Segway VILLIAN SSV Series Manuals

Segway VILLIAN SSV Series Manuals

Manuals and User Guides for Segway VILLIAN SSV Series. We have 1 Segway VILLIAN SSV Series manual available for free PDF download: Service Manual

Segway VILLIAN SSV Series Service Manual

Segway VILLIAN SSV Series Service Manual (407 pages)

Brand: Segway | Category: Offroad Vehicle | Size: 66.14 MB

Table of Contents

General Information

6
Maintenance

16
- Table of Contents
  16
- Maintenance Reference
  21
- Grease
  23
- Frame, Nuts, Bolts, and Fasteners
  24
- General Vehicle Inspection and Maintenance
  24
- Pre-Ride / Daily Inspection
  24
- Shift Cable Inspection / Adjustment
  25
- Fuel Filter
  26
- Fuel System
  26
- Fuel System and Air Intake
  26
- Fuel Lines
  27
- Air Filter Service
  28
- Engine Intake Pre-Filter Service
  28
- Engine
  29
- Engine Oil Level
  29
- Engine Oil Change
  30
- Replace Oil Fi Lter/Oil Strainer
  31
- Add Engine Oil
  32
- Engine / Oil Tank Breather Hose Inspection
  33
- Engine Cylinder Leakdown Test
  33
- Spark Arrester
  34
- Check the Level of Rear Gear Box
  35
- Transmission and Front Gearcase
  35
- Check the Level of Front Gear Box
  36
- Front/Rear Gearbox Oil Discharge
  36
- Cooling System
  38
- Cooling System Hoses
  38
- Cooling Bottle Coolant
  39
- CVT Belt
  40
- Pvt / Final Drive / Wheel and Tire
  40
- Drive Shaft Boot Inspection
  41
- The CVT Dry
  41
- Wheel
  42
- Wheel Installation
  42
- Wheel Removal
  42
- Battery Charging
  43
- Battery Disassembly
  43
- Electrical and Ignition System
  43
- Battery Installation
  44
- Spark Plug
  44
- Spark Plug Inspection
  45
- Brake System
  47
- Brake Oil
  48
Engine Lubrication System

49
- Exploded View
  50
- Technical Parameter
  52
- Special Tools
  53
- Engine Oil Flow Chart
  54
- Oil and Oil Filter
  55
- Oil Level Check
  55
- Clean the Oil Fi Lter Combination
  56
- Engine Oil Change
  56
- Remove the Oil Filter
  56
- Measure Oil Pressure
  57
- Oil Pressure
  57
- Install the Oil Filter Assembly
  58
- Install the Oil Pump Assembly
  58
- Oil Pump
  58
- Remove the Oil Fi Lter Assembly
  58
- Remove the Oil Pump Assembly
  58
- Install the Main Engine Oil Pump Rotor
  59
- Remove the Main Engine Oil Pump Rotor
  59
- Install the Auxiliary Oil Pump Rotor
  60
- Install the Oil Pump Shaft and Oil Seal
  60
- Remove the Auxiliary Oil Pump Rotor
  60
- Remove the Oil Pump Shaft and Oil Seal
  60
- Install the Oil Cooler Assembly
  61
- Oil Cooler Assembly
  61
- Remove the Oil Cooler Assembly
  61
Starting System

66
Crankcase\Crankshaft\Balance Shaft

74
- Explosive View
  75
- Explosive View of up and down the Case Sub-Assembly
  76
- Explosive View of Left Crankcase Cover Sub-Assembly
  78
- Explosive View of Upper Crankcase Cover Sub-Assembly
  80
- Explosive View of Lower Crankcase Cover Sub-Assembly
  81
- Explosive View of Oil Pan Sub-Assembly
  82
- Technical Parameter
  83
- Special Tools
  84
- Left Crankcase Cover
  85
- Left Crankcase Cover Disassembly
  85
- Check Left Crankcase Cover
  86
- Crankcase\Crankshaft\Balance Shaft
  86
- Install Left Crankcase Cover
  86
- Crankcase Assembly
  87
- Remove Balance Shaft
  89
- Check Balance Shaft
  90
- Remove the Crankshaft
  90
- Check the Crankshaft
  91
- Install the Crankshaft
  92
- Mounting Balancing Shaft
  92
- Crankcase Assembly
  93
- Bearing Selection
  96
- Bearing Shell Group
  96
- Group Identifi er
  96
- Balancing Shaft Bearing Bush Optional
  97
- Connecting Rod Bearing Bush Optional
  97
- Spindle Bushing Selection
  97
Cylinder Head, Cylinder, Piston

