Segway SNARLER ATV 2021 Series Manuals

Manuals and User Guides for Segway SNARLER ATV 2021 Series. We have 1 Segway SNARLER ATV 2021 Series manual available for free PDF download: Service Manual

Segway SNARLER ATV 2021 Series Service Manual

Segway SNARLER ATV 2021 Series Service Manual (386 pages)

Brand: Segway | Category: Offroad Vehicle | Size: 40.09 MB

Table of Contents

General Information

7
- Vehicle Identification Number
  8
- Technical Parameters of Vehicle
  9
- Unit Conversion Table
  12
- Torque
  12
Maintenance

16
- Table of Contents
  16
- Maintenance Periodic Table
  18
- Check and Adjust Free Play of Throttle Cable
  21
- Throttle Lever Free Play Inspection
  21
- Cleaning or Replacing Air Fi Lter
  22
- Brake System
  23
- Inspection of Front Brake Hose and Connection
  23
- Check Fl Uid Level of Front Brake Oil Cup
  24
- Replace Brake Hose
  24
- Check Rear Brake Oil Cup Liquid Level
  25
- Pump out Brake Fl Uid from Brake System
  25
- Replace Brake Fluid
  25
- Refill Brake Fluid
  26
- Discharge Air in the Brake System
  27
- Replace of Front Brake Disc
  28
- Replace of Rear Brake Disc
  28
- Check Cylinder
  29
- Check Free Play of Rear Brake Pedal
  30
- Adjustment of Free Play of Parking Handle
  31
- Check Rear Parking Handle Work Play
  31
- Cooling System
  32
- Radiator Cleaning
  32
- Radiator Hose and Connection Inspection
  32
- Adding Cooling Liquid
  33
- Engine Oil Level Check
  34
- Changing Engine Oil&Fi Lter
  35
- Oli Strainer Clean
  35
- Front/Rear Axle Gear Oil
  36
- Oil Fi Lter Change
  36
- Tire Inspection
  37
Engine Lubrication System

38
- Exploded View
  39
- Technical Parameter
  41
- Special Tools and Sealant
  42
- Engine Oil Flow Chart
  43
- Engine Oil and Oil Filter
  44
- Oil Level Inspection
  44
- Engine Oil Change
  45
- Oil Filter Change
  45
- Oil Pressure Measurement
  46
- Oil Pressure Valve
  47
- Oil Pressure Valve Inspection
  47
- Oil Pressure Valve Installation
  47
- Oil Pressure Valve Removal
  47
- Oil Pump
  48
- Oil Pump Installation
  48
- Oil Pump Removal
  48
- Oil Pump Gear
  49
- Oil Pump Gear Installation
  49
- Oil Pump Gear Removal
  49
- Oil Cooler
  50
- Oil Cooler Installation
  50
- Oil Cooler Removal
  50
Crankshaft / Transmission

51
- Exploded View
  52
- Crankcase
  61
- Crankcase Disassembly
  61
- Crankcase Assembly
  64
- Connecting Rod Big End Side Clearance
  75
- Crankshaft Main Bearing/Journal Wear
  75
- Crankshaft Runout
  75
- Transmission
  76
- Transmission Removal
  76
- Transmission Installation
  78
- Shift Fork Bending
  79
- Shift Fork/Gear and Shifter Groove Wear
  79
- Transmission and Shift Mechanism Inspection
  80
- Ball and Needle Bearing Replacement
  82
- Ball and Needle Bearing Wear
  82
- Ball Bearing, Needle Bearing, and Oil Seal
  82
- Oil Seal Inspection
  83
Engine-Electrical System

84
- Exploded View
  85
- Technical Parameter
  87
- Special Tools
  88
- Alternator Cover Installation
  89
- Alternator Cover Removal
  89
- Charging System
  89
- Alternator Rotor Removal
  90
- Alternator Rotor Installation
  91
- Alternator Stator Removal
  91
- Alternator Stator Installation
  92
- Alternator Inspection
  93
- Electric Starter System
  95
- Starter Motor Installation
  95
- Starter Motor Removal
  95
- Starter Gear Assembly
  97
Engine-Cooling System

98
- Exploded View
  99
- Technical Parameter
  101
- Special Tools
  102
- Water Pump
  103
- Water Pump Installation
  103
- Water Pump Removal
  103
- Impeller Removal
  104
- Water Pump Cover Removal
  104
- Water Pump Impeller Inspection
  104
- Mechanical Seal Replacement
  105
- Water Pump Shaft Removal
  105
- Water Pump Cover Installation
  107
- Thermostat
  108
- Thermostat Installation
  108
- Thermostat Inspection
  109
- Coolant Temperature Sensor
  110
- Coolant Temperature Sensor Inspection
  110
- Coolant Temperature Sensor Installation
  110
- Coolant Temperature Sensor Removal
  110
Engine Top End

