Segway Snarler AATT66 LL User Manual Download

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MAINTENANCE

144

SUSPENSION LUBRICATION

Front suspension, rear suspension, drive shafts and
stabilizer bar are provided with grease nipples

A