98
- Exploded View
  100
- Explosive View of Cylinder Head Cover Sub-Assembly
  101
- Explosive View of Cylinder Head Sub-Assembly
  102
- Explosive View of Cylinder Sub-Assembly
  104
- Explosive View of Valve Mechanism
  105
- Explosive View of Piston Connecting Rod Assembly
  106
- Technical Parameters
  108
- Technical Parameter
  109
- Special Tools
  110
- Cylinder Head Cover
  111
- Install the Cylinder Head Cover
  111
- Remove the Cylinder Head Cover
  111
- Camshaft Cover / Camshaft
  112
- Install the Tensioner
  112
- Remove the Tensioner
  112
- Disassemble Camshaft
  113
- Camshaft / Camshaft Lobe Inspection
  114
- Camshaft Sprocket Inspection
  114
- Install Camshaft Sprocket
  115
- Camshaft Installation / Timing Adjustment
  116
- Valve Clearance Adjustment
  118
- Optional Tappet Specifi Cations
  119
- Selection of Valve Tappet
  119
- Check the Cylinder Head Deformation
  122
- Cylinder Head
  122
- Cylinder Head Inspection
  122
- Install the Intake Pipe Assembly
  123
- Install Thermostat and Water Temperature Sensor
  123
- Remove the Intake Pipe Assembly
  123
- Disassemble the Spark Plug
  124
- Install Spark Plug
  124
- Thermostat Check
  124
- Remove the Valve
  125
- Valve Guide / Valve Inspection
  126
- Combustion Chamber Cleaning
  127
- Seat Ring Inspection
  128
- Seat Ring Repair
  128
- Seat Ring Repair (Valve Grinding)
  129
- Cylinder Head Assembly
  131
- Cylinder Block and Piston
  132
- Cylinder Block Inspection
  132
- Cylinder Block Removal
  132
- Disassemble the Piston
  133
- Piston Measurement
  134
- Measure the Gap of the Piston Ring Groove
  135
- Connecting Rod Measurement
  136
- Measure the Closed Gap of the Piston Ring
  136
- Measure the Piston Pin
  136
- Piston Connecting Rod Assembly
  137
- Piston Ring Installation
  137
- Cylinder Block Assembly
  138
- Cylinder Pressure Measurement
  139
Cvt System

140
- Exploded View
  141
- Special Tools
  144
- Disassemble the CVT Cover
  145
- Install the CVT Cover
  145
- Disassemble the CVT Inner Cover
  146
- Install the CVT Inner Cover
  146
- Check the Drive Belt
  147
- Disassemble the Drive Belt
  147
- Install the Drive Belt
  147
- Transmission Belt
  147
- Disassemble the Drive Pulley and the Driven Pulley
  148
- Install Drive Pulley and Driven Pulley
  149
Water Pump Assembly

150
- Exploded View
  151
- Special Tools
  153
- Water Pump Assembly
  153
- Disassemble the Water Pump
  154
- Install the Water Pump
  155
Front Axle and Rear Gearbox

156
- Exploded View of Front Axle
  158
- Special Tools
  161
- Add New Gear Oil
  162
- Drain the Old Gear Oil
  162
- Replacement of Front Axle Gear Oil
  162
- Disassemble
  163
- Inspection of Parts Wear
  163
- Install
  163
- Adjustment of Gear Clearance
  164
- Disassemble
  164
- Install
  164
- Exploded View of Rear Gearbox
  165
- Add Gearbox Oil
  168
- Drain the Gearbox Oil
  168
- Replacement of Gearbox Gear Oil
  168
- Dismantling the Driven Bevel Gear Cover Assembly
  169
- Dismantling the Driving Bevel Gear
  169
- Dismantling the Gearbox
  169
- Dismantling the Shift Shaft Cover Assembly
  169
- Gear Setting
  169
- Dismantling the Connecting Nut between the Shaft and the Box Body
  170
- Dismantling the Oil Pump Components
  170
- Dismantling the Shift Mechanism
  170
- Dismantling the Reverse Gear Idler Shaft Assembly and Main Shaft Assembly
  171
- Dismantling the Right Gearbox Assembly
  171
- Dismantling the Right Gearbox Connector
  171
- Dismantling the Box Connector
  172
- Dismantling the Gear Transmission Parts
  172
- Dismantling the Parking Mechanism
  172
- Dismantling the Shifting System
  172
- Dismantling the Countershaft Assembly
  173
- Assemble the Gearbox
  174
- Install the Left Box Bearing
  174
- Install the Right Gearbox Combined Bearing
  174
- Install the Bearing Plate of the Left Box Body
  175
- Install the Parking Mechanism
  175
- Assemble the Rear Axle Output Gear Assembly
  176
- Install the Countershaft Assembly
  176
- Install the Left Box Connector
  176
- Assemble the HR Shift Fork Shaft Assembly
  177
- Assemble the L Gear Shift Fork Shaft Assembly
  177
- Install the Gear Set
  177
- Install the HR Shift Fork Shaft Assembly
  178
- Install the L Gear Shift Fork Shaft Assembly
  178
- Install the Parking Shaft and Shift Drum Assembly
  179
- Install the Gear Assembly
  180
- Install the Main Shaft Assembly
  180
- Install the Right Box Body Combination
  180
- Install the Countershaft Low-Speed Gear
  181
- Install the Driven Bevel Gear Shaft
  181
- Install the Driven Bevel Gear Cover
  182
- Install the Driven Bevel Gear Cover Oil Seal
  182
- Install the Gear Sensor and Rotary Shaft Oil Seal
  183
- Install the Gear Set Nut
  183
- Install the Oil Pump Assembly
  184
- Install the Rear Axle Output Shaft Oil Seal
  184
- Install the Needle Bearing and Locating Pin
  185
- Install the Shift Mechanism
  185
Fuel System