111
- Exploded View
  113
- Special Tools
  119
- Spark Plug / Valve Cover / Throttle Body / Camshaft
  120
- Air Intake Pipe Installation
  121
- Air Intake Pipe Removal
  121
- Throttle Body Installation
  121
- Throttle Body Removal
  121
- Fuel Injector Installation
  122
- Fuel Injector Removal
  122
- Spark Plug Inspection
  123
- Spark Plug Installation
  123
- Spark Plug Removal
  123
- Valve Cover Installation
  124
- Valve Cover Removal
  124
- Crank Position Sensor Removal
  125
- Camshaft Chain Tensioner Installation
  126
- Camshaft Chain Tensioner Removal
  126
- Camshaft Carrier Removal
  127
- Automatic Compression Release
  128
- Automatic Compression Release Installation
  129
- Automatic Compression Release Removal
  129
- Camshaft Sprocket Inspection
  129
- Camshaft Sprocket Installation
  129
- Cam Wear
  130
- Cylinder Head
  131
- Cylinder Head Inspection
  131
- Cylinder Head Removal
  131
- Cylinder Head Warp
  131
- Cylinder Head Disassembly
  132
- Valve Guide / Valve Inspection
  133
- Combustion Chamber Cleaning
  134
- Valve Seat Inspection
  135
- Valve Seat Reconditioning
  135
- Valve Seat Repair (Valve Lapping)
  136
- Cylinder and Piston
  139
- Cylinder Removal
  139
- Cylinder, Piston Installation
  140
- Piston Wear
  141
- Piston Ring Groove Width
  142
- Piston Ring Thickness
  142
- Piston Ring, Piston Ring Groove Wear
  142
- Piston/Cylinder Clearance
  142
- Piston Ring End Gap
  143
- Cylinder Head Installation
  144
- Camshaft Installation / Timing
  145
- Camshaft Chain Tensioner Installation
  146
- Valve Clearance Adjustment
  147
- Valve Lash - Tappet Selection
  149
- Cylinder Compression Measurement
  150
- Valve Cover Installation
  150
Cvt System

152
- Exploded View
  153
- Special Tools
  158
- CVT Cover
  159
- CVT Inner Cover Disassembly
  160
- CVT Inner Cover Installation
  160
- CVT Inner Cover Removal
  160
- Drive Belt
  161
- Drive Belt Inspection
  161
- Drive Belt Installation
  161
- Drive Pulley and Driven Pulley
  162
- Drive Pulley and Driven Pulley Removal
  162
- Drive Pulley Disassembly
  163
- Drive Pulley Inspection
  164
- Drive Pulley Assembly
  166
- Driven Pulley Disassembly
  168
- Driven Pulley Inspection
  169
- Driven Pulley Assembly
  170
- Drive Pulley and Driven Pulley Installation
  172
Front and Rear Differential

174
- Add Gear Oil
  193
- Drain Gear Oil
  193
- Rear Diff Erential Gear Oil Replacement
  193
- Assemble
  197
- Disassemble
  197
- Inspection of Parts Wear
  197
- Oil Seal 37×55×7
  197
- Assemble
  198
- Assemble
  199
- Disassemble
  199
- Tooth Gap Adjustment
  199
- Assemble
  200
- Disassemble
  200
- Solenoid Valve Assembly Inspection and Replacement
  200
Fuel System

201
- Exploded View of Fuel System
  202
- Assembly
  203
- Disassembly
  203
- Fuel Tank
  203
- Disassembly
  204
- Fuel Pump
  204
- Inspection
  204
- Assembly
  205
- Assembly
  206
- Disassembly
  206
- Fuel Filter
  206
Cooling System

207
- Exploded View of Cooling System
  208
- Coolant Flow
  209
- Technical Parameter
  211
- Coolant
  213
- Coolant Deterioration Inspection
  213
- Coolant Level Check
  213
- Pressure Test
  214
- Radiator Removal
  215
- Radiator Fan Installation
  216
- Radiator Fan Removal
  216
- Radiator Cap Inspection
  217
- Radiator Cleaning
  217
- Radiator Inspection
  217
Intake / Exhaust System

218
- Exploded View of Intake System
  219
- Disassemble Air Filter
  220
- Exploded View of Exhaust System
  221
- Muffl er and Exhaust Pipe
  222
- Muffl er Disassembly
  222
- Assembly
  223
- Exhaust Pipe Disassembly
  223
- Inspection
  223
Front & Rear Suspension

229
- Exploded View of Front Suspension
  230
- Exploded View of Rear Suspension
  232
- Technical Parameter
  234
- Absorber Inspection
  236
- Normal Hydraulic Damping Absorber Preloading Adjustment
  236
- Shock Absorber
  236
- Absorber Damping Adjustment
  237
- Measure Free Length of Spring
  237
- Absorber Disassembly
  238
- Rebound Damping Adjustment
  238
- Suspension
  240
- Rocker Arm Assembly
  241
- Rocker Arm Disassembly
  241
- Rocker Arm Maintenance
  242
- Rear Stabilizer Bar Maintenance
  244
Wheels and Tires

