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Table of Contents
Troubleshooting
Related Manuals for Segway SGW500F-A6 2023
Summarization of Contents
General Information
Vehicle Identification Number/Engine Serial Code
Details on vehicle identification number (VIN) and engine serial number location and purpose.
Technical Parameters of Vehicle
Specifications for vehicle dimensions, weight, engine, transmission, tires, and brakes.
Unit Conversion Table
Converts units for torque, pressure, power, volume, speed, and temperature.
Torque
Lists tightening torques for major fasteners and parts requiring non-permanent locking agent.
Maintenance
Technical Specifications
Details general and fluid specifications for maintenance, including tire pressure and brake disc thickness.
Vehicle Lifting Support Position
Illustrates correct positions for lifting the vehicle using jacks.
Maintenance Cycle Table
Describes periodic maintenance schedules, symbols for service, and definitions of heavy use.
Break-in Maintenance
Outlines maintenance tasks and intervals for the initial break-in period.
Periodic Maintenance
Details regular maintenance items, intervals (hours, calendar, miles), and required remarks.
Remaining Lubrication Filling
Specifies lubrication points, number of locations, and annotations for filling grease.
General Vehicle Inspection and Maintenance
Outlines daily pre-ride inspections and checks required during scheduled maintenance.
Engine Maintenance
Covers engine oil level checks, emissions, filter cleaning, and oil changes.
Front Gearbox and Rear Gearbox
Instructions for checking front and rear transmission fluid levels and oil replacement.
Cooling System
Details cooling system overview, hoses, radiator checks, coolant replacement, and fan.
Intake and Exhaust Maintenance
Covers air filter replacement, drain checks, spark arrestor, and exhaust heat shield inspection.
Fuel System and Air Intake
Information on fuel system components, fuel filter, and vent lines.
Drive Shaft Maintenance / Tires
Procedures for inspecting drive shaft dust sleeves and wheel parts removal/mounting.
Tire Tread Depth
Guidance on checking tire tread wear and replacement criteria.
Tire Pressure Check
Steps for checking tire pressure and guidelines for accurate readings.
Steering Maintenance
Covers steering system checks, power steering maintenance, and tie rod inspection.
Front Beam Adjustment
Procedure for adjusting the front beam value to ensure proper alignment.
Shock Absorber
Details on shock absorber inspection and adjustable pneumatic shock adjustments.
Braking System
Covers brake fluid checks, brake pad/disc wear, pedal adjustments, and troubleshooting.
Electrical and Ignition Systems
Information on battery maintenance, removal, installation, charging, and spark plugs.
Engine Lubrication System
Exploded View
Detailed exploded view of the engine lubrication system components.
Technical Parameter
Specifies engine oil grade, viscosity, capacity, and oil pressure measurement standards.
Special tools and sealants
Lists special tools required for oil pressure testing and sealant applications.
Engine Oil Flow Chart
Diagram illustrating the flow path of engine oil through the lubrication system.
Engine Oil and Oil Filter
Guidance on checking engine oil level and precautions for oil changes.
Engine Oil Change
Reference for engine oil and oil filter changes within the periodic maintenance chapter.
Oil Filter Change
Reference for oil filter changes within the periodic maintenance chapter.
Coarse Filter Removal
Procedure for removing the coarse filter from the crankcase.
Oil Pressure
Covers oil pressure measurement and related components.
Oil Pump
Details on oil pump removal and installation procedures.
Oil Pump Gear
Instructions for checking oil pump shaft rotation and gear removal/installation.
Oil Cooler
Procedures for oil cooler removal, installation, and oil filter replacement.
Crankshaft / Transmission
Exploded view
Exploded diagrams of the crankshaft and transmission components.
Technical Parameter
Specifies standard and service limit values for transmission components like shift forks.
Special tools and sealants
Lists special tools such as circlip pliers and bearing driver sets for transmission work.
Crankcase
Covers crankcase disassembly and assembly procedures.
Crankshaft
Details on measuring crankshaft and connecting rod clearances, runout, and bearing wear.
Transmission
Procedures for transmission removal, installation, and inspection of gears and shift forks.
Ball Bearing, Needle Bearing, and Oil Seal
Guidance on replacing and inspecting ball bearings, needle bearings, and oil seals.
Engine Top End
Technical Parameter
Provides standard and service limit specifications for cylinder head, piston, rings, and camshafts.
Special tools
Lists special tools required for engine top end work, such as compression gauges.
Spark Plug / Valve Cover / Throttle Body / Camshaft
Covers removal and installation procedures for spark plugs, valve covers, throttle bodies, and camshafts.
Throttle Body
Details on throttle body and air intake pipe removal and installation procedures.
