Segway 450 ATV 2023 Series Manuals

Manuals and User Guides for Segway 450 ATV 2023 Series. We have 1 Segway 450 ATV 2023 Series manual available for free PDF download: Service Manual

Segway 450 ATV 2023 Series Service Manual (371 pages)

Brand: Segway | Category: Offroad Vehicle | Size: 18 MB

General Information
6
VEHICLE Identification NUMBER/ENGINE SERIAL Code
7
TECHNICAL PARAMETERS of VEHICLE
8
UNIT Conversion TABLE
11
Torque
11
Table of Contents
15
Maintenance
17
Technical Specifications
17
Vehicle Lifting Support Position
18
Maintenance Cycle Table
19
Symbol Description
19
Break-In Maintenance
20
Periodic Maintenance
20
Remaining Lubrication Filling
24
General Vehicle Inspection and Maintenance
25
Engine Maintenance
26
Engine Oil Level Check
26
Engine Oil Emissions
27
Cleaning the Filters
28
Changing the Oil Filter
28
Filling the Engine Oil
29
Engine/Fuel Tank Hose Inspection
30
Engine Cylinder Leakage Test
30
Valve Lash Check
31
Front Gearbox and Rear Gearbox
32
Check Front and Rear Transmission Fluid Levels
32
Front Reduction Gearbox Oil Drain
33
Front Reduction Gearbox Gear Oil Filling
33
Rear Reduction Gearbox Drain
34
Rear Reduction Gearbox Gear Oil Filling
34
Shift Lever Inspection/Adjustment
35
Cooling System
36
Cooling System Overview
36
Cooling System Hoses
36
Radiator Check
37
Coolant Bottle Coolant Level Check and Refill
37
Coolant Replacement
38
Ntake and Exhaust Maintenance
39
Air Filter
39
Air Filter Drain Check
39
Spark Arrestor
40
Exhaust Heat Shield Inspection
40
Fuel System and Air Intake
41
Fuel System
41
Fuel Filter
41
Fuel Line
42
Cvt
43
Cvt Intake Screen Check
43
Cvt Belt
43
Dry Cvt
44
Installation of Drive Belts
44
Drive Shaft Dust Sleeve Inspection
45
Wheel Parts Removal
45
Wheel Mounting
45
Tire Tread Depth
46
Tire Pressure Check
46
Steering Maintenance
47
Steering System Check
47
Power Steering (Eps Models)
47
Transverse Tie Rod Inspection
48
Anterior Beam Check
48
Front Beam Adjustment
49
Shock Absorber
50
Shock Absorber Inspection
50
Adjustable Pneumatic Shock Adjustment
50
Oil Shock Absorber Adjustment
51
Braking System
52
Brake Fluid Level Check on Handbrake Upper Pump
52
Brake Fluid Cup Level Check
53
Brake Linings and Discs
53
Brake Pedal Air Travel Check
54
Parking Handle Working Stroke Check
54
Parking Handle Free Travel Adjustment
54
Electrical and Ignition Systems
55
Battery Maintenance
55
Battery Removal
55
Battery Installation
56
Battery Charging
56
Spark Plugs
57
Spark Plug Check
57
Throttle Cable Free Travel Check and Adjustment
58
Throttle Lever Free Play Check
58
Engine Lubrication System
59
Exploded View
60
Technical Parameter
62
Engine Oil
62
Special TOOLS and SEALANTS
63
OIL Pressure GAUGE, 10 Kgf/CM
63
ENGINE OIL Flow Chart
64
ENGINE OIL and OIL FILTER
65
Oil Level Inspection
65
Engine Oil Change
66
Oil Filter Change
66
Coarse Filter Removal
66
OIL Pressure
67
Oil Pressure Measurement
67
Oil Pressure Valve Removal
68
Oil Pressure Valve Installation
68
Oil Pressure Valve Inspection
68
OIL Pump
69
Oil Pump Removal
69
Oil Pump Installation
69
OIL Pump GEAR
70
Oil Pump Gear Removal
70
Oil Pump Gear Installation
70
Oil Cooler
71
Oil Cooler Removal
71
Oil Cooler Installation
71
Oil Filter Removal
71
Oil Filter Installation
71
Exploded View
73
Technical Parameter
79
Special Tools and Sealants
80
Crankcase
81
Crankcase Disassembly
81
Crankcase Assembly
84
Crankshaft
95
Connecting Rod Big End Side Clearance
95
Crankshaft Runout
95
Crankshaft Main Bearing/Journal Wear
95
Transmission
96
Transmission Removal
96
Transmission Installation
98
Shift Fork Bending
99
Shift Fork/Gear and Shifter Groove Wear
99
Transmission and Shift Mechanism Inspection
100
Ball Bearing, Needle Bearing, and Oil Seal
102
Ball and Needle Bearing Replacement
102
Ball and Needle Bearing Wear
102
Oil Seal Inspection
103
Engine-Electrical System
104
Exploded View
105