186
- Exploded View of Fuel System
  187
- Assembly
  188
- Disassembly
  188
- Fuel Tank
  188
- Disassembly
  189
- Fuel Pump
  189
- Inspection
  189
- Assembly
  190
- Assembly
  191
- Disassembly
  191
- Fuel Filter
  191
Cooling System

192
- Exploded View of Cooling System
  193
- Coolant Flow
  194
- Technical Parameter
  196
- Special Tools and Sealants
  197
- Coolant
  198
- Coolant Deterioration Inspection
  198
- Coolant Level Check
  198
- Pressure Test
  199
- Radiator Removal
  200
- Remove the Engine Raditor
  200
- Remove the Oil Radiator
  200
- Radiator Fan Installation
  201
- Radiator Fan Removal
  201
- Radiator Cap Inspection
  202
- Radiator Cleaning
  202
- Radiator Inspection
  202
Intake / Exhaust System Intake/Exhaust System

203
- Exploded View of Intake System
  204
- Air Filter Element Replacement
  205
- Air Inlet Filter Disassembly
  205
- Air Cleaner Disassembly
  206
- Disassemble
  206
- Muffler
  208
- Air Exhaust Disassembly
  209
- Air Exhaust System Inspection
  210
Drive System

211
Front & Rear Suspension

226
- Exploded View of Front Suspension
  227
- Exploded View of Rear Suspension
  229
- Technical Parameter
  231
- Dedicated Tools
  232
- Absorber Inspection
  233
- Shock Absorber
  233
- Absorber Scrapped
  237
- Front Suspension
  238
Wheels and Tires

243
- Exploded View of Wheels and Tires
  244
- Technical Parameters
  246
- Special Tools
  247
- Front Beam Inspection
  248
- Wheel Alignment
  248
- Front Bundle Adjustment
  249
- Wheel Check
  250
- Wheel Disassembly
  250
- Wheel（Rim
  250
- The Replacement of the Wheel
  251
- Tire
  252
- Tire Disassembly
  252
- Tire Disassembly (for Anti-Drop Rims)
  254
- Tyre Mounting (for Anti-Drop Rims)
  255
- Tire Check
  256
- Wheel Hub
  257
- Wheel Hub Assembly
  257
- Wheel Hub Disassembly/Assembly
  257
Brake System

258
- Specifications
  260
- Special Tools
  261
- Brake Fluid
  262
- Caliper
  263
- Caliper Installation
  263
- Caliper Assembly
  264
- Caliper Disassembly
  264
- Caliper Holder Shaft Wear Inspection
  265
- Piston and Cylinder Damage
  265
- Brake Discs
  266
- Brake Pad Installation
  266
- Brake Pad Removal
  266
- Brake Pad Wear Inspection
  266
- Brake Pads
  266
- Disc Cleaning
  267
- Disc Installation
  267
- Disc Removal
  267
- Disc Wear
  267
- Brake Hose Inspection
  268
- Brake Pedal
  268
- Brake Pedal Position Adjustment
  268
- Installation of Parking Cable
  268
- Parking Cable
  268
- Parking Cable Removal
  268
Vehicle Body and Frame

278
- Seat Removal
  288
- Power Switch
  289
- Battery Repair Cover
  290
- Electrical Repair Cover
  290
- Foot Pedal Drain Cover
  290
- Gasoline Pump Repair Cover
  291
- Regular Engine Maintenance
  291
- Roll Cage Removal
  293
- Frame Attachment Removal
  295
- Front Bumper Removal
  299
- Removal of Rear Bumper Assembly
  302
- Front Axle Disassembly
  304
- Engine Disassembly
  307
Electrical System

