Table of Contents
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Table of Contents
Troubleshooting
Related Manuals for Segway SGW500F-A5 2023
Summarization of Contents
NOTES BEFORE MAINTENANCE
Preparation of tools and gauges
Prepare necessary tools and measuring instruments before repair work.
Specialized tools
Use special tools for disassembly of some parts, do not use other tools.
Parts disassembly
Identify malfunction cause and confirm if disassembly is required based on actual condition.
Disassemble
Take care not to damage parts if disassembly process is complex.
Parts
When parts are damaged and need replacement, use parts approved or recommended by Segway.
Replacements
Assemble components with strict adherence to standard values like torque and adjustment.
Rubber parts and hoses
Prevent rubber parts and hoses from coming into contact with gasoline or lubricating oil.
GENERAL INFORMATION
Vehicle identification number/engine serial code
Location and purpose of VIN and engine serial number for identification and ordering parts.
Technical parameters of vehicle
Detailed specifications for vehicle dimensions, weight, engine, tires, and brakes.
Unit conversion table
Conversion factors for torque, pressure, power, volume, speed, and temperature.
Torque
Lists tightening torque specifications for various fasteners used in the vehicle.
MAINTENANCE
TECHNICAL SPECIFICATIONS
Lists general and fluid specifications for the vehicle.
VEHICLE LIFTING SUPPORT POSITION
Provides instructions and diagrams for safely lifting the vehicle.
MAINTENANCE CYCLE TABLE
Outlines the recommended maintenance schedule based on time and mileage.
BREAK-IN MAINTENANCE
Specific maintenance tasks required during the initial break-in period.
PERIODIC MAINTENANCE
Detailed schedule for regular inspections, adjustments, and replacements.
Maintenance Reference
Reference for engine oil and coolant specifications and maintenance.
Grease
Instructions for greasing suspension arms, balance rods, and drive shafts.
REMAINING LUBRICATION FILLING
Table listing lubrication points and annotations for filling grease.
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Daily pre-ride checks for essential vehicle components.
ENGINE OIL LEVEL CHECK
Detailed procedure for checking engine oil level using the dipstick.
Engine oil emissions
Recommendations for regular oil and filter changes, including warnings.
Cleaning the filters
Instructions for cleaning the oil filter screen and the oil filter.
Changing the oil filter
Procedure for removing and installing the oil filter, including torque.
Filling the engine oil
Step-by-step guide for filling the engine with the correct type and amount of oil.
Engine/fuel tank hose inspection
Inspection of vent hoses for kinks, damage, or cracks.
Engine cylinder leakage test
Procedure for testing cylinder leakage to assess engine condition.
Valve lash check
Procedure for checking valve lash on a cold engine, including disassembly steps.
Front gearbox and rear gearbox
Overview of front and rear gearbox fluid level checking procedures.
Check front and rear transmission fluid levels
Detailed steps for checking and draining gearbox oil.
Front Reduction Gearbox Oil Drain
Procedure for draining oil from the front reduction gearbox, including torque.
Front reduction gearbox gear oil filling
Procedure for filling the front reduction gearbox with gear oil, including torque.
Rear reduction gearbox drain
Procedure for draining oil from the rear reduction gearbox, including torque.
Rear reduction gearbox gear oil filling
Procedure for filling the rear reduction gearbox with gear oil, including torque.
Shift lever inspection/adjustment
Procedures for inspecting and adjusting the shift lever for proper gear engagement.
Cooling System Overview
Explanation of the cooling system components and their functions.
Cooling System Hoses
Inspection and replacement guidelines for cooling system hoses.
Radiator check
Instructions for checking the radiator core and fins for blockages or damage.
Coolant bottle coolant level check and refill
Procedure for checking and refilling the coolant level in the sub-tank.
Coolant Replacement
Procedure for draining, flushing, and refilling the cooling system with new coolant.
Air Filter
Information on air filter replacement intervals and procedures.
Air Filter Drain Check
Checks the air filter drain to ensure it is not clogged.
Spark Arrestor
Maintenance of the spark arrestor to prevent carbon buildup.
Exhaust Heat Shield Inspection
Inspection of the exhaust heat shield for condition and security.