Technical Parameter
107
Special Tools
108
Charging SYSTEM
109
Alternator Cover Removal
109
Alternator Cover Installation
109
Alternator Rotor Removal
110
Alternator Rotor Installation
111
Alternator Stator Removal
111
Alternator Stator Installation
112
Alternator Inspection
113
Alternator Output Voltage
113
Stator Coil Resistance
114
Electric Starter System
115
Starter Motor Removal
115
Starter Motor Installation
115
One-Way Clutch Removal
116
One-Way Clutch Installation
116
One-Way Clutch Inspection
116
Starter Gear Removal
117
Starter Gear Installation
117
Engine Cooling System
118
Exploded View
119
Technical Parameter
121
Water Pump
122
Water Pump Removal
122
Water Pump Installation
122
Thermostat
123
Thermostat Removal
123
Thermostat Installation
123
Thermostat Inspection
124
Coolant Temperature Sensor
125
Coolant Temperature Sensor Removal
125
Coolant Temperature Sensor Installation
125
Coolant Temperature Sensor Inspection
125
Engine Top End
126
Exploded View
128
Technical Parameter
131
Special Tools
133
Spark Plug / Valve Cover / Throttle Body / Camshaft
134
Throttle Body
135
Throttle Body Removal
135
Throttle Body Installation
135
Air Intake Pipe Removal
135
Air Intake Pipe Installation
135
Fuel Injector / Thermostat
136
Fuel Injector Removal
136
Fuel Injector Installation
136
IGNITION Coil / Spark Plug
137
Spark Plug Removal
137
Spark Plug Installation
137
Valve Cover
138
Valve Cover Removal
138
Valve Cover Installation
138
Crank POSITION Sensor
139
Crank Position Sensor Removal
139
Camshaft Chain Tensioner
140
Camshaft Chain Tensioner Removal
140
Camshaft Carrier / Camshaft
141
Camshaft Carrier Removal
141
Camshaft Inspection
142
Automatic Compression Release
142
Automatic Compression Release Removal
143
Automatic Compression Release Installation
143
Camshaft Sprocket Installation
143
Camshaft Sprocket Inspection
143
Camshaft / Camshaft Bore Inspection
144
Cam Wear
144
Cylinder Head
145
Cylinder Head Removal
145
Cylinder Head Inspection
145
Cylinder Head Warp
145
Cylinder Head Disassembly
146
Valve Guide / Valve Inspection
147
Combustion Chamber Cleaning
148
Valve Seat Reconditioning
149
Valve Seat Inspection
149
Valve Seat Repair (Valve Lapping)
150
Cylinder and PISTON
153
Cylinder Removal
153
Piston Removal
153
Cylinder, Piston Installation
154
Cylinder Wear
155
Piston Wear
155
Piston/Cylinder Clearance
156
Piston Ring, Piston Ring Groove Wear
156
Piston Ring Groove Width
156
Piston Ring Thickness
156
Piston Ring End Gap
157
Cylinder Head Installation
158
Camshaft Installation / Timing
159
Camshaft Chain Tensioner Installation
160
Valve Clearance Adjustment
161
Valve Lash - Tappet Selection
163
Valve Cover Installation
164
Cylinder Compression Measurement
164
Cylinder Compression
165
Cvt System
166
CVT System Explosion Diagram
167
Special Tools
169
CVT Cover Removal/Installation
170
CVT Cover Removal
170
CVT Cover Lining Installation
170
CVT Cover Installation
170
CVT Inner Cover Removal
171
CVT Inner Cover Installation
171
Drive Belt Removal/Installation
172
Drive Belt Removal
172
Drive Belt Installation
172
Pulleys Geometrical Specifications
172
Drivie and Driven Pulley Removed from the Vehicle
173
Exploded Diagram of Drive Assembly
174
Drive Assembly Disassembly and Installation
175
Pulley Removal from the Vehicle
175
Drive Pulley Disassembly
176
Drive Pulley Re-Assembly
177
Tightening the Pulley
177
Pulley Tightening
178
CVT Driven Pulley Assembly Exploded View
179
Pulley Disassembly
180
Removing the Driven Pulley
180
Spring Disassembly
181
Recommended Inspection
182
Sliding Flange Mainten
183
Recommended Inspection
183
Pulley Re-Assembly
184
Rollers ③ Re-Assembly
185
Technical Specifications
187
Special Tools
188
Exploded View of Front Axle
190
REAR AXLE with DIFFERENTIAL EXPLOSION Diagram
192
Diagram of REAR AXLE EXPLOSION Without DIFFERENTIAL
194
FRONT AXLE Gear OIL Replacement
