
INTAKE / EXHAUST SYSTEM SEGWAY AT5 INTAKE / EXHAUST SYSTEM EXplodEd vIEw of INTAKE SYSTEM ..............7-2 AIr fIlTEr rEMovAl ....................7-3 Start by placing the car in a horizontal poSition ......7-3 mounting .......................7-3 EXplodEd vIEw of EXHAUST SYSTEM ..............7-4 MUfflErS ANd EXHAUST pIpES ................7-5 muffler removal ....................7-5...
Page 222: Exploded View Of Intake System
INTAKE / EXHAUST SYSTEM SEGWAY AT5 EXplodEd vIEw of INTAKE SYSTEM torque fastener remarks n·m kgf·m ft·lb Air filter mounting bolts M6×35 8 ～ 12 0.8~1.2 type a worm drive hose clamp 70 Steel band elastic hose clamp 24 http://www.segwaypowersports.com...
Page 223: Air Filter Removal
INTAKE / EXHAUST SYSTEM SEGWAY AT5 AIr fIlTEr rEMovAl STArT bY plAcINg THE cAr IN A HorIzoNTAl poSITIoN 【a】Air filter cover 【b】hexagonal screw ◆ remove the 2 hexagonal screws 【a】 ◆ Remove the air filter cover 【b】【c】Air filter mounting bolts 【D】type a worm drive hose clamp 70...
Page 224: Exploded View Of Exhaust System
INTAKE / EXHAUST SYSTEM SEGWAY AT5 EXplodEd vIEw of EXHAUST SYSTEM torque fastener remarks n·m kgf·m ft·lb cap nut front pipe heat shield Muffler tension spring graphite sealed bowl Hexagon flange bolt m6×12 8 ～ 12 0.8~1.2 m12 oxygen sensor...
Page 225: Mufflers And Exhaust Pipes
INTAKE / EXHAUST SYSTEM SEGWAY AT5 MUfflErS ANd EXHAUST pIpES wArNINg Whenever checking or maintaining components of the exhaust system, it is necessary to inspect whether each part of the exhaust system is overheated to avoid being scalded by high temperatures.
Page 226: Probe
INTAKE / EXHAUST SYSTEM SEGWAY AT5 ◆ exhaust pipe removal ◆ remove exhaust pipe bracket bolts 【a】 ◆ remove exhaust pipe retaining nut【b】 ◆ remove exhaust pipe 【c】 probE ◆ check externally for cracks, holes or ruptures in the muffler, as this can affect engine performance and emissions.
Page 227: Drive System
DRIVE SYSTEM SEGWAY AT5 DRIVE SYSTEM EXPLODED VIEW OF DRIVESHAFT (SINGLE CAB VEHICLES) .......8-2 DRIVE SHAFT REMOVAL .....................8-3 Removal of fRont dRive shaft ..............8-4 ReaR dRive shaft assembly disassembly ..........8-4 fRont and ReaR dRive shaft .................8-4 EXPLODED VIEW OF FRONT AND REAR LEFT/RIGHT CONSTANT VELOCITY DRIVE SHAFTS ..8-5 DOJ DRIVE SHAFT REPAIR ..................8-6...
Page 228: Exploded View Of Driveshaft (Single Cab Vehicles)
DRIVE SYSTEM SEGWAY AT5 EXPLODED VIEW OF DRIVESHAFT (SINGLE CAB VEHICLES) torque fastener Remarks n·m kgf·m ft·lb hexagon socket head screw m10×1.25×25 A: Apply a non-permanent locking agent. http://www.segwaypowersports.com 8 - 2...
Page 229: Drive Shaft Removal
DRIVE SYSTEM SEGWAY AT5 DRIVE SHAFT REMOVAL WARNING do not remove the dust boot when removing the drive shaft, it is filled with grease. 【a】front left constant velocity drive shaft assembly 【b】front right constant velocity drive shaft assembly 【C】Rear left constant velocity drive shaft assembly 【d】Rear right constant velocity drive shaft assembly...
Page 230: Removal Of Front Drive Shaft
DRIVE SYSTEM SEGWAY AT5 REMOVAL OF FRONT DRIVE SHAFT 【a】hexagon socket head screw m10×1.25×25 【b】front drive shaft assembly 【C】diameter 10mm spring washer ◆ loosen the screws【a】(4pcs) ◆ spring washers 【C】 (4 pieces) ◆ move the【b】front drive shaft assembly back in the...
Page 231: Exploded View Of Front And Rear Left/Right Constant Velocity Drive Shafts
DRIVE SYSTEM SEGWAY AT5 EXPLODED VIEW OF FRONT AND REAR LEFT/RIGHT CONSTANT VELOCITY DRIVE SHAFTS torque fastener Remarks n·m kgf·m ft·lb front and rear left/right inner ball cage assemblies Retaining ring front and rear axle left/right corrugated sleeve repair kit...
Page 232: Doj Drive Shaft Repair
DRIVE SYSTEM SEGWAY AT5 DOJ DRIVE SHAFT REPAIR CAUTION the drive shaft is a precision part. Cleanliness must be ensured when replacing and installing, and the operation must be strictly followed the instructions. do not use a hammer or sharp objects for disassembly and installation, which will affect the performance and service life of the half shaft.
Page 233 DRIVE SYSTEM SEGWAY AT5 ◆ after taking out the retaining ring, you can directly pull out the intermediate shaft, pay attention not to drop the steel balls on the cage and the star sleeve, and clean the grease in the universal joint and the dust cover;...
Page 234 DRIVE SYSTEM SEGWAY AT5 ◆ first install the small clamp, adjust the position of the dust cover to ensure that the dust cover is stuck in the groove of the intermediate shaft, and then use the clamp pliers to clamp the small clamp;...
Page 235 INTAKE / EXHAUST SYSTEM SEGWAY AT5 INTAKE / EXHAUST SYSTEM EXplodEd dIAgrAM of froNT SUSpENSIoN ............9-2 rEAr SUSpENSIoN EXploSIoN dIAgrAM .............9-3 TECHNICAl pArAMETEr ..................9-4 dEdICATEd ToolS .....................9-5 SHoCK AbSorbEr .....................9-6 shock absorber inspection ................9-6 ordinary hydraulic damping and shock absorption preload adjustment ....9-6 spring adjustment table ................9-6...
Page 236: Exploded Diagram Of Front Suspension
INTAKE / EXHAUST SYSTEM SEGWAY AT5 EXplodEd dIAgrAM of froNT SUSpENSIoN torque fastener remarks n·m kgf·m ft·lb Hex flange lock nut M10×1.25 40～50 4.0~5.0 29.5~36.9 Shock absorber mounting bolts 40～50 4.0~5.0 29.5~36.9 M10×1.25×55 Rocker arm mounting bolts 55～65 5.6~6.6 40.5~47.9 M10×1.25×75...
Page 237: Rear Suspension Explosion Diagram
INTAKE / EXHAUST SYSTEM SEGWAY AT5 rEAr SUSpENSIoN EXploSIoN dIAgrAM torque fastener remarks n·m kgf·m ft·lb Hex flange lock nut M10×1.25 40～50 4.0~5.0 29.5~36.9 Shock absorber mounting bolts 40～50 4.0~5.0 29.5~36.9 M10×1.25×55 Rocker arm mounting bolts 55～65 5.6~6.6 40.5~47.9 M10×1.25×75 Mounting bolts for rear stabilizer bar 20～25...