Fuel System
Safety precautions and checks related to the fuel system and refueling.
Fuel Filter
Symptoms of a restricted fuel tank vent and inspection/replacement of the fuel filter.
Fuel line
Inspection of fuel lines and connections for leaks, wear, or damage.
CVT intake screen check
Periodic checking and cleaning of CVT air intake filters.
CVT Belt
Procedure for replacing the CVT drive belt if damaged or at specified intervals.
Installation of drive belts
Steps for installing new drive belts, emphasizing correct orientation.
DRY CVT
Procedure for drying the CVT system if it becomes soaked with water.
Drive Shaft Dust Sleeve Inspection
Inspection of drive shaft dust boots for cuts, damage, or leaks.
Wheel parts removal
Steps for removing wheels, including loosening nuts and jacking the vehicle.
Wheel Mounting
Procedure for mounting wheels, including tightening nuts to specified torque.
Tire Tread Depth
Checking tire tread wear and replacement criteria.
Tire pressure check
Steps for checking tire pressure, including guidelines for accurate cold readings.
Steering system check
Periodic checks of steering components for loose fasteners, wear, and smooth travel.
Power steering (EPS models)
Accessing and cleaning the power steering unit for proper cooling.
Transverse Tie Rod Inspection
Checking for clearance and movement in the transverse tie rod.
Anterior beam check
Checking the front beam value, which affects wheel alignment and tire wear.
Front Beam Adjustment
Procedure for adjusting the front beam value using tie rods and jam nuts.
Shock absorber inspection
External inspection of front shock absorbers; replace as a set if damaged.
Adjustable pneumatic shock adjustment
Adjustments for compression damping and spring preload on pneumatic shock absorbers.
Spring preload position (C) setting
Standard and usage range settings for front and rear shock absorber spring preload.
Spring Lock Nut Torque
Torque specification for the spring lock nut.
Recovery Damping Adjustment
Adjustment of recovery damping on shock absorbers based on position settings.
Oil shock absorber adjustment
Adjusting damping positions for different loads, terrain, and speeds using a hook wrench.
Compression Damping Adjustment
Procedure for adjusting compression damping using the adjuster knob.
BRAKING SYSTEM
Overview of front and rear brakes, hydraulic disc systems, and general checks.
BRAKE FLUID LEVEL CHECK ON HANDBRAKE UPPER PUMP
Procedure for checking and replenishing brake fluid in the handbrake master pump reservoir.
Brake fluid cup level check
Checking the rear brake fluid oil cup level and resetting the oil cup gasket.
BRAKE LININGS AND DISCS
Wear inspection for brake linings and discs, with standard and minimum thickness values.
Brake pedal air travel check
Checking and adjusting the air travel of the brake pedal.
Parking handle working stroke check
Checking the working stroke of the parking handle and adjusting if necessary.
Parking handle free travel adjustment
Adjusting the parking handle free travel using the brake lever adjuster.
Battery maintenance
Procedures for cleaning battery terminals and connections, including warnings.
Battery Removal
Steps for safely removing the battery, including disconnecting cables.
Battery Installation
Procedures for installing the battery, including cable connections and torque.
Battery charging
Precautions and procedures for safely charging the 12V battery, including warnings.
Spark plugs
Recommended spark plug type, gap, torque specifications, and cautions.
Spark plug check
How to inspect spark plug condition and notes on plug tip colors.
Throttle lever free play check
Checking and adjusting the free play of the throttle lever for smooth operation.
ENGINE LUBRICATION SYSTEM
Procedures and specifications for engine oil, oil filter, and oil pressure.
Exploded view
Detailed exploded diagram of the engine lubrication system components with numbered parts.
Torque
Table listing torque specifications for engine lubrication system fasteners.
Technical Parameter
Specifications for engine oil grade, viscosity, capacity, and oil pressure.
SPECIAL TOOLS AND SEALANTS
Images and names of special tools and sealants for engine lubrication service.
Engine Oil Flow Chart
Diagram illustrating the path of engine oil through the lubrication system.
ENGINE OIL AND OIL FILTER
Procedures for checking engine oil level and warnings about low oil.
Engine Oil Change
Reference to periodic maintenance chapter for engine oil change.
