Segway Personal Transporter i2, Parts Replacement Manual

Page: 66 / 126

8 ‐ 4 Segway® Personal Transporter i2, x2, x2 Turf Parts Replacement
Gearbox Removal
Support your Segway PT by means other than
resting on its wheels. Support of unit from below
batteries is recommended. As an alternative, the
Segway PT can be positioned on its side.
To remove gearbox:
1. Make sure Segway PT is powered off and
unplugged.
2. Remove LeanSteer frame ( page 1 ‐ 5 ).
3. Remove mats ( page 2 ‐ 3 ).
4. Remove wheel ( page 4 ‐ 3 ).
5. (Model i2) Remove fender ( page 5 ‐ 3 ).
6. (Model x2) Remove fender and frame
assembly ( page 5 ‐ 5 ).
7. Remove front and rear fascia trim ( page 6 ‐ 4 ).
8. Remove gearbox trim cover ( page 6 ‐ 5 ).
9. Remove gearbox fasteners. Using a 3/8”
ratchet fitted with a T ‐ 45 6 ‐ lobe socket,
loosen and remove (3) gearbox fasteners.
Gearbox fasteners are installed with thread lock
compound and require significant leverage to
loosen for the duration of thread engagement.
Use of new gearbox fasteners with new thread
lock compound is required for proper installation
.
10. Remove gearbox. Using rubber mallet,
gently tap chassis side of gearbox housing
alternating front to back. Repeat until
gearbox is unseated. Lift gearbox off chassis
and set aside.
Gearbox might separate from gearbox spacer. If
this occurs, remove battery pack ( page 3-3 ) to
gain access to bottom inside edge of spacer. To
remove, tap inside edge of spacer. Do not pry
aluminum-to-aluminum surfaces to prevent
surface damage; preserve gasket integrity for
reuse. If gasket is damaged or becomes
damaged through removal or installation,
replacement of the damaged gasket is required.
Figure 8 ‐ 2: Tap Gearbox to Unseat
Machined surfaces of
gearbox can be sharp.
Keep hand and fingers
clear of mating surfaces
while seating gearbox
and spacer to chassis.
Sharp edge
.
Finger or
hand hazard.