Page 238: Technical Parameter
INTAKE / EXHAUST SYSTEM SEGWAY AT5 TECHNICAl pArAMETEr item setting available range 3 gear 1st gear to 5th gear Front Shock Absorber: (Optional) • Ordinary hydraulic damping shock absorber spring preload setting position • Type A: air pressure adjustable damping shock...
Page 239: Dedicated Tools
INTAKE / EXHAUST SYSTEM SEGWAY AT5 dEdICATEd ToolS Needle nose pliers Slotted screwdriver Hook wrench grease gun Bearing drive kit Internal circlip pliers Lifting jack http://www.segwaypowersports.com 7 - 5...
Page 240: Shock Absorber
INTAKE / EXHAUST SYSTEM SEGWAY AT5 SHoCK AbSorbEr SHoCK AbSorbEr INSpECTIoN Since the front shocks are sealed units, they cannot be disassembled, only external inspection is required. If one unit is damaged, replace both shock absorbers as a set. If only one unit is replaced and both are not balanced, it may result in vehicle instability at high speeds or poor overall comfort.
Page 241: Measure The Free Length Of The Spring
INTAKE / EXHAUST SYSTEM SEGWAY AT5 MEASUrE THE frEE lENgTH of THE SprINg 【a】Adjusting nut 【b】Lock Nut 【c】Spring preload position ◆ Screw the adjusting nut 【a】 to the desired position, then tighten the lock nut 【b】, adjust the nut position 【c】...
Page 242: Recovery Damping Adjustment
INTAKE / EXHAUST SYSTEM SEGWAY AT5 rECovErY dAMpINg AdjUSTMENT Type A: Use a flat-blade screwdriver to turn the damping Type A adjuster at the bottom. Instantly increase the damping in the needle direction (H) and decrease the damping in the counterclockwise direction (S).
Page 243: Rear Shock Absorber Scrapped
INTAKE / EXHAUST SYSTEM SEGWAY AT5 rEAr SHoCK AbSorbEr SCrAppEd WArNINg Since the rear shock absorber reservoir contains nitrogen gas, do not incinerate any unreleased gas in the container or it may explode. 【a】Valve cover ◆ Remove the shock absorber (see Shock Absorber Removal) ◆...
Page 244: Suspension
INTAKE / EXHAUST SYSTEM SEGWAY AT5 SUSpENSIoN rEMovAl of THE roCKEr ArM 【a】Brake hose fixing bolt 【b】Steering knuckle \ axle support assembly 【c】Tie rod nut 【d】Ball Pin Connecting Rod Nut 【e】Rocker arm mounting bolt 【f】rocker arm assembly ◆ Remove the brake caliper mounting bolts and remove the caliper body ◆...
Page 245: Disassembly Of Rocker Arm
INTAKE / EXHAUST SYSTEM SEGWAY AT5 dISASSEMblY of roCKEr ArM 【a】Rocker arm assembly mounting bolts 【b】Rocker arm dust cover 【c】Rocker arm buffer bushing 【d】nut 【e】Retaining ring for shaft 【f】Upper and lower kingpin assembly ◆ Remove the rocker arm assembly mounting bolts 【a】...
Page 246: Rocker Arm Maintenance
INTAKE / EXHAUST SYSTEM SEGWAY AT5 roCKEr ArM MAINTENANCE 【a】Straight-through oil cup ◆ Use a grease gun to fill the straight-through oil cup with grease ◆ When the inspection finds that the lubricating grease in the hub of the axle support is reduced, or after the...
Page 247: Hub Bearing Replacement
INTAKE / EXHAUST SYSTEM SEGWAY AT5 HUb bEArINg rEplACEMENT If the hub bearing in the steering knuckle assembly and rear axle support assembly is damaged, it needs to be replaced. 【a】Open retaining ring 【b】Wheel hub bearing 【c】Front steering knuckle 【d】Rear wheel axle support...
Page 248: Rear Balance Bar
INTAKE / EXHAUST SYSTEM SEGWAY AT5 rEAr bAlANCE bAr rEAr STAbIlIzEr bAr dISASSEMblY 【a】Stabilizer bar buffer sleeve 【b】Rear stabilizer bar 【c】Stabilizer bar mounting base 【d】Mounting base fixing bolts 【e】Connecting rod assembly mounting nut 【f】Connecting rod assembly 【g】Straight-through oil cup Mounting seat fixing bolt torque 35N·m（3.5 kgf·m，25.8 ft·lb）...
Page 249 BRAKE SYSTEM SEGWAY AT5 BRAKE SYSTEM ExplodEd viEw of BRAKing SYSTEM ................. 11-3 pARKing BRAKE ExploSion diAgRAM ................ 11-4 SpEcificATionS ......................... 11-4 TEchnicAl pARAMETERS ..................11-5 SpEciAl ToolS ........................11-5 BRAKE fluid ........................11-6 Brake fluid replacement/Brake Bleeding ............. 11-6 fooT BRAKE MASTER cYlindER REpAiR ..............
Page 250: Brake System
BRAKE SYSTEM SEGWAY AT5 disc brake systems are lightweight, low-maintenance and perform well in conditions commonly encountered by vehicles. when replacing disc brake pads or performing brake system repairs, there are a few things to remember to ensure proper system function and maximum brake pad life.
Page 251: Exploded View Of Braking System
BRAKE SYSTEM SEGWAY AT5 ExplodEd viEw of BRAKing SYSTEM Torque fastener remarks n·m kgf·m ft·lb Brake disc mounting bolts brake hose mounting bolts Brake fastening bolt l: use non-permanent locking agent 1. Brake disc bolts, brake main pump bolts, and brake fastening bolts need to be inspected and tightened regularly.
Page 252: Parking Brake Explosion Diagram
BRAKE SYSTEM SEGWAY AT5 pARKing BRAKE ExploSion diAgRAM Torque fastener remarks n·m kgf·m ft·lb parking Brake lever screw 78in.lb junction box fastening bolts 78in.lb SpEcificATionS item standard service limit Brake fluid: type dot 4 – – – front disc Brake: pad lining thickness 4.0 mm (0.16 in.)
Page 253: Technical Parameters
BRAKE SYSTEM SEGWAY AT5 TEchnicAl pARAMETERS item standard use limit Brake fluid: type total dot 4 – – – front and rear brake pad parameters: 5.0 mm (0.19 in) Brake pad thickness 1.5 mm (0.06 in) front and rear brake disc parameters: 4.8~5.2mm (0.19～...
Page 254: Brake Fluid
BRAKE SYSTEM SEGWAY AT5 BRAKE fluid wARning 1. when using disc brakes, please observe the following precautions. 2. 1. Never reuse old brake fluid. 3. 2. Do not use brake fluid that is not sealed or has been opened for a long time.
Page 255 BRAKE SYSTEM SEGWAY AT5 1. the foot brake oil cup 【a】 is located under the front access cover and in front of the front right shock absorber. The fluid level can be observed through the window in front of the front right shock absorber.