Oil Filter Change
Reference to periodic maintenance chapter for oil filter service.
Coarse Filter Removal
Procedure for removing the coarse filter cover and the filter itself.
Coarse Filter Cleaning
Instructions for cleaning the coarse filter, including warnings about flammable liquids.
OIL PRESSURE
Information on measuring and diagnosing engine oil pressure.
Oil Pump
Procedures for removing and installing the oil pump assembly.
Oil Pump Gear
Checking oil pump shaft rotation and installing driven gear.
OIL COOLER
Procedures for removing and installing the oil cooler.
Oil Filter Removal
Procedure for removing the oil filter.
Oil Filter Installation
Procedure for installing the oil filter, including torque.
CRANKSHAFT / TRANSMISSION
Procedures for crankshaft and transmission service, including disassembly, assembly, and inspection.
Exploded view
Exploded diagram of the crankshaft and transmission assembly, showing numbered parts.
Torque
Table listing torque specifications for crankshaft and transmission components.
TECHNICAL PARAMETER
Technical parameters for transmission, including shift fork ear thickness and groove width.
SPECIAL TOOLS AND SEALANTS
Images of special tools and sealants for crankshaft and transmission service.
CRANKCASE
Procedures for crankcase disassembly and assembly.
CRANKSHAFT
Information on crankshaft measurements, wear, and bearing checks.
TRANSMISSION
Procedures for transmission removal and installation, shift fork, and mechanism inspection.
BALL BEARING, NEEDLE BEARING, AND OIL SEAL
Procedures for replacing and inspecting ball bearings, needle bearings, and oil seals.
ENGINE-ELECTRICAL SYSTEM
Procedures and specifications for engine electrical components like battery, charging system, starter, and sensors.
Exploded view
Exploded diagram of the engine electrical system, showing numbered parts.
Torque
Table listing torque specifications for engine electrical system fasteners.
TECHNICAL PARAMETER
Specifications for charging system components like alternator and stator.
SPECIAL TOOLS
Images of special tools like flywheel puller assembly and flywheel holder.
CHARGING SYSTEM
Procedures for alternator cover, rotor, and stator removal/installation/inspection.
ALTERNATOR ROTOR REMOVAL
Procedure for removing the alternator rotor using a flywheel puller and holder.
ALTERNATOR ROTOR INSTALLATION
Procedure for installing the alternator rotor, including cleaning, key fitting, and torque.
ALTERNATOR STATOR REMOVAL
Procedure for removing the alternator stator, including bolts and cover removal.
ALTERNATOR STATOR INSTALLATION
Procedure for installing the alternator stator, including lubrication and torque.
Alternator Inspection
Procedures for checking alternator output voltage and stator coil resistance.
Stator Coil Resistance
Procedure for measuring stator coil resistance, including open circuit and short circuit conditions.
ELECTRIC STARTER SYSTEM
Procedures for starter motor, one-way clutch, and starter gear removal/installation/inspection.
STARTER MOTOR REMOVAL
Procedure for removing the starter motor, including cable and bolt removal.
STARTER MOTOR INSTALLATION
Procedure for installing the starter motor, including cleaning, lubrication, and torque.
ONE-WAY CLUTCH REMOVAL
Procedure for removing the one-way clutch, including bolts and rotor removal.
ONE-WAY CLUTCH INSTALLATION
Procedure for installing the one-way clutch, including flange fitting and torque.
ONE-WAY CLUTCH INSPECTION
How to inspect the one-way clutch operation for correct rotation and noise.
STARTER GEAR REMOVAL
Procedure for removing the starter gear assembly, including related components.
STARTER GEAR INSTALLATION
Procedure for installing the starter gear assembly, including bearing and lubrication.
ENGINE-COOLING SYSTEM
Procedures and specifications for the cooling system, including coolant, thermostat, and radiator.
EXPLODED VIEW OF COOLING SYSTEM
Exploded diagram of the cooling system, showing numbered parts.
Torque
Table listing torque specifications for cooling system fasteners.
TECHNICAL PARAMETER
Specifications for coolant type, color, mixing ratio, freezing point, and radiator cap pressure.
WATER PUMP REMOVAL
Procedure for removing the water pump, including draining fluids and removing components.