196
Drain Front Axle Oil
196
Add Front Axle Oil
196
Disassemble and Replace Oil Seal
197
Disassemble the Cross Joint
197
Disassemble and Replace Oil Seal
198
Install the Cross Joint
198
DIFFERENTIAL REAR AXLE Gear OIL Replacement
199
Drain Differential Rear Axle Oil
199
Add Differential Rear Axle Oil
199
Disassemble and Replace Oil Seal
200
Disassemble the Cross Joint
200
Disassemble and Replace Oil Seal
201
NON-DIFFERENTIAL REAR AXLE Gear OIL Replacement
202
Drain Differential Rear Axle Oil
202
Add Differential Rear Axle Oil
202
OIL SEAL Replacement and Assembly
203
Disassemble and Replace Oil Seal
203
Disassemble the Cross Joint
203
Disassemble and Replace Oil Seal
204
Install the Cross Joint
204
Fuel System
205
FUEL Tank Exploded View of FUEL SYSTEM
206
FUEL Tank Removal/Installation
207
Disassembly
207
Installation
207
FUEL Filter Removal / Installation
208
Removal
208
Installation
209
Carbon Canister Assembly Removal / Installation
210
Disassembly
210
Installation
211
Cooling System
212
Exploded View of Cooling System
213
Coolant Flow
214
Technical Parameter
216
Cooling System Pressure Test
217
Radiator Cap Pressure Test
218
Radiator Check
219
Radiator Removal / Installation
219
Radiator Fan Removal/Installation
220
Intake / Exhaust System
221
Exploded View of INTAKE SYSTEM
222
Air Filter Removal
223
Start by Placing the Car in a Horizontal Position
223
Mounting
223
Exploded View of EXHAUST SYSTEM
224
Mufflers and EXHAUST Pipes
225
Muffler Removal
225
Probe
226
Mounting
226
Drive System
227
Exploded View of Driveshaft (Single Cab Vehicles)
228
Drive Shaft Removal
229
Removal of Front Drive Shaft
230
Rear Drive Shaft Assembly Disassembly
230
Front and Rear Drive Shaft
230
Exploded View of Front and Rear Left/Right Constant Velocity Drive Shafts
231
Doj Drive Shaft Repair
232
Exploded Diagram of Front Suspension
236
Rear Suspension Explosion Diagram
237
Technical Parameter
238
Dedicated Tools
239
Shock Absorber
240
Shock Absorber Inspection
240
Ordinary Hydraulic Damping and Shock Absorption Preload Adjustment
240
Spring Adjustment Table
240
Air Damping Shock Preload Adjustment
240
Measure the Free Length of the Spring
241
Shock Absorber Damping Adjustment
241
Compression Damping Adjustment
241
Recovery Damping Adjustment
242
Shock Absorber Removal
242
Front Shock Absorber Installation
242
Rear Shock Absorber Scrapped
243
Adjustable Gas Shock Absorber Inspection
243
Suspension
244
Removal of the Rocker Arm
244
Disassembly of Rocker Arm
245
Rocker Arm Maintenance
246
Hub Bearing Replacement
247
Disassembly of Rear Axle Support Assembly
247
Rear Balance Bar
248
Rear Stabilizer Bar Disassembly
248
Rear Stabilizer Bar Maintenance
248
Brake System
250
Exploded View of Braking SYSTEM
251
Parking BRAKE Explosion Diagram
252
Specifications
252
Technical Parameters
253
Special Tools
253
BRAKE Fluid
254
Brake Fluid Replacement/Brake Bleeding
254
Foot BRAKE MASTER Cylinder Repair
256
Foot Brake Master Cylinder Disassembly
256
Handbrake Main Pump BRAKE Fluid Filling
257
Foot BRAKE MASTER Pump BRAKE Fluid Filling
257
Master Pump Installation
258
Front BRAKE Assembly
259
Removal of Front Brake Assembly
259
Front Brake Assembly Installation
259
Front BRAKE Caliper Body
260
Front Brake Caliper Body Removal
260
Front BRAKE Caliper Body Installation
261
Front BRAKE Pad
262
Front Brake Pad Removal
262
Front Brake Pad Installation
262
Front Brake Pad Wear Inspection
262
Front BRAKE Disc
263
Front Brake Disc Cleaning
263
Front Brake Disc Removal
263
Front Brake Disc Installation
263
Front Brake Disc Inspection
263
REAR BRAKE Assembly
264
Rear Brake Assembly Removal
264
Rear Brake Assembly Installation
264
REAR BRAKE Caliper Body
265
Rear Brake Caliper Body Removal
265
Rear Brake Caliper Body Installation
266
REAR BRAKE Pad
267
Rear Brake Pad Removal
267
Rear Brake Pad Installation
267
Rear Brake Pad Wear Inspection