Page 256: Foot Brake Master Cylinder Repair
BRAKE SYSTEM SEGWAY AT5 Master pump liquid level: between min and max lines cAuTion maintain at least a minimum level of brake fluid in the reservoir to prevent air from entering the master cylinder. 14. repeat steps 9-13 for the remaining brake calipers.
Page 257: Handbrake Main Pump Brake Fluid Filling
BRAKE SYSTEM SEGWAY AT5 hAndBRAKE MAin puMp BRAKE fluid filling Master pump liquid level: between the min and max lines. cAuTion maintain at least a minimum level of brake fluid in the reservoir to prevent air from entering the master cylinder.
Page 258: Master Pump Installation
BRAKE SYSTEM SEGWAY AT5 MASTER puMp inSTAllATion ◆ install the brake line to the master cylinder with a new gasket. ◆ install the brake lines correctly. ◆ tighten the front brake oil pipe 【e】 and rear brake oil pipe 【f】.
Page 259: Front Brake Assembly
BRAKE SYSTEM SEGWAY AT5 fRonT BRAKE ASSEMBlY REMovAl of fRonT BRAKE ASSEMBlY ◆ removal of front brake assembly ◆ remove the front wheel (see wheels/tires section page 9-8). ◆ loosen the fixing bolt 【a】 at the lower part of the brake hose 【e】, but do not completely remove it yet.
Page 260: Front Brake Caliper Body
BRAKE SYSTEM SEGWAY AT5 fRonT BRAKE cAlipER BodY fRonT BRAKE cAlipER BodY REMovAl ◆ remove the front brake assembly first (see front Brake assembly removal) ◆ remove the brake pad (see front brake pad removal) ◆ using special tools, remove the piston.
Page 261: Front Brake Caliper Body Installation
BRAKE SYSTEM SEGWAY AT5 fRonT BRAKE cAlipER BodY inSTAllATion ◆ replace with a new rectangular circle 【B】. ◆ apply a thin layer of silicone grease to the rectangular ring and install it into the brake card ◆ clamp. ◆ replace with new dust ring 【a】, ◆...
Page 262: Front Brake Pad
BRAKE SYSTEM SEGWAY AT5 fRonT BRAKE pAd fRonT BRAKE pAd REMovAl ◆ remove the front rim assembly. ◆ loosen the fastening bolt 【d】 from the front brake assembly guide rod 【c】. during the process of loosening the bolt 【d】, it is required that the head of 【c】...
Page 263: Front Brake Disc
BRAKE SYSTEM SEGWAY AT5 fRonT BRAKE diSc fRonT BRAKE diSc clEAning poor braking can be caused by dirt on the brake discs. stains on brake discs must be cleaned with an oil-free cleaning fluid such as trichlorethylene or acetone. wARning These cleaning fluids are often highly flammable and can be harmful to humans if inhaled over a prolonged period of time.
Page 264: Rear Brake Assembly
BRAKE SYSTEM SEGWAY AT5 REAR BRAKE ASSEMBlY REAR BRAKE ASSEMBlY REMovAl ◆ remove the rear wheel (see wheels/tires section). ◆ Loosen the fixing bolt 【a】 of the brake hose 【B】 without completely removing it yet. ◆ loosen the two mounting bolts 【d】 of the rear brake assembly.
Page 265: Rear Brake Caliper Body
BRAKE SYSTEM SEGWAY AT5 REAR BRAKE cAlipER BodY REAR BRAKE cAlipER BodY REMovAl ◆ remove the rear brake assembly first (see Brake assembly removal 11-6) ◆ remove the rear brake pad (see rear Brake pad removal) ◆ using special tools, remove the piston.
Page 266: Rear Brake Caliper Body Installation
BRAKE SYSTEM SEGWAY AT5 REAR BRAKE cAlipER BodY inSTAllATion ◆ replace with a new rectangular circle 【B】. ◆ apply a thin layer of silicone grease to the rectangular ring and install it into the rear brake caliper. ◆ replace with new dust ring 【a】, ◆...
Page 267: Rear Brake Pad
BRAKE SYSTEM SEGWAY AT5 REAR BRAKE pAd REAR BRAKE pAd REMovAl remove the rear rim assembly or rear rim assembly. ◆ loosen the fastening bolt 【d】 from the brake assembly guide rod 【c】. during the process of loosening the bolt 【d】, it is required that the head of 【c】...
Page 268: Rear Brake Disc
BRAKE SYSTEM SEGWAY AT5 REAR BRAKE diSc REAR BRAKE diSc clEAning poor braking can be caused by dirt on the brake discs. stains on brake discs must be cleaned with an oil-free cleaning fluid such as trichlorethylene or acetone. wARning...
Page 269: Brake Hoses
BRAKE SYSTEM SEGWAY AT5 BRAKE hoSES BRAKE hoSE inSpEcTion ◆ refer to the Brakes in the periodic maintenance chapter. ◆ Brake Hose replacement ◆ refer to the Brakes in the periodic maintenance chapter. REAR BRAKE pEdAl BRAKE pEdAl poSiTion AdjuSTMEnT ◆...
Page 270: Parking Cable
BRAKE SYSTEM SEGWAY AT5 pARKing cABlE pARKing cABlE REMovAl ◆ take the parking cable head 【c】 out of the swivel arm 【B】 in the rear brake. ◆ disassemble 2 pieces of m8 nuts 【a】. ◆ loosen the knurled locknut 【e】 on the parking handle and screw in the adjuster 【f】.
Page 271: Troubleshooting Brake Noise
BRAKE SYSTEM SEGWAY AT5 BRAKE SYSTEM TRouBlEShooTing TRouBlEShooTing BRAKE noiSE dirt or dust buildup on the brake pads and discs is the most common cause of brake noise (squealing caused by vibration). it is necessary to strengthen the cleaning of the contact surfaces of the brake pads and the brake discs to reduce the noise caused by dust or other particles existing between the two working surfaces.
Page 272 BRAKE SYSTEM SEGWAY AT5 pedal vibration, please check the following components or systems ◆ damaged brake disc ◆ Brake disc wear (runout or thickness change beyond service limit) caliper overheating (brake resistance), please check the following components or systems ◆ compensation port clogged ◆...
Page 273 STEERING SYSTEM SEGWAY AT5 STEERING SYSTEM ExplodEd VIEw of STEERING SYSTEM ..............12-2 STEERING whEEl .....................12-4 Steering Wheel Folding ................12-4 Steering Wheel inStallation ..............12-4 STEERING ColuMN ....................12-5 Steering Column removal ................12-5 Steering Column mounting .................12-5 EpS ..........................12-6 ePS total diSaSSembly ...................12-6 ePS aSSembly mounting .................12-6...
Page 274: Exploded View Of Steering System
STEERING SYSTEM SEGWAY AT5 ExplodEd VIEw of STEERING SYSTEM http://www.segwaypowersports.com 7 - 2...
Page 275 STEERING SYSTEM SEGWAY AT5 torque Fastener remarks n·m kgf·m ft·lb hexagon socket cheese head screws m8×65 25.8 Hexagonal flange face bolts M8×16 25.8 Hexagonal flange face bolts M8×30 25.8 Hexagonal flange face bolts M10×1.5×20 33.2 Hexagonal flange face bolts M8×35 25.8...