WATER PUMP INSTALLATION
Procedure for installing the water pump, including O-ring, gasket, bolts, and torque.
THERMOSTAT REMOVAL
Procedure for removing the thermostat, including draining coolant and removing housing.
THERMOSTAT INSTALLATION
Procedure for installing the thermostat, including O-ring, housing, and bolt tightening.
Thermostat Inspection
Procedure for inspecting the thermostat valve at room temperature and checking opening temperature.
Coolant Temperature Sensor Removal
Procedure for removing the coolant temperature sensor, including draining coolant.
Coolant Temperature Sensor Installation
Procedure for installing the coolant temperature sensor, including sealant and torque.
ENGINE TOP END
Procedures and specifications for engine top end components like cylinder head, piston, camshaft, and valves.
TECHNICAL PARAMETER
Technical specifications for cylinder head, piston, connecting rod, and balance shaft.
Cylinder Head Disassembly
Detailed steps for disassembling the cylinder head, including valve removal.
Valve Guide / Valve Inspection
Inspection of valve guides and valves, including clearance measurements.
COMBUSTION CHAMBER CLEANING
Procedure for cleaning combustion chambers and valve seat areas.
Valve Seat Reconditioning
Procedures for reconditioning valve seats, including inspection and repair.
Valve Seat Inspection
Procedure for inspecting valve seating surface, including coating and contact pattern check.
Valve Seat Repair (Valve Lapping)
Detailed steps for valve seat repair using lapping tools, including cutting and checking contact area.
CYLINDER AND PISTON
Procedures for cylinder removal, piston removal, installation, and wear checks.
CYLINDER REMOVAL
Procedure for removing the cylinder, including head, bolts, and gasket.
PISTON REMOVAL
Procedure for removing the piston, including snap rings, pin, and rings.
CYLINDER, PISTON INSTALLATION
Procedure for installing the cylinder and piston, including clearances and new rings.
Cylinder Wear
Procedure for measuring cylinder inside diameter and checking wear limits.
PISTON WEAR
Procedure for measuring piston outside diameter and checking wear limits.
Piston/Cylinder Clearance
Calculating piston-to-cylinder clearance.
PISTON RING, PISTON RING GROOVE WEAR
Checking piston ring groove wear and fitting rings.
Piston Ring Groove Width
Measuring piston ring groove width and comparing to service limits.
Piston Ring Thickness
Measuring piston ring thickness using a micrometer.
PISTON RING END GAP
Procedure for measuring piston ring end gap inside the cylinder and checking service limits.
Cylinder Head Installation
Procedures for installing the cylinder head, including pins, gasket, guide, and bolts.
CAMSHAFT INSTALLATION / TIMING
Procedures for installing camshafts and setting timing, including alignment marks.
Camshaft Chain Tensioner Installation
Procedure for installing the camshaft chain tensioner, including gasket and bolts.
Valve Clearance Adjustment
Procedure for inspecting and adjusting valve clearance before camshaft installation.
Valve Lash - Tappet Selection
Explanation of how to calculate and obtain the proper valve tappet thickness.
Available Tappets
Table listing available tappet part numbers and their corresponding 3-digit numbers.
CYLINDER HEAD INSTALLATION
Procedures for installing the cylinder head, including dowel pins, gasket, chain guide, and bolts.
CAMSHAFT INSTALLATION / TIMING
Procedures for installing camshafts and setting timing, including alignment marks.
Camshaft Chain Tensioner Installation
Procedure for installing the camshaft chain tensioner, including gasket and bolts.
Valve Clearance Adjustment
Procedure for inspecting and adjusting valve clearance before camshaft installation.
CVT SYSTEM
Procedures and specifications for the CVT system, including belt, pulleys, and covers.
CVT system explosion diagram
Exploded diagram of the CVT system, showing numbered components.
Torque
Table listing torque specifications for CVT system fasteners.
SPECIAL TOOLS
Images of special tools required for CVT system service.
CVT COVER REMOVAL/INSTALLATION
Procedures for removing and installing the CVT cover and lining.
CVT inner cover removal
Procedure for removing the CVT inner cover and its seals.
CVT inner cover installation
Procedure for installing the CVT inner cover, including sealing surfaces and bolts.