Fuel Injector / Thermostat
Covers fuel injector and thermostat removal, installation, and inspection.
Ignition Coil / Spark Plug
Procedures for removing, installing, and inspecting ignition coils and spark plugs.
Valve Cover
Instructions for removing and installing the valve cover, including insulator and seal replacement.
Crank Position Sensor
Procedures for removing and installing the crank position sensor and related components.
Camshaft Chain Tensioner
Details on camshaft chain tensioner removal and installation, including cautions.
Camshaft Carrier / Camshaft
Procedures for removing the camshaft carrier and camshafts, including timing marks.
Camshaft Inspection
Inspection of automatic compression release mechanism and camshafts for wear.
Camshaft Sprocket Installation
Instructions for installing camshaft sprockets and applying locking agent.
Camshaft / Camshaft Bore Inspection
Guidance on inspecting camshaft lobe height, journals, and bore wear.
Cylinder Head
Procedures for cylinder head removal, inspection, and checking for warp.
Cylinder Head Disassembly
Detailed steps for disassembling the cylinder head, including valve components.
Valve Guide / Valve Inspection
Instructions for measuring valve spring free length and checking valve guide/valve clearance.
Combustion Chamber Cleaning
Procedures for cleaning combustion chambers and valve seat areas.
Valve Seat Reconditioning
Guidance on valve seat reconditioning techniques and inspection of seating patterns.
Valve Seat Repair (Valve Lapping)
Detailed steps for valve seat repair using lapping tools and cutters.
Cylinder and Piston
Procedures for cylinder and piston removal, ring installation, and checking clearances.
Cylinder Wear
Methods for measuring cylinder inside diameter and checking for wear.
Piston Wear
Instructions for measuring piston outside diameter and checking for wear.
Piston/Cylinder Clearance
Calculation of piston to cylinder clearance by subtracting diameters.
Piston Ring, Piston Ring Groove Wear
Checking for uneven groove wear and measuring ring/groove clearance.
Piston Ring Groove Width
Measurement of piston ring groove width using a vernier caliper.
Piston Ring Thickness
Measurement of piston ring thickness using a micrometer.
Piston Ring End Gap
Procedure for measuring piston ring end gap inside the cylinder.
Cylinder Head Installation
Steps for installing the cylinder head assembly and tightening bolts with specified torque.
Camshaft Installation / Timing
Procedure for installing camshafts and aligning timing marks for proper engine timing.
CVT System
CVT system explosion diagram
Exploded diagram of the Continuously Variable Transmission (CVT) system components.
Special tools
Lists special tools required for CVT system maintenance, such as pliers and retainers.
CVT cover removal/installation
Procedures for removing and installing the CVT outer cover and lining.
Drive belt removal/installation
Instructions for removing and installing the drive belt, including alignment checks.
Drive and Driven Pulley Removed from the Vehicle
Disassembly steps for drive and driven pulleys, including cautions for left-hand threads.
Drive assembly disassembly and installation
Steps for removing and installing the drive pulley using specialized tools.
Drive Pulley Disassembly
Inspection and replacement procedures for drive pulley components like blocks and cap shoes.
Drive Pulley Re-Assembly
Instructions for re-assembling the drive pulley, aligning sheaves, and tightening nuts.
Pulley Tightening
Procedure for tightening fixation bolts and drive pulley nuts with proper tools.
CVT Driven Pulley Assembly Exploded view
Exploded diagram and parts list for the CVT driven pulley assembly.
Pulley Disassembly
Steps for disassembling the driven pulley, including spring and cam removal.
Spring disassembly
Detailed procedure for disassembling the spring using a specialized tool.
Recommended inspection
Inspection of cam, spring, and sliding sheave bushings for wear.
Sliding Flange Mainten
Inspection and replacement of cam shoes on the sliding flange.
Pulley Re-assembly
Instructions for re-assembling the pulley using the disassembly tool.
Front and Rear Differential
Technical Specifications
Specifications for front and rear axle assemblies, including oil type, volume, and backlash.
Special Tools
Lists special tools required for differential work, such as Allen wrenches and sealants.
Exploded View of Front Axle
Exploded diagram of the front axle components with fastener torque values.
Front Axle Gear Oil Replacement
Procedures for draining and adding front axle gear oil, including oil seal replacement.
Differential Rear Axle Gear Oil Replacement
Steps for draining and adding rear axle gear oil for differential assemblies.
Non-differential Rear Axle Gear Oil Replacement
Procedures for draining and adding gear oil for non-differential rear axles.
Oil Seal Replacement and Assembly
Instructions for disassembling and replacing oil seals on differential components.
Fuel System
Fuel Tank Exploded view of Fuel System
Exploded diagram of the fuel system, including fuel tank and related components.