Page 276: Steering Wheel
STEERING SYSTEM SEGWAY AT5 STEERING whEEl STEERING whEEl foldING 【a】locking bolt 【b】Steering handle gland 【C】steering wheel ◆ handlebar locking bolt 【a】 loose ◆ Take off the handlebar gland【b】. ◆ remove the steering wheel 【C】. STEERING whEEl INSTAllATIoN CAuTIoN install the steering handle so that the angle of the steering handle matches the angle of the steering column, keeping it parallel.
Page 277: Steering Column
STEERING SYSTEM SEGWAY AT5 STEERING ColuMN STEERING ColuMN REMoVAl First remove the instrument housing cover and the left front upper inner fender, see body disassembly section 【a】Steering Spherical Seat 【b】Spherical seat locking plate 【C】Wire harness Storage Wire 【d】Steering Column assembly 【e】bolt m8×16...
Page 278: Eps
STEERING SYSTEM SEGWAY AT5 EpS ToTAl dISASSEMBlY 【a】Steering Column assembly 【b】bolt m8×30 【C】ePS assembly 【d】chassis 【e】bolt m10×1.5×20 【F】Steering rocker arm 【g】Spring washers 8 【h】bolt m8×35 【i】Steering rocker arm spacer 【J】Slotted nut m10 【K】cotter pin ◆ disconnect the power to the whole vehicle and remove the connector on the ePS assembly 【C】.
Page 279: Steering Tie Rod
STEERING SYSTEM SEGWAY AT5 STEERING TIE Rod STEERING Rod foldING 【a】cotter pin 【b】Slotted nut m10 【C】Steering rocker arm 【d】tie rods 【e】knuckle ◆ 拆下开口销【A】和开槽螺母M10【B】 ◆ remove the steering tie rods 【d】 from the steering rocker arms 【C】 and steering knuckles 【e】.
Page 280 BODY AND FRAME SEGWAY AT5 BODY AND FRAME ExplOsiON DiAgRAM OF FRONt ExtERiOR tRiM ........... 13-2 ExplOsiON DiAgRAM OF MiDBODY ExtERiOR tRiM ........13-4 ExplOsiON DiAgRAM OF REAR ExtERiOR tRiM ..........13-6 ExplOsiON DiAgRAM OF uNDERBODY ExtERiOR tRiM ........ 13-7 Front shelF cover ..................
Page 281: Body And Frame
BODY AND FRAME SEGWAY AT5 ExplOsiON DiAgRAM OF FRONt ExtERiOR tRiM torque Fastener remarks n·m kgf·m ft·lb instrument panel cross recessed pan head tapping screw st4.2x16 m6 nut clamp meter cover Hexagon flange bolts M6x16 8~12 0.8~1.2 69~103.6 in·lb http://www.segwaypowersports.com...
Page 282 BODY AND FRAME SEGWAY AT5 large pan head hexagon bolt m6x16 8~12 0.8~1.2 69~103.6 in·lb meter mounting support Front fender Front access cover expansion buckle components left front inner fender Waist type i-shaped rubber ring left headlamp tail cover right front inner fender...
Page 283: Explosion Diagram Of Midbody Exterior Trim
BODY AND FRAME SEGWAY AT5 ExplOsiON DiAgRAM OF MiDBODY ExtERiOR tRiM torque Fastener remarks n·m kgf·m ft·lb Air filter cover expansion buckle components spring buckle Waist type i-shaped rubber ring Hexagon flange bolts M6x16 8~12 0.8~1.2 69~103.6 in·lb shift decorative cover...
Page 284 BODY AND FRAME SEGWAY AT5 cvt anti-ironing plate Hexagon flange bolts M5×12 left foot pedal - short car cross recessed pan head tapping screws st4.2x16 large pan head hexagon bolts m6x16 8~12 0.8~1.2 69~103.6 in·lb 4.2 self-tapping cleats tail box cover pin shaft...
Page 285: Explosion Diagram Of Rear Exterior Trim
BODY AND FRAME SEGWAY AT5 ExplOsiON DiAgRAM OF REAR ExtERiOR tRiM torque Fastener remarks n·m kgf·m ft·lb rear taillight mask lampshade rear trim board left foot pedal - short car large pan head hexagon bolts m6x16 8~12 0.8~1.2 69~103.6 in·lb m6 nut clamp 4.2 self-tapping cleats...
Page 286: Explosion Diagram Of Underbody Exterior Trim
BODY AND FRAME SEGWAY AT5 ExplOsiON DiAgRAM OF uNDERBODY ExtERiOR tRiM torque Fastener remarks n·m kgf·m ft·lb large pan head hexagon bolt m6x16 8~12 0.8~1.2 69~103.6 in·lb Hexagon flange bolts M6x16 8~12 0.8~1.2 69~103.6 in·lb m6 nut clamp Frame front bottom plate...
Page 287: Front Shelf Cover
BODY AND FRAME SEGWAY AT5 FRONt shElF cOvER First place the car body in a horizontal position ◆ take out 8 bolts of front shelf cover plate 【a】. remove the front shelf cover from the body. ◆ REAR shElF cOvER First place the car body in a horizontal position ◆...
Page 288: Air Filter Cover Removed
BODY AND FRAME SEGWAY AT5 AiR FiltER cOvER REMOvED ◆ remove the expansion screws on both sides 【a】 ◆ Pull out service cover in arrow direction MOuNtiNg cushiON ◆ align the positioning card slot downward into place. ◆ P r e s s t h e e x p a n s i o n s c r e w 【 a 】 i n t o t h e corresponding mounting hole.
Page 289 BODY AND FRAME SEGWAY AT5 ENgiNE DisAssEMBlY ExplOsiON DiAgRAM torque Fastener remarks n·m kgf·m ft·lb 1 Hexagon flange bolt M8×30 30 40 3.0~4.0 22.1~29.5 Hexagon flange bolts M6x12 8~12 0.8~1.2 69~103.6 in·lb Hexagon flange shaft bolt M12×1.25×210 50 60 5.0~6.0 36.9~44.3...
Page 290: Disassembly
BODY AND FRAME SEGWAY AT5 DisAssEMBlY ◆ remove the bottom plate. (see car body section for details) ◆ remove the outer central plastic parts. (see car body section for details) ◆ Pull out the connectors or cables on the engine, disconnect the connection with the main cable.
Page 291 BODY AND FRAME SEGWAY AT5 ◆ Remove the injector mounting bolt with the appropriate tool 【e】, remove the injector. CAUTION After removing the injector, please effectively protect the injector to prevent debris from blocking the injection hole of the injector, thus damaging the injector.
Page 292 BODY AND FRAME SEGWAY AT5 ◆ remove the 4 mounting screws of the rear drive shaft and engine with appropriate tools【J】, disconnect the front drive shaft from the engine.. CAUTION after removing the front and rear drive shafts, apply thread glue to the mounting screws during assembly and fastening to prevent screws from loosening and falling off.