DRIVE BELT REMOVAL/INSTALLATION
Procedures for removing and installing the drive belt, including pulley alignment.
DRIVE PULLEY DISASSEMBLY
Inspection and replacement of drive pulley components like blocks, cap shoes, and freewheel.
DRIVE PULLEY RE-ASSEMBLY
Procedure for re-assembling the drive pulley, including sheave alignment and nut tightening.
PULLEY TIGHTENING
Procedure for tightening the fixation bolt and drive pulley using retaining tools.
CVT DRIVEN PULLEY ASSEMBLY EXPLODED VIEW
Exploded diagram of the CVT driven pulley assembly, showing numbered components.
PULLEY DISASSEMBLY
Procedure for disassembling the driven pulley, including spring removal.
SPRING DISASSEMBLY
Procedure for disassembling the spring using a disassembly tool, including warnings.
Recommended inspection
Inspection of cam, spring, and sliding sheave bushings for wear.
SLIDING FLANGE MAINTEN
Recommended inspection of cam shoes for wear and replacement of cam shoe screws.
PULLEY RE-ASSEMBLY
Procedure for re-assembling the pulley using a disassembly tool, including sheave and washer installation.
FRONT AND REAR DIFFERENTIAL
Procedures and specifications for front and rear differential systems, including oil replacement and cross joint service.
TECHNICAL SPECIFICATIONS
Specifications for front, rear differential, and rear axle assemblies, including oil type and backlash.
SPECIAL TOOLS
Images of special tools for front and rear differential service.
EXPLODED VIEW OF FRONT AXLE
Exploded diagram of the front axle components, showing numbered fasteners and torque.
Front axle gear oil replacement
Procedures for draining and adding front axle gear oil, including torque and cautions.
Disassemble and replace oil seal
Procedure for removing and replacing oil seals on the front axle assembly.
DISASSEMBLE THE CROSS JOINT
Procedure for disassembling the cross joint using retaining rings and pliers.
DISASSEMBLE AND REPLACE OIL SEAL
Procedure for removing and replacing oil seals on the universal joint fork assembly.
INSTALL THE CROSS JOINT
Procedure for installing the cross joint using retaining rings.
NON-DIFFERENTIAL REAR AXLE GEAR OIL REPLACEMENT
Procedures for draining and adding rear axle gear oil, including torque and cautions.
OIL SEAL REPLACEMENT AND ASSEMBLY
Procedures for replacing and assembling oil seals on the rear axle assembly.
DISASSEMBLE THE CROSS JOINT
Procedure for disassembling the cross joint using retaining rings and pliers.
DISASSEMBLE AND REPLACE OIL SEAL
Procedure for removing and replacing oil seals on the universal joint fork assembly.
INSTALL THE CROSS JOINT
Procedure for installing the cross joint using retaining rings.
FUEL SYSTEM
Procedures and specifications for the fuel system, including fuel tank, filter, and carbon canister.
Fuel Tank Exploded view of Fuel System
Exploded diagram of the fuel system components, showing numbered fasteners.
Fuel tank removal/installation
Procedures for removing and installing the fuel tank, including safety precautions.
Fuel Filter Removal / Installation
Procedures for removing and installing the fuel filter, including clamps and warnings.
CARBON CANISTER ASSEMBLY REMOVAL / INSTALLATION
Procedures for removing and installing the carbon canister assembly, including hoses and bolts.
COOLING SYSTEM
Procedures and specifications for the cooling system, including coolant, thermostat, and radiator.
EXPLODED VIEW OF COOLING SYSTEM
Exploded diagram of the cooling system, showing numbered components.
Torque
Table listing torque specifications for cooling system fasteners.
COOLANT FLOW
Explanation of how coolant circulates through the cooling system, including thermostat and fan operation.
TECHNICAL PARAMETER
Specifications for coolant type, radiator cap pressure, and thermostat operation.
COOLING SYSTEM PRESSURE TEST
Procedure for testing the cooling system pressure, including warnings.
RADIATOR CAP PRESSURE TEST
Procedure for testing the radiator cap's pressure relief valve and seals.
RADIATOR CHECK
Instructions for checking the radiator core and fins for blockages or damage.