311
- Exploded View
  314
- Technical Parameters
  318
- Multimeter
  319
- Special Tools
  319
- Battery
  320
- Battery Installation
  320
- Remove the Battery
  320
- Battery Charging
  321
- Charging Condition Check
  323
- Generator Inspection
  324
- Circuit Diagram of Charging System
  325
- Remove
  326
- Voltage Regulating Rectifi er Inspection
  326
- Lighting System Circuit
  327
- Headlight
  328
- Replace
  328
- Replace
  329
- Tail Light
  329
- Licence Lamp
  330
- Remove
  330
- Replace
  330
- Flasher
  331
- Power Lock
  332
- Switch
  332
- Emergency Switch
  334
- Flameout Switch
  334
- 2WD/4WD Drive Mode Switch
  335
- Start Switch
  335
- 2WD/4WD Drive Mode Switch Removal and Installation
  336
- Starting System Layout
  337
- Schematic Diagram of Starting System
  338
- Starting System Troubleshooting
  338
- Switch Position Diagram
  340
- Electrical Wiring
  341
- Wiring Check
  341
- Disassembly of Power Lock, Start Button, Various Switches, Etc
  342
- Combination Fuse Box Cover Inner Part
  343
- Combination Fuse Box Main Body Segment
  343
- Fuse Box
  343
- Fuse Continuity Test
  344
- Disassemble
  346
- Start Relay Troubleshooting
  346
- Disassemble
  347
- Installation
  347
- Start Motor
  347
- Disassemble the ECU
  348
- Ecu
  348
- ECU Connector Removal Skills
  348
- Install ECU
  348
- Disassemble
  349
- Fuel Pump Assembly
  349
- Fuel Pump Assembly Inspection
  350
- Fuel Pump Assembly
  351
- Install Trailer Power Socket
  352
- Remove Trailer Power Socket
  352
- Trailer Power Socket
  352
- Efi System
  353
- Schematic Diagram of EFI System
  353
- Coolant Temperature Sensor
  354
- Function Description
  354
- Working Principle
  354
- Fault Diagnosis
  355
- Performance Parameter
  355
- Function Introduction
  356
- Oxygen Sensor
  356
- Working Principle
  356
- Electrical Characteristic Parameter
  357
- Performance Parameter
  357
- Electrical Characteristics
  358
- Electronic Control Unit（Ecu
  359
- Function Description
  359
- Electrical Characteristics
  360
- Fault Diagnosis
  360
- ECU Pin Defi Nition
  361
- Fuel Injector
  363
- Working Principle
  363
- Fault Diagnosis
  364
- Performance Parameter
  364
- Ignition Coils
  365
- Working Principle
  365
- Fault Diagnosis
  366
- Performance Parameters
  366
- Remove and Install Spark Plugs
  367
- Spark Plug
  367
- Engine Speed Sensor
  368
- Fault Diagnosis
  368
- Technical Performance Test
  368
- Disassembly Requirements
  369
- Electronic Throttle Valve Body Assembly
  369
- Inlet Pressure Temperature Sensor
  370
- Fault Diagnosis
  371
- Three-In-One Sensor Performance Characteristics
  371
- Throttle Position Sensor and Throttle Actuator
  372
- Throttle Position Sensor Performance Characteristics
  372
- Fault Diagnosis
  373
- Throttle Actuator (DC Motor) Technical Performance Parameters
  373
- Electronic Accelerator Pedal
  374
- Remove and Install the Accelerator Pedal
  374
- Fault Diagnosis
  375
- Technical Performance Parameters
  375
- Fault Code Reading
  376
- Troubleshooting Instrument Operation
  376
- Summary of Failure Codes
  377
- Eps
  382
- EPS System Wiring Schematic Diagram
  383
- EPS Trouble Removal
  384
- Display and Human-Computer Interaction Assembly
  386
- Instrumentation
  387
- Meter Dismantling
  391
- Technical Parameters
  391
- Central Control Display
  393
- Disassembly and Installation of Central Control
  394
- Function Introduced
  395
- AM Performance Index
  396
- Performance Parameter
  396
- Fault Diagnosis
  397
- FM Performance Index
  397
- Tbox
  398
- Tbox Fault Code Display Area
  399
- Winch Assebly
  400
- Removal of Winch Motor
  402
- Winch Motor Position
  402
- Install Winch Motor
  403
- Schematic Diagram of Trailer System
  405
- Color Comparison Table
  406
- Electric Schematic Diagram
  407

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