245
- Exploded View of Wheels and Tires
  246
- Technical Parameters
  248
- Special Tools
  249
- Front Beam Inspection
  250
- Wheel Alignment
  250
- Wheel Check
  252
- Wheels (Rims)
  252
- Wheels Assembly
  252
- Wheels Disassembly
  252
- Tire
  254
- Tire Check
  258
- Take the Wheels Apart
  259
- Wheel Hub
  259
Brake System

260
- Exploded View of Parking Brake
  263
- Specifications
  263
- Special Tools
  264
- Brake Fluid
  265
- Disassembly
  266
- Installation
  266
- Master Cylinder
  266
- Master Cylinder Disassembly
  267
- Caliper
  268
- Caliper Assembly
  269
- Caliper Disassembly
  269
- Caliper Holder Shaft Wear Inspection
  270
- Piston and Cylinder Damage
  270
- Brake Pad Installation
  271
- Brake Pad Removal
  271
- Brake Pad Wear Inspection
  271
- Brake Pads
  271
- Brake Discs
  272
- Disc Cleaning
  272
- Disc Installation
  272
- Disc Removal
  272
- Disc Wear
  272
Vehicle Body and Frame

282
- Rear Light Panel
  291
- Left and Right Pedals
  292
- Rear Fender
  292
- Rear Storage Box
  292
- Headlight Mask and Front Grille
  293
- Left and Right Front Mudguards
  293
- Disassembly
  296
- Disassembly
  302
- Disassembly
  305
- Front Shelf Repair
  305
- Rear Shelf Repair
  305
- Disassembly
  307
- Front Bumper Repair
  307
- Disassembly
  308
Electrical System

309
- Exploded View
  311
- Technical Parameters
  314
- Battery
  316
- Remove the Battery
  316
- Turn off Ignition Switch
  316
- Battery Charging
  317
- Charging Condition Check
  319
- Generator Inspection
  320
- Circuit Diagram of Charging System
  321
- Remove
  322
- Voltage Regulating Rectifi er Inspection
  322
- EFI System
  323
- Schematic Diagram of EFI System
  323
- Function Introduction
  324
- Temperature Sensor
  324
- Working Principle
  324
- Fault Diagnosis
  325
- Performance Parameter
  325
- Function Introduction
  326
- Oxygen Sensor
  326
- Working Principle
  326
- Electrical Characteristic Parameter
  327
- Performance Parameter
  327
- Troubleshooting
  328
- Electrical Characteristics
  329
- Electronic Control Unit（Ecu
  329
- Fault Diagnosis
  329
- Function Introduction
  329
- Fuel Injector
  331
- Working Principle
  331
- Fault Diagnosis
  332
- Performance Parameters
  332
- Ignition Coils
  333
- Working Principle
  333
- Fault Diagnosis
  334
- Performance Parameters
  334
- Remove and Install Spark Plugs
  335
- Spark Plug
  335
- Engine Speed Sensor
  336
- Fault Diagnosis
  336
- Technical Performance Test
  336
- Fault Diagnosis
  337
- Oil Pressure Sensor
  337
- Three-In-One Sensor
  338
- Throttle Valve Body Assembly
  338
- Three-In-One Sensor Performance Characteristics
  339
- Idle Motor
  340
- Fault Diagnosis
  341
- Idle Motor Fault Check
  341
- Idle Motor Fl Ow Characteristics
  341
- Fault Code Reading
  342
- Troubleshooter Operation
  342
- Summary of Failure Codes（Ecu
  343
- Lighting System Circuit
  345
- Headlamps
  346
- Replace
  346
- Replace
  347
- Tail Lamp
  347
- License Plate Lamp
  348
- Remove
  348
- Replace
  348
- Disassembly
  349
- Flasher
  349
- EPS-Brushless
  350
- EPS System Wiring Schematic Diagram
  351
- EPS Trouble Removal
  352
- EPS Fault Code
  353
- EPS-Brush
  354
- Dashboard
  356
- Display
  356
- Dashboard Indicator Light Description
  357
- Instrument Information Display
  359
- Dashboard (Meter)Button Function Introduction
  362
- Dashboard (Meter)Disassembly
  362
- T-Box
  364
- T-BOX Fault Code Display Area
  364
- Power Lock
  366
- Switch
  366
- Left Handlebar Switch
  368
- Disassembly and Assembly of Left Handlebar Switch
  372
- Right Handlebar Switch
  373
- Assembly and Disassembly of Right Handlebar Switch
  374
- Removal
  375
- Fuse Box
  378
- Wire Harness
  380
- Color Comparison Table
  385
- Wiring Diagram
  385
- Wiring Diagram
  386

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