RADIATOR REMOVAL / INSTALLATION
Procedures for removing and installing the radiator, including warnings.
Radiator Fan Removal/Installation
Procedures for removing and installing the radiator fan, including torque.
INTAKE / EXHAUST SYSTEM
Procedures and specifications for the intake and exhaust systems, including air filter and mufflers.
Exploded view of intake system
Exploded diagram of the intake system components, showing numbered fasteners.
AIR FILTER REMOVAL
Steps for removing the air filter cover, screws, hose clamps, and the filter itself.
Exploded view of exhaust system
Exploded diagram of the exhaust system components, showing numbered fasteners.
MUFFLERS AND EXHAUST PIPES
Procedures for removing mufflers and exhaust pipes, including warnings about hot surfaces.
DRIVE SYSTEM
Procedures and specifications for the drive system, including driveshafts and universal joints.
EXPLODED VIEW OF DRIVESHAFT (SINGLE CAB VEHICLES)
Exploded diagram of the driveshaft assembly, showing numbered fasteners.
DRIVE SHAFT REMOVAL
Procedures for removing drive shafts, including warnings about dust boots.
Removal of front drive shaft
Steps for removing the front drive shaft assembly, including screws and washers.
Rear drive shaft assembly disassembly
Steps for disassembling the rear drive shaft assembly, including screws and washers.
FRONT AND REAR DRIVE SHAFT
Procedure for installing front and rear drive shaft assemblies.
EXPLODED VIEW OF FRONT AND REAR LEFT/RIGHT CONSTANT VELOCITY DRIVE SHAFTS
Exploded diagram of CV joint assemblies, showing numbered components.
DOJ DRIVE SHAFT REPAIR
Procedures for repairing drive shafts, including cautions about cleanliness and tool usage.
BRAKE SYSTEM
Procedures and specifications for the brake system, including fluid, pads, discs, and troubleshooting.
Exploded view of braking system
Exploded diagram of the braking system, showing numbered fasteners and torque.
Parking brake explosion diagram
Exploded diagram of the parking brake system, showing numbered components.
SPECIFICATIONS
Specifications for brake fluid, pad thickness, disc thickness, runout, and pedal/handle stroke.
Technical Parameters
Technical parameters for brake fluid, pad, and disc specifications.
SPECIAL TOOLS
Image of special tools required for brake system service.
BRAKE FLUID
Precautions for handling brake fluid and general information about disc brake systems.
Brake fluid replacement/brake bleeding
Procedure for changing brake fluid and bleeding the brake lines, including safety warnings.
Foot brake master cylinder repair
Procedure for foot brake master cylinder disassembly and removal.
Handbrake main pump brake fluid filling
Procedure for filling the handbrake master pump with brake fluid, including cautions.
Foot brake master pump brake fluid filling
Procedure for filling the foot brake master pump with brake fluid, including cautions.
Master pump installation
Procedure for installing the master cylinder, including brake lines, bolts, and pedal connection.
FRONT BRAKE ASSEMBLY
Procedures for front brake assembly removal and installation, including fluid checks and bleeding.
FRONT BRAKE CALIPER BODY
Procedures for front brake caliper body removal and disassembly.
Front brake caliper body installation
Procedure for installing the front brake caliper body, including replacement parts and lubrication.
FRONT BRAKE PAD
Procedures for front brake pad removal, installation, and wear inspection.
FRONT BRAKE DISC
Procedures for front brake disc cleaning, removal, installation, and inspection.
REAR BRAKE ASSEMBLY
Procedures for rear brake assembly removal and installation, including fluid checks and bleeding.
REAR BRAKE CALIPER BODY
Procedures for rear brake caliper body removal and disassembly.
Rear brake caliper body installation
Procedure for installing the rear brake caliper body, including replacement parts and lubrication.
REAR BRAKE PAD
Procedures for rear brake pad removal, installation, and wear inspection.
REAR BRAKE DISC
Procedures for rear brake disc cleaning, removal, installation, and inspection.
Brake Hoses
Inspection of brake hoses and procedure for brake hose replacement.
rear brake pedal
Procedure for adjusting brake pedal position and removing/installing the rear brake pedal.
PARKING CABLE
Procedures for parking cable removal and installation.