Page 293 BODY AND FRAME SEGWAY AT5 ◆ remove the clamp with the water pipe clamp clamp 【m】 remove the engine exhaust pipe. cAutiON after removing the exhaust pipe and radiator inlet and outlet pipes, protect the corresponding interfaces on the engine to prevent debris from falling into the engine and damaging the engine.
Page 294 BODY AND FRAME SEGWAY AT5 FRONt AND REAR AxlE DisAssEMBlY ExplOsiON DiAgRAM torque Fastener remarks n·m kgf·m ft·lb Hexagon flange bolt M10×1.25×105 40 50 4.0~5.0 29.5~36.9 Hexagon flange locking nut M10 x 1.25 40 50 4.0~5.0 29.5~36.9 Hexagon flange bolts M10 x 1.25 x 20 40～50...
Page 295: Disassembly
BODY AND FRAME SEGWAY AT5 FRONt AxlE MAiNtENANcE DisAssEMBlY ◆ remove front lower right rocker arm welding assembly and front upper right rocker arm welding assembly. (see suspension section for details) ◆ remove front lower left rocker arm welding assembly and front upper left rocker arm welding assembly.
Page 296: Rear Axle Maintenance
BODY AND FRAME SEGWAY AT5 REAR AxlE MAiNtENANcE DisAssEMBlY ◆ Pull out or remove the connectors on the rear axle assembly and disconnect the connection with the main cable. ◆ remove the connection between brake assembly and rear axle assembly.
Page 297: Front And Rear Shelf Disassembly Explosion Diagram
BODY AND FRAME SEGWAY AT5 FRONt AND REAR shElF DisAssEMBlY ExplOsiON DiAgRAM torque Fastener remarks n·m kgf·m ft·lb Front plate mounting bolts m6x12 8~12 0.8~1.2 69~103.6 in·lb bolts m8x16 30~40 3.0~4.0 22.1~29.5 bolts m8x16 30~40 3.0~4.0 22.1~29.5 bolts m8x16 30~40 3.0~4.0...
Page 298 BODY AND FRAME SEGWAY AT5 FRAME AccEssORY ExplOsiON DiAgRAM torque Fastener remarks n·m kgf·m ft·lb Frame accessory explosion diagram 30~40 3.0~4.0 22.1~29.5 Hexagon flange bolts M8×40 30~40 3.0~4.0 22.1~29.5 Hexagon flange bolts M8×25 30~40 3.0~4.0 22.1~29.5 m6 nut clamp Hexagon flange bolts M6×12 8~12 0.8~1.2...
Page 299: Frame Accessory Removed
BODY AND FRAME SEGWAY AT5 FRAME AccEssORY REMOvED ◆ remove the bolt on the upper support of the rear storage box (hexagonal flange bolt 2-M8×16,2- 2-M8×40) and remove the front shelf support assembly. ◆ Remove the bolt (hex flange bolt 4-M8×30) and remove the left and right foot pedal welding assembly.
Page 300: Front Bumper Explosion Diagram
BODY AND FRAME SEGWAY AT5 FRONt BuMpER ExplOsiON DiAgRAM torque Fastener remarks n·m kgf·m ft·lb large pan head hexagon bolt m6x16 40~50 4.0~5.0 30~37 Hexagon flange bolts M8×20 22~30 2.2~3.0 17~22 http://www.segwaypowersports.com 13 - 21...
Page 301: Front Bumper Removal
BODY AND FRAME SEGWAY AT5 FRONt BuMpER REMOvAl ◆ remove the lock nut of the winch motor line and remove the winch motor line. CAUTION after removing the winch motor line, the head of the cable should be protected to prevent short circuit.
Page 302 BODY AND FRAME SEGWAY AT5 ◆ unplug the pin of the winch hook, remove the winch hook and the winch rubber pad. ◆ remove the mounting bolt of the winch motor (hexagon flange bolt M8×20) and remove the winch motor.
Page 303 ELECTRICAL SYSTEM SEGWAY AT5 ELECTRICAL SYSTEM ExpLodEd VIEw ..................... 14-3 TEChnICAL pARAMETERS ..................14-6 SpECIAL TooLS ...................... 14-7 BATTERY ......................... 14-8 Remove the batteRy ..................14-8 tuRn off ignition switch ................14-8 BATTERY ChARgIng ..................... 14-9 chaRging condition check ............... 14-11 geneRatoR inspection ................
Page 304 ELECTRICAL SYSTEM SEGWAY AT5 ThRoTTLE VALVE BodY ASSEMBLY ..............14-31 ThREE-In-onE SEnSoR ..................14-31 thRee-in-one sensoR peRfoRmance chaRacteRistics ....14-32 IdLE MoToR ......................14-33 idle motoR flow chaRacteRistics ............14-34 fault diagnosis ....................14-34 idle motoR fault check: ................14-34 fault code Reading ..................
Page 305: Electrical System
ELECTRICAL SYSTEM SEGWAY AT5 ExpLodEd VIEw torque fastener Remarks n·m kgf·m ft·lb Hexagonal flange bolt M8×1.25×20 22~28 2.2~2.8 16.2~20.7 Hexagonal flange bolt M8×1.5×1 8~10 0.8~1.0 70.8~88.4in·lb Cross recessed pan head screw M5×12 0.3~0.4 26.5~35.4in·lb Hexalobular pan head screw M6×12 0.3~0.5 26.5~44.2in·lb...
Page 306 ELECTRICAL SYSTEM SEGWAY AT5 ExpLodEd VIEw torque fastener Remarks n·m kgf·m ft·lb Hexagonal flange bolt 0.7~0.9 61.9~79.6in·lb M6×1.25×20 Cross recessed pan head M5×12 0.3~0.4 26.5~35.4in·lb Hexagonal flange bolt 0.4~0.5 35.4~44.2in·lb M6×1.25×12 Hexagonal flange bolt M6×30 10~12 1.0~1.2 7.4~8.8 cross recessed round head self- 0.4~0.5...
Page 307 ELECTRICAL SYSTEM SEGWAY AT5 torque fastener Remarks n·m kgf·m ft·lb Hexagonal flange bolt 0.8~1.0 70.8~88.4in·lb M6×1.25×12 Hexagonal flange bolt 0.8~1.0 70.8~88.4in·lb M6×1.25×12 m6 nut 0.7~0.9 61.9~79.6in·lb Hexagonal flange bolt 0.5~0.7 44.2~61.9in·lb M6×1.25×12 http://www.segwaypowersports.com 14 - 5...
Page 308: Technical Parameters
ELECTRICAL SYSTEM SEGWAY AT5 TEChnICAL pARAMETERS project standard use limit Battery: sealed battery type 12 v 32 ah capacity Charging System: three-phase dc 14 ～ 15 v alternator type charging voltage (Regulator/rectifier output voltage) Alternator ac 36 ～ 54 V 3 000 r/min (rpm) output voltage 0.33 ～...
Page 309: Special Tools
ELECTRICAL SYSTEM SEGWAY AT5 SpECIAL TooLS multimeter CAuTIon ◆ when the multimeter is measuring voltage, the meter pen should not be inserted into the current measuring hole ◆ when measuring resistance, please be sure to disconnect the battery positive pole.