267
REAR BRAKE Disc
268
Rear Brake Disc Cleaning
268
Rear Brake Disc Removal
268
Rear Brake Disc Installation
268
Rear Brake Disc Inspection
268
BRAKE Hoses
269
Brake Hose Inspection
269
REAR BRAKE Pedal
269
Brake Pedal Position Adjustment
269
Rear Brake Pedal Removal
269
Installation of Rear Brake Pedal
269
Parking Cable
270
Parking Cable Removal
270
Installation of Parking Cable
270
Troubleshooting Brake Noise
271
BRAKE SYSTEM Troubleshooting
271
Exploded View of STEERING SYSTEM
274
STEERING Wheel
276
Steering Wheel Folding
276
Steering Wheel Installation
276
STEERING Column
277
Steering Column Removal
277
Steering Column Mounting
277
Eps
278
STEERING TIE Rod
279
Steering Rod Folding
279
Steering Tie Rod Installation
279
Body and Frame
281
Explosion Diagram of Front Exterior Trim
281
Explosion Diagram of Midbody Exterior Trim
283
Explosion Diagram of REAR Exterior Trim
285
Explosion Diagram of Underbody Exterior Trim
286
Front Shelf Cover
287
Rear Shelf Cover
287
Cushion Removal
287
Mounting Cushion
287
Front Service Cover Removed
287
Pre-Installation Service Cover
287
Air Filter Cover Removed
288
Mounting Cushion
288
Frame Bottom Maintenance Cover Removed
288
Remove the Right Guard Plate
288
Disassembly
290
Disassembly
295
Assembly
295
Front Axle Maintenance
295
REAR Axle Maintenance
296
Disassembly
296
Assembly
296
Front and REAR Shelf Disassembly Explosion Diagram
297
Frame Accessory Removed
299
Front Bumper Explosion Diagram
300
Front Bumper Removal
301
Electrical System
305
Exploded View
305
Technical Parameters
308
Special Tools
309
Battery
310
Remove the Battery
310
Remove the Battery
313
BATTERY Charging
313
Charging Condition Check
313
Generator Inspection
314
Voltage Regulating Rectifier Inspection
316
Efi System
317
Schematic Diagram of Efi System
317
Temperature Sensor
318
Function Introduction
318
Working Principle
318
Performance Parameter
319
Fault Diagnosis
319
Oxygen Sensor
320
Function Introduction
320
Working Principle
320
Performance Parameter
321
Electrical Characteristic Parameter
321
Carbon Canister Solenoid VALVE
323
Function Description
323
Function Introduction
324
Electrical Characteristics
324
Fault Diagnosis
324
Ecu Stitch Definition
325
Electronic Throttle Body Dve Self-Learning Process
326
Fuel Injector
326
Performance Parameters
327
Fault Diagnosis
327
Ignition Coils
328
Working Principle
328
Performance Parameters
329
Fault Diagnosis
329
Remove and Install Spark Plugs
330
Engine Speed Sensor
331
Technical Performance Test
331
Fault Diagnosis
331
Oil Pressure Sensor
332
Fault Diagnosis
332
Throttle VALVE Body ASSEMBLY
333
Three-In-One Sensor
333
Three-In-One Sensor Performance Characteristics
334
Idle Motor
335
Idle Motor Flow Characteristics
336
Fault Diagnosis
336
Idle Motor Fault Check
336
Fault Code Reading
337
Troubleshooter Operation
337
Summary of Failure Codes（Ecu
338
Lighting SYSTEM Circuit
340
Headlamps
341
TAIL Lamp
342
Tail Lamp 1
342
Tail Lamp 2
342
License Plate Lamp
343
Remove
343
Flasher
344
Disassembly
344
Eps-Brushless
345
Eps System Wiring Schematic Diagram
346
Eps Trouble Removal
347
Troubleshooting
347
Display and Human-Computer Interaction
349
Dashboard
349
Dashboard Indicator Light Description
350
Instrument Information Display
352
Dashboard Disassembly and Assembly
355
T-Box
357
T-Box Fault Code Display Area
357
T-Box Interface Definition
358
Switch
359
Power Lock
359
Left Handlebar Switch
360
Assembly and Disassembly of Left Handlebar Switch
362
Right Handlebar Switch
363
Assembly and Disassembly of Right Handlebar Switch
363
Winch ASSEMBLY
364
Removal
364
Fuse Box
367
Wire Harness
369
Wire Harness Assembly
370
Wiring Diagram
371

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Segway 450 ATV 2023 Series Manuals

Segway 450 ATV 2023 Series Service Manual (371 pages)

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