BRAKE SYSTEM TROUBLESHOOTING
Troubleshooting guide for common brake noises and poor braking performance.
STEERING SYSTEM
Procedures and specifications for the steering system, including wheel, column, and tie rod.
Exploded View of Steering System
Exploded diagram of the steering system components, showing numbered parts.
STEERING WHEEL
Procedures for steering wheel folding and installation, including torque.
STEERING COLUMN
Procedures for steering column removal and mounting, including caution notes.
EPS
Procedures for EPS total disassembly and assembly, including cautions and pin definitions.
STEERING TIE ROD
Procedures for steering tie rod folding and installation, including warnings.
BODY AND FRAME
Procedures and diagrams for body and frame components, including exterior trim, underbody, and engine mounting.
EXPLOSION DIAGRAM OF FRONT EXTERIOR TRIM
Exploded diagram of the front exterior trim components, showing numbered fasteners.
EXPLOSION DIAGRAM OF M IDBODY EXTERIOR TRIM
Exploded diagram of the midbody exterior trim components, showing numbered fasteners.
EXPLOSION DIAGRAM OF REAR EXTERIOR TRIM
Exploded diagram of the rear exterior trim components, showing numbered fasteners.
EXPLOSION DIAGRAM OF UNDERBODY EXTERIOR TRIM
Exploded diagram of the underbody exterior trim components, showing numbered fasteners.
Front shelf cover
Procedure for removing the front shelf cover.
Rear shelf cover
Procedure for removing the rear shelf cover.
Cushion removal
Procedure for removing the cushion.
Mounting cushion
Procedure for aligning and securing cushions.
Front service cover removed
Procedure for removing the front service cover.
Pre-installation service cover
Procedure for aligning and installing the pre-installation service cover.
Air filter cover removed
Procedure for removing the air filter cover.
FRAME BOTTOM MAINTENANCE COVER REMOVED
Procedure for removing the frame bottom maintenance cover.
Remove the right guard plate
Procedure for removing the right guard plate.
Engine disassembly explosion diagram
Exploded diagram of the engine assembly, showing numbered fasteners.
disassembly
Procedures for disassembling components like CVT inlet/outlet pipes and throttle valve.
Front axle maintenance
Procedures for front axle disassembly and assembly, including warnings.
Rear axle maintenance
Procedures for rear axle disassembly and assembly, including cautions.
Front and rear shelf disassembly explosion diagram
Exploded diagram of front and rear shelf components, showing numbered fasteners.
Frame accessory explosion diagram
Exploded diagram of frame accessory components, showing numbered fasteners.
Front bumper explosion diagram
Exploded diagram of the front bumper components, showing numbered fasteners.
Front bumper removal
Procedures for removing the front bumper assembly, including winch motor and trim panel.
ELECTRICAL SYSTEM
Procedures and specifications for the electrical system, including battery, charging, starter, sensors, and wiring.
Exploded View
Exploded diagram of electrical system components, showing numbered fasteners.
Exploded View
Exploded diagram of electrical system components, showing numbered fasteners.
TECHNICAL PARAMETERS
Specifications for battery, charging system, ignition system, electric starter, fuel pump, and switches.
SPECIAL TOOLS
Images of special tools like multimeter and fault diagnosis instrument.
BATTERY
Procedures for removing and installing the battery, including cautions.
Battery charging
Procedures and specifications for charging the battery, including preventive measures.
Charging condition check
Procedure for checking battery terminal voltage and charging status.
GENERATOR INSPECTION
Procedures for checking alternator output voltage and stator coil resistance.
Circuit diagram of charging system
Diagram illustrating the charging system circuit.
VOLTAGE REGULATING RECTIFIER INSPECTION
Procedure for inspecting the voltage regulating rectifier's charging voltage and resistance.
EFI SYSTEM
Schematic diagram of the EFI system, showing major components.
TEMPERATURE SENSOR
Function and working principle of the temperature sensor, including pin definition.
Performance parameter
Specifications for temperature sensor resistance and electrical characteristics.
Fault diagnosis
Troubleshooting steps for temperature sensor failures.
OXYGEN SENSOR
Function and working principle of the oxygen sensor, including pin definition.
Performance parameter
Specifications for oxygen sensor performance characteristics.