Page 310: Battery
ELECTRICAL SYSTEM SEGWAY AT5 BATTERY REMoVE ThE BATTERY 【a】positive + 【b】negative - ◆ Turn off ignition switch. ◆ Remove seat(Please read frame and body section) ◆ loosen the bolts on the battery seat ◆ Remove the battery bracket. ◆ First disconnect the battery negative (-) cable, then disconnect the positive (+) cable.
Page 311 ELECTRICAL SYSTEM SEGWAY AT5 BATTERY ChARgIng in the case shown in the following table, to start the vehicle fully to start the engine, and it should be charged before use. however, if the battery voltage is higher than 12.6v after 10 minutes of charging, no initial charge is required.
Page 312 ELECTRICAL SYSTEM SEGWAY AT5 wARnIng the battery is designed to withstand no abnormal damage if it is recharged as specified above. however, if charged under conditions other than those described above, the performance of the battery may degrade significantly. Do not remove the seal cover during recharging. If excess gas is generated due to overcharging, a safety valve ensures battery safety.
Page 313: Remove The Battery
ELECTRICAL SYSTEM SEGWAY AT5 ChARgIng CondITIon ChECk battery charging status can be measured to check the battery terminal voltage. ◆ Remove the battery (refer to the section on Removing the battery). wARnIng First, make sure to disconnect the negative (-) ◆...
Page 314: Generator Inspection
ELECTRICAL SYSTEM SEGWAY AT5 gEnERAToR InSpECTIon there are three types of alternator faults: short circuit, disconnection, or rotor magnetic loss. short- circuiting one of the coils or disconnecting the wire will result in low output or no output at all. a loss...
Page 315 ELECTRICAL SYSTEM SEGWAY AT5 CIRCuIT dIAgRAM oF ChARgIng SYSTEM DYNAVOL T 1. Alternator 2. regulator/rectifier 3. Battery 4. main fuse 5. ignition lock 6. load http://www.segwaypowersports.com 14 - 13...
Page 316: Voltage Regulating Rectifier Inspection
ELECTRICAL SYSTEM SEGWAY AT5 VoLTAgE REguLATIng RECTIFIER InSpECTIon test and Judgment method of charging voltage on whole vehicle test conditions and methods output voltage 1. connect the product according to the normal loading state, after the vehicle started, the speed will remain output voltage:14.0-15.0v...
Page 317: Efi System
ELECTRICAL SYSTEM SEGWAY AT5 EFI SYSTEM SChEMATIC dIAgRAM oF EFI SYSTEM 1.1.5. MSE6.0 系统总览点火线圈/火花塞点火线圈/火花塞 Ignition Coil/Spark plug Ignition Coil/Spark plug 节气门体 throttle body 节气门体 throttle body 节气门位置传感器 throttle position 节气门位置传感器 throttle position sensor sensor 集成式节气门体集成式节气门体进气压力传感器 intake pressure sensor 进气压力传感器...
Page 318: Temperature Sensor
ELECTRICAL SYSTEM SEGWAY AT5 TEMpERATuRE SEnSoR FunCTIon InTRoduCTIon the temperature sensor function is used to monitor the temperature of the engine coolant. the sensor delivers engine temperature information to the ecu to determine engine performance and the display. the temperature sensor is generally installed on the intake side of the engine block. the cylinder temperature sensor can be seen by disassembling the left side cover and seat cushion of the whole vehicle (see 【a】...
Page 319: Performance Parameter
ELECTRICAL SYSTEM SEGWAY AT5 pERFoRMAnCE pARAMETER ◆ Power: 0.25W under standard use conditions ◆ Working temperature：-30°C～+130°C ◆ Vibration level：≤600m/s2 ◆ Insulation resistance: DC voltage of 500V is applied between the A and C end circuits and the B end circuit, and the insulation resistance is greater than 10MΩ.
Page 320: Oxygen Sensor
ELECTRICAL SYSTEM SEGWAY AT5 oxYgEn SEnSoR FunCTIon InTRoduCTIon it is used in the feedback system of the electronic control fuel injection device to achieve closed-loop control and improve the control accuracy of the air-fuel ratio of the electronic control unit. it is installed on the exhaust pipe (see【a】...
Page 321: Performance Parameter
ELECTRICAL SYSTEM SEGWAY AT5 pERFoRMAnCE pARAMETER new oxygen 500h durable after oxygen Item Exhaust temperature 350℃ 850℃ 350℃ 850℃ λ = 0.97 when the sensor 840±70 710±70 840±80 710±70 element voltage(mv) λ = 1.10 when the sensor 20±50 55±30 20±50 40±40...
Page 322 ELECTRICAL SYSTEM SEGWAY AT5 TRouBLEShooTIng the electronic control unit ecu monitors various sensors, actuators, power amplifier circuits and detection circuits. common fault codes are shown in the fault list. CAuTIon when the fault of oxygen sensor signal is checked, the engine should be run for at least 5-10min to ensure the completion of heating of oxygen sensor.
Page 323: Carbon Canister Solenoid Valve
ELECTRICAL SYSTEM SEGWAY AT5 CARBon CAnISTER SoLEnoId VALVE FunCTIon dESCRIpTIon the carbon canister solenoid valve is used to control the regeneration gas flow rate of fuel tank vapor flowing through activated carbon. It is triggered by a pulse, and the duration of the pulse or the frequency of the electronic controller is adjusted according to the engine's operating conditions.
Page 324: Function Introduction
ELECTRICAL SYSTEM SEGWAY AT5 Electronic control unit（ECU） FunCTIon InTRoduCTIon ECU first collects the running data of the engine system in real time through the sensors of the engine management system, and then drives the actuator to control the engine operation according to the system calibration and the stored calibration data.
Page 325: Ecu Stitch Definition
ELECTRICAL SYSTEM SEGWAY AT5 ECu STITCh dEFInITIon item name item name oxygen sensor heating start motor relay idle motor a starter relay vehicle speed signal upstream oxygen sensor continuous power throttle position sensor engine speed sensor a end cooling fan relay...
Page 326: Electronic Throttle Body Dve Self-Learning Process
ELECTRICAL SYSTEM SEGWAY AT5 ELECTRonIC ThRoTTLE BodY dVE SELF-LEARnIng pRoCESS 1. after replacing either ecu or electronic throttle body, it is necessary to restart the electronic throttle body self-learning; 2. for vehicles that have completed self-learning, turn the key to the on again, after waiting for 29 seconds, the electronic throttle body self-learning will also be started again.
Page 327: Performance Parameters
ELECTRICAL SYSTEM SEGWAY AT5 pERFoRMAnCE pARAMETERS project parameter Static flow 207.8g/min Dynamic flow 6.65mg/stroke Jet angle 23° coil resistance 12Ω hydraulic leak 1.8mm3/min FAuLT dIAgnoSIS ecu only implements fault diagnosis for the fuel injector drive stage. when the fuel injector drive stage is short-...
Page 328: Ignition Coils
ELECTRICAL SYSTEM SEGWAY AT5 IgnITIon CoILS the ignition coil converts the low-voltage electricity of the primary winding into the high-voltage electricity of the secondary winding, and generates sparks through the discharge of the spark plug to ignite the fuel-air mixture in the gas cylinder.