Fuel tank removal/installation
Procedures for removing and installing the fuel tank, including safety precautions.
Fuel Filter Removal / Installation
Steps for removing and installing the fuel filter, including clamp replacement.
Carbon Canister Assembly Removal / Installation
Procedures for removing and installing the carbon canister assembly and related tubes.
Cooling System
Exploded view of cooling system
Exploded diagram of the cooling system components.
Coolant Flow
Explanation of coolant circulation, thermostat operation, and radiator fan control.
Technical Parameter
Specifications for coolant type, color, mixing ratio, radiator cap relief pressure, and thermostat.
Cooling system pressure test
Procedure for testing the cooling system pressure using a pressure tester.
Radiator cap pressure test
Method for testing the radiator cap's pressure relief valve standard.
Radiator check
Instructions for checking the radiator core, fins, and obstructions.
Radiator Removal / Installation
Steps for removing and installing the engine radiator, including safety precautions.
Radiator Fan Removal/Installation
Procedures for removing and installing the radiator fan assembly.
Intake / Exhaust System
Exploded view of intake system
Exploded diagram of the intake system components.
Air filter removal
Steps for removing the air filter cover, screws, and the filter itself.
Exploded view of exhaust system
Exploded diagram of the exhaust system components.
Mufflers and exhaust pipes
Procedures for removing mufflers and exhaust pipes, including safety warnings.
Probe
Inspection of muffler for cracks, holes, looseness, and carbon buildup.
Drive System
Exploded View of Driveshaft (Single Cab Vehicles)
Exploded diagram of driveshaft components for single cab vehicles.
Drive Shaft Removal
General procedures for removing drive shafts, including cautions.
Removal of Front Drive Shaft
Steps for removing the front drive shaft assembly.
Rear Drive Shaft Assembly Disassembly
Procedure for disassembling the rear drive shaft assembly.
Front and Rear Drive Shaft
Instructions for installing front and rear drive shaft assemblies.
Exploded View of Front and Rear Left/Right Constant Velocity Drive Shafts
Exploded diagrams of CV joint components.
DOJ Drive Shaft Repair
Guidance on repairing drive shafts, emphasizing cleanliness and proper tool usage.
Brake System
Exploded view of braking system
Exploded diagram of the front and rear braking systems.
Parking brake explosion diagram
Exploded diagram of the parking brake components.
Specifications
Standard and service limit specifications for brake fluid, pads, discs, and pedal travel.
Technical Parameters
Technical specifications for brake fluid, pad thickness, disc parameters, and pedal/handle stroke.
Special Tools
Lists special tools required for brake system maintenance, such as circlip pliers.
Brake Fluid
Precautions and procedures for brake fluid replacement and brake bleeding.
Foot brake master cylinder repair
Steps for disassembling the foot brake master cylinder.
Front brake assembly
Procedures for removing and installing the front brake assembly, including fluid checks.
Front brake caliper body
Steps for removing and installing the front brake caliper body.
Front brake pad
Procedures for front brake pad removal, installation, and wear inspection.
Front brake disc
Instructions for cleaning, removing, installing, and inspecting front brake discs.
Rear brake assembly
Procedures for removing and installing the rear brake assembly, including fluid checks.
Rear brake caliper body
Steps for removing and installing the rear brake caliper body.
Rear brake pad
Procedures for rear brake pad removal, installation, and wear inspection.
Rear brake disc
Instructions for cleaning, removing, installing, and inspecting rear brake discs.
Brake Hoses
Guidance on brake hose inspection and replacement.
Rear brake pedal
Procedures for adjusting rear brake pedal position and removal/installation.
Parking Cable
Steps for removing and installing the parking cable.
Brake System Troubleshooting
Troubleshooting guide for common brake noise issues and poor braking performance.
Steering System
Exploded View of Steering System
Exploded diagram of the steering system components.
Steering Wheel
Details on steering wheel folding, installation, and torque specifications.
Steering Column
Procedures for steering column removal and mounting.
EPS
Information on EPS total disassembly and assembly mounting.
Steering Tie Rod
Instructions for steering rod folding and installation, including cautions.
Body and Frame
Explosion diagram of front exterior trim
Exploded diagram of front exterior trim components.
Explosion diagram of midbody exterior trim
Exploded diagram of midbody exterior trim components.
Explosion diagram of rear exterior trim
Exploded diagram of rear exterior trim components.
Explosion diagram of underbody exterior trim
Exploded diagram of underbody exterior trim components.
Front shelf cover
Procedure for removing the front shelf cover.
Rear shelf cover
Procedure for removing the rear shelf cover.
Cushion removal
Steps for removing the seat cushion.