Troubleshooting
Troubleshooting steps for oxygen sensor failures, including warnings.
CARBON CANISTER SOLENOID VALVE
Function and technical parameters of the carbon canister solenoid valve, including fault diagnosis.
Electronic control unit（ECU）
Function introduction, electrical characteristics, and fault diagnosis of the ECU.
ECU stitch definition
Definition of ECU pin connections and their descriptions.
ELECTRONIC THROTTLE BODY DVE SELF-LEARNING PROCESS
Procedure for electronic throttle body self-learning, including conditions and fault analysis.
FUEL INJECTOR
Function and working principle of the fuel injector.
Performance parameters
Performance parameters for fuel injector, including static and dynamic flow.
Fault diagnosis
Troubleshooting steps for fuel injector failures.
IGNITION COILS
Function and working principle of the ignition coil.
Performance parameters
Performance parameters for ignition coils, including voltage and resistance.
Fault diagnosis
Troubleshooting steps for ignition coil failures.
REMOVE AND INSTALL SPARK PLUGS
Procedures for removing and installing spark plugs, including torque and cautions.
ENGINE SPEED SENSOR
Function and working principle of the engine speed sensor.
Technical performance test
Testing the speed sensor's output signal.
Fault diagnosis
Troubleshooting steps for engine speed sensor failures.
OIL PRESSURE SENSOR
Function and working principle of the oil pressure sensor, including specifications.
Fault diagnosis
Troubleshooting steps for oil pressure sensor failures.
THROTTLE VALVE BODY ASSEMBLY
Function and components of the throttle valve body assembly.
THREE-IN-ONE SENSOR
Description of the three-in-one sensor, including pin definitions.
IDLE MOTOR
Function and working principle of the idle motor, including pin definition.
Idle motor flow characteristics
Flow characteristics of stepper motors used in idle motor.
Fault diagnosis
Troubleshooting steps for three-in-one sensor and idle motor failures.
FAULT CODE READING
Explanation of fault indicator lights and how to read fault codes.
TROUBLESHOOTER OPERATION
Procedure for using a fault diagnosis instrument to read fault information.
SUMMARY OF FAILURE CODES（ECU）
List of common ECU fault codes, descriptions, and fault indicator status.
LIGHTING SYSTEM CIRCUIT
Diagram of the lighting system circuit, showing components and connections.
HEADLAMPS
Procedures for replacing headlamps, including warnings about LED lamps.
TAIL LAMP
Procedures for replacing tail lamps, including warnings about LED sources.
LICENSE PLATE LAMP
Procedures for removing and replacing the license plate lamp, including cautions.
FLASHER
Procedures for disassembling and assembling the flasher, including testing.
EPS-BRUSHLESS
Disassembly and assembly of the EPS assembly, including cautions and pin definitions.
EPS system wiring schematic diagram
Schematic diagram of the EPS system wiring.
EPS TROUBLE REMOVAL
Troubleshooting steps for EPS system malfunctions, including checking fuses and fault lights.
Dashboard button function introduction
Explanation of dashboard button functions for adjusting brightness, clearing mileage, and settings.
Dashboard disassembly and assembly
Procedures for removing and installing the dashboard, including cautions.
Dashboard Indicator light description
Description of dashboard indicator lights, their functions, fault phenomena, and troubleshooting.
SWITCH
Information on power lock operation and replacement, including cautions.
LEFT HANDLEBAR SWITCH
Description and testing of left handlebar switches, including cautions.
RIGHT HANDLEBAR SWITCH
Description and testing of right handlebar switches, including 2-4WD and 4WD lock functions.
Assembly and disassembly of right handlebar switch
Procedures for removing and installing the right handlebar switch.
WINCH ASSEMBLY
Procedures for removing the winch assembly, including warnings and cautions.
FUSE BOX
Information about the fuse box, including location, removal, and replacement of fuses.
Fuel box label
Label indicating fuse and relay locations and their power ratings.
WIRE HARNESS
Description of wire colors and cautions regarding battery connections and screw tightening.
Wire Harness Assembly
Diagram showing the wire harness assembly and identification of various plugs.
WIRING DIAGRAM
Wiring diagram for the electrical system.
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