Page 329: Performance Parameters
ELECTRICAL SYSTEM SEGWAY AT5 pERFoRMAnCE pARAMETERS value item unit Rated calibration voltage operating voltage 16.5 primary mΩ winding Resistance （20--25℃ secondary 8.27 10.53 kΩ winding primary current (Charging time 3.9ms) secondary voltage (Load 35pF) ignition energy (Zener voltage 1000V) FAuLT dIAgnoSIS...
Page 330: Remove And Install Spark Plugs
ELECTRICAL SYSTEM SEGWAY AT5 火花塞 the spark plug introduces the pulsed high voltage electricity generated by the ignition coil into the combustion chamber, and uses the electric spark generated by the electrode to ignite the mixture to complete the combustion. The spark plug sample diagram (see the figure below).
Page 331: Engine Speed Sensor
ELECTRICAL SYSTEM SEGWAY AT5 EngInE SpEEd SEnSoR The working principle of the speed sensor is to use the magnetoelectric effect. When the shaft rotates, the signal wheel is driven to rotate together, and the teeth on the signal wheel will cut the magnetic line of the sensor.
Page 332: Oil Pressure Sensor
ELECTRICAL SYSTEM SEGWAY AT5 oIL pRESSuRE SEnSoR the oil pressure sensor detects the size of the engine oil pressure when it is working, and it is usually screwed into the oil passage of the cylinder block. its working principle is that there is a variable resistor inside the sensor, one end outputs the signal, and the other end is connected to the grounded sliding arm.
Page 333: Throttle Valve Body Assembly
ELECTRICAL SYSTEM SEGWAY AT5 ThRoTTLE VALVE BodY ASSEMBLY The throttle valve body assembly is connected to the engine and the air filter. The user can control the opening and closing angle of the throttle valve through the throttle cable to achieve different driving intentions.
Page 334: Three-In-One Sensor Performance Characteristics
ELECTRICAL SYSTEM SEGWAY AT5 ThREE-In-onE SEnSoR pERFoRMAnCE ChARACTERISTICS intake temperature sensor 2kΩ±3% b25/85 3520k±2% temperature-resistance see the left picture characteristics throttle position sensor linearity see the left picture operating temperature -30℃ --+110℃ intake pressure sensor change sensitivity 40.5mv/kpa output voltage characteristic see the left picture http://www.segwaypowersports.com...
Page 335: Idle Motor
ELECTRICAL SYSTEM SEGWAY AT5 IdLE MoToR the idle motor is composed of a plurality of steel stators and rotors arranged in a circle. each steel stator is wound with a coil; the rotor is a permanent magnet, and the center of the permanent magnet is a nut. all stator coils are always energized.
Page 336: Idle Motor Flow Characteristics
ELECTRICAL SYSTEM SEGWAY AT5 IdLE MoToR FLow ChARACTERISTICS the ecu controls the number of moving steps of the stepper motor by controlling the number of times the current direction of the coil is replaced, thereby adjusting the cross-sectional area of the bypass channel and the air flow through it.the flow characteristics of stepper...
Page 337: Fault Code Reading
ELECTRICAL SYSTEM SEGWAY AT5 FAuLT CodE REAdIng there is a fault indicator (【a】in the left figure) in the instrument. when the key switch is turned on, the fault indicator is always on. when the engine is running, if the vehicle electronically controlled fuel injection system has no faults, the indicator light should go out;...
Page 338: Summary Of Failure Codes（Ecu
ELECTRICAL SYSTEM SEGWAY AT5 SuMMARY oF FAILuRE CodES（ECu） pcode description（uaes） fault indicator on p0030 o2 sensor 1 heater contr. circ. high √ p0031 o2 sensor 1 heater contr. circ. low √ p0032 o2 sensor 1 heater contr. circ. open √...
Page 339 ELECTRICAL SYSTEM SEGWAY AT5 pcode description（uaes） fault indicator on p0509 idle air control circuit low high √ p0511 idle air control circuit open √ p0560 system voltage malfunction √ p0562 system voltage low voltage √ p0563 system voltage high voltage √...
Page 340: Lighting System Circuit
ELECTRICAL SYSTEM SEGWAY AT5 LIghTIng SYSTEM CIRCuIT 1 battery main fuse fuse 15A fuse 15A 5 lgnition lock brake lamp relay Diode Brake SW d a y t i m e r u n n i n g 9 Brake relay...
Page 341: Headlamps
ELECTRICAL SYSTEM SEGWAY AT5 hEAdLAMpS Headlamp rear guard (see chapter "Frame") 【a】 mounting clips 【b】 headlamp rear guard 【c】 headlamp body 【d】 headlamp bolts *4 【e】 adjustment bolts for high and low beam REpLACE CAuTIon ◆ lamps are led lamps;...
Page 342: Tail Lamp
ELECTRICAL SYSTEM SEGWAY AT5 TAIL LAMp TAIL LAMp 1 【a】tail lamp body 【b】 tail lamp bolts*3 、 TAIL LAMp 2 【c】tail lamp body 【d】 tail lamp bolts*5 Replace CAuTIon lamps are led lamps led tail lamp source damaged, only tail lamps assembly can be replaced ◆...
Page 343: License Plate Lamp
ELECTRICAL SYSTEM SEGWAY AT5 LICEnSE pLATE LAMp 【a】license plate lamp bolt*1 【b】license plate lamp REMoVE ◆ Remove the license plate lamp bolt 【a】 ◆ Remove the license plate lamp【b】 ◆ disassembly license plate lamp灯 REpLACEMEnT ASSEMBLY the assembly should be performed in the reverse order...
Page 344: Flasher
ELECTRICAL SYSTEM SEGWAY AT5 FLAShER disassembly and assembly of the front shelf and front guard (please refer to the relevant sections of the body) 【a】rubber sleeve 【b】flasher dISASSEMBLY ◆ Remove the installation rubber sleeve【a】from the installation bracket ◆ Remove the wiring harness connector ◆...
Page 345: Eps-Brushless
ELECTRICAL SYSTEM SEGWAY AT5 EpS-BRuShLESS CAuTIon the method of disassembling the eps assembly refers to the method of disassembling the steering assembly. only the electrical functions of the eps are introduced here. before disassembling the eps assembly【a】, firstly remove the power connector【b】and power connector 【c】...
Page 346: Eps System Wiring Schematic Diagram
ELECTRICAL SYSTEM SEGWAY AT5 EpS SYSTEM wIRIng SChEMATIC dIAgRAM 1. Battery 2. Fuse 50A 3. Fuse 40A 4. Fuse 15A 5. key switch 6. diode 7. Ig relay 8. Fuse 5A 9. oBd 10. EpS http://www.segwaypowersports.com 14 - 44...
Page 347: Eps Trouble Removal
(only vehicles with TBOX can be adjusted) If the EpS fault light on the meter is on, it means that the EpS is malfunctioning.
Page 348 ELECTRICAL SYSTEM SEGWAY AT5 The EpS fault codes displayed in the instrument are listed below: Recoverability fault with or without within the fault fault description fault light grade power current ignition code cycle Recoverable torque midpoint not written after fault...