Front service cover removed
Procedure for removing the front service cover.
Air filter cover removed
Steps for removing the air filter cover.
Frame bottom maintenance cover removed
Procedure for removing the frame bottom maintenance cover.
Remove the right guard plate
Steps for removing the right guard plate.
Engine disassembly explosion diagram
Exploded diagram of engine mounting and related components.
disassembly
Disassembly procedures for CVT related parts like inlet and outlet pipes.
Front and rear axle disassembly explosion diagram
Exploded diagram of front and rear axle components.
Front axle maintenance
Procedures for front axle disassembly and assembly, including drive shaft mounting.
Rear axle maintenance
Steps for rear axle assembly disassembly and assembly.
Front and rear shelf disassembly explosion diagram
Exploded diagram of front and rear shelf components.
Frame accessory explosion diagram
Exploded diagram of frame accessory components.
Frame accessory removed
Procedures for removing frame accessories like storage boxes and guards.
Front bumper explosion diagram
Exploded diagram of the front bumper components.
Front bumper removal
Steps for removing the front bumper assembly and related components.
Electrical System
Exploded View
Exploded diagrams of electrical system components.
Technical Parameters
Provides standard and use limit values for battery, charging system, ignition, starter, fuel pump, and switches.
Special Tools
Lists special tools required for electrical system diagnostics, such as multimeters.
Battery
Instructions for battery removal, turning off ignition, and battery model identification.
Battery charging
Guidance on initial charging conditions, charging methods, and preventive measures.
Charging condition check
Methods 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
Schematic diagram of the charging system including alternator, regulator, and battery.
Voltage regulating rectifier inspection
Test and judgment methods for charging voltage and output resistance characteristics.
EFI system
Schematic diagram of the EFI system, showing major components.
Temperature Sensor
Function introduction, working principle, performance parameters, and fault diagnosis of the temperature sensor.
Oxygen sensor
Function introduction, working principle, and electrical connector pin definitions of the oxygen sensor.
Fuel injector
Information on fuel injector function, working principle, performance parameters, and fault diagnosis.
Ignition coils
Explanation of ignition coil function, working principle, and performance parameters.
Engine speed sensor
Working principle, technical performance test, and fault diagnosis for the engine speed sensor.
Oil Pressure Sensor
Function introduction, working principle, and fault diagnosis for the oil pressure sensor.
Throttle valve body assembly
Details on throttle valve body assembly, three-in-one sensor, and their functions.
Idle motor
Explanation of the idle motor's composition, working principle, and pin definitions.
Fault code reading
Information on the instrument's fault indicator and how to read fault codes.
Troubleshooter operation
Procedure for using a fault diagnosis instrument to read and analyze fault information.
Summary of failure codes (ECU)
List of common ECU fault codes, descriptions, and fault indicator status.
Lighting system circuit
Schematic diagram of the lighting system, including battery, fuses, relays, and switches.
Headlamps
Instructions for replacing LED headlamps and adjusting beam height.
Tail lamp
Procedures for replacing tail lamp assemblies.
License plate lamp
Instructions for removing and replacing the LED license plate lamp.
Flasher
Disassembly and assembly of the flasher, including testing procedures.
EPS-brushless
Information on EPS assembly, connector pin definitions, and cautions.
EPS system wiring schematic diagram
Wiring schematic diagram for the Electric Power Steering (EPS) system.
EPS trouble removal
Troubleshooting guide for EPS issues, including checking fuses and fault lights.
Dashboard
Overview of the dashboard display and key information provided to the user.
Dashboard Indicator light description
Explanation of dashboard indicator lights, their functions, faults, and troubleshooting.
Dashboard button function introduction
Guide to dashboard buttons for functions like brightness, trip clear, and clock settings.
Dashboard disassembly and assembly
Procedures for removing and installing the vehicle dashboard.
T-BOX
T-BOX fault code display area
Lists common T-BOX fault codes and their descriptions.
T-BOX Interface Definition
Defines the pin descriptions and notes for the T-BOX interface.
Switch
Power lock
Information on power lock function, checks, and replacement procedures.
Left handlebar switch
Details on left handlebar switch functions, testing, and assembly/disassembly.
Right handlebar switch
Information on right handlebar switch functions, testing, and assembly/disassembly.
Winch assembly
Procedures for removing and installing the winch assembly.
Fuse Box
Fuse Box Label
Diagram and list of fuses and relays in the fuse box.
Wire Harness
Description of wire colors
Guide to wire colors used in the harness assembly.
Wire Harness Assembly
Diagram illustrating the wire harness assembly and connector identification.
Wiring Diagram
Complete wiring diagram for the vehicle's electrical system.
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