Page 349: Display And Human-Computer Interaction
ELECTRICAL SYSTEM SEGWAY AT5 dISpLAY And huMAn-CoMpuTER InTERACTIon dAShBoARd the dashboard displays key information to the user. see the next page for display functions and instructions wARnIng using a high-pressure water gun may damage the dashboard. you should use your hands or hoses to clean the vehicle with neutral soap.
Page 350: Dashboard Indicator Light Description
ELECTRICAL SYSTEM SEGWAY AT5 dAShBoARd IndICAToR LIghT dESCRIpTIon fault analysis of cause and trouble item icon function description shooting phenomenon this indicator check whether pin 29 has high this indicator will be not on when the level input, if yes, replace the...
Page 351 ELECTRICAL SYSTEM SEGWAY AT5 Right this indicator will this indicator not check if pin12 has high level turning light be on when right on when right input, if so ,replace the meter, indicator turning light is on turning light is on if no.
Page 352: Instrument Information Display
ELECTRICAL SYSTEM SEGWAY AT5 InSTRuMEnT InFoRMATIon dISpLAY function Area Fault Toubleshouting description Showing current time time display —— —— check dashboard can- when mobile buuetooth power on remotely h,can-l wire harness, and t-boX are bluetooth by bluetooth, this if not solve it ，replace...
Page 353 ELECTRICAL SYSTEM SEGWAY AT5 display the correctly gear L -low speed check gear position gear display h -high speed no gear display sensor and related electric line R -Reverse p -parking check cna-h,can-l no engine speed wire harness, check display actual engine speed...
Page 354 ELECTRICAL SYSTEM SEGWAY AT5 displays the total mileage —— —— total mileage accumulated by the vehicle eps mode was set in the c h e c k c n a - h , app and the preferred mode can-l of the rider was selected:...
Page 355: Dashboard Disassembly And Assembly
ELECTRICAL SYSTEM SEGWAY AT5 dashboard button function introduction function a button b button display adjust backlight brightness brightness short press adjustment (default: brightest) Zero subtotal subtotal clear long press mileage eps gear short press eps level shift switching signal sent...
Page 356 ELECTRICAL SYSTEM SEGWAY AT5 description note description note can-l —— brake failure alarm low level can-h —— 4wd signal —— sensor power supply —— —— —— vehicle speed pulse signal seat cushion switch low level power ground —— oil pressure low level ——...
Page 357: T-Box
ELECTRICAL SYSTEM SEGWAY AT5 T-Box CAuTIon if multiple vehicles are repaired at the same time, do not exchange and install the t-boX ◆ power off the whole vehicle first and remove the front shelf assembly ◆ pull out the connector【a】...
Page 358: T-Box Interface Definition
ELECTRICAL SYSTEM SEGWAY AT5 Failure phenomenon and failure reason trouble solution fault code t0001 Replace t-boX fault code t0002 Replace t-boX fault code t0003 Replace t-boX fault code t0004 Replace t-boX check pin9 and pin14 fault code t0005 have signal...
Page 359: Switch
ELECTRICAL SYSTEM SEGWAY AT5 SwITCh powER LoCk CAuTIon when the indicator does not display after the key is turned on, check the circuit failure (see page xx), and replace the power lock after confirming that the power lock is broken check power lock →...
Page 360: Left Handlebar Switch
ELECTRICAL SYSTEM SEGWAY AT5 LEFT hAndLEBAR SwITCh CAuTIon the switch is valid only when the power lock is in the on position 【a】turn on high beam 【b】turn on lower beam 【c】Turn off light 【d】turn on position light CAuTIon Gr/R G B/Br...
Page 361 ELECTRICAL SYSTEM SEGWAY AT5 【a】start button 【b】left and right turn signal switch 【c】flameout switch when the engine is running, press the flameout switch button to stop the engine; when the engine is stopped, first pop up the flameout switch button, and then press the start button to start the engine;...
Page 362: Assembly And Disassembly Of Left Handlebar Switch
ELECTRICAL SYSTEM SEGWAY AT5 【e】emergency switch when the emergency switch is pressed, the four front and rear turning lights flash at the same time; when the FUNC emergency switch is pressed, if a single turning light does not light up, check the relevant fuse or the lamp itself.；...
Page 363: Right Handlebar Switch
ELECTRICAL SYSTEM SEGWAY AT5 RIghT hAndLEBAR SwITCh CAuTIon the switch is valid only when the power lock is in the on position 【a】2-4wd switch 【b】4wd lock switch 【c】accelerator Test 2-4wd switch for damage → when the knob switch is turned to the 2wd position, the switch is in 2wd, at which time brown-red and blue-green and blue-black can conduct;...
Page 364: Winch Assembly
ELECTRICAL SYSTEM SEGWAY AT5 wInCh ASSEMBLY REMoVAL CAuTIon When removing the winch, first power off the vehicle power ◆ Remove external related plastic parts ◆ first remove the battery positive electrode 【a】 ◆ Remove the power cable of the winch 【b】...
Page 365 ELECTRICAL SYSTEM SEGWAY AT5 ◆ Remove the bolt【e】, remove the winch switch 【f】 ◆ Remove the bolt【h】, then the winch power cord 【i】, winch motor wire 【J】 and winch relay【g】 can be removed together ◆ after disassembling the bolt【p】 and the wire rope 【R】, you can remove the strap【Q】, hook【o】,...
Page 366 ELECTRICAL SYSTEM SEGWAY AT5 CAuTIon the winch work does not exceed 1min each time, and then works after an interval of 30s ◆ Rated working voltage dc12v ◆ maximum working tension 2500lbs or 3000lbs ◆ The maximum working current ≤185 A, the maximum working current lasts for 1 min, and work after an interval of 30 seconds.
Page 367: Fuse Box
ELECTRICAL SYSTEM SEGWAY AT5 FuSE Box all fuses for the vehicle are in the fuse box the fuse box is located under the front instrument mask. Remove front panel repair cover ◆ after the front panel repair cover is removed, the fuse box located at the bottom can be seen.
Page 368 ELECTRICAL SYSTEM SEGWAY AT5 FuEL Box LABEL Fuse/Relay power Fuse/Relay power ignition lock Remote power-on relay 12v 20a head light auxiliary start relay 12v 20a ecu/instrument/tboX-- ig relay 12v 20a fuel pump main relay 12v 20a 12v power socket daytime running light relay...
Page 369: Wire Harness
ELECTRICAL SYSTEM SEGWAY AT5 wIRE hARnESS CAuTIon 1. the positive and negative connections of the battery cannot be reversed, which will cause the wires to burn out all wiring screws must be tightened according to the required torque description of wire colors：...
Page 370: Wire Harness Assembly
ELECTRICAL SYSTEM SEGWAY AT5 wIRE hARnESS ASSEMBLY ◆ 【s】-ecu plug ◆ 【a6】-gear position sensor ◆ 【t】-12v power socket plug ◆ 【a7】-cdi trigger ◆ 【u】-usb plug ◆ 【b1】-Rear taillight plug ◆ 【v】-leave seat alarm switch plug ◆ 【b3】-trailer power socket plug ◆...
Page 371: Wiring Diagram
ELECTRICAL SYSTEM SEGWAY AT5 wIRIng dIAgRAM http://www.segwaypowersports.com 14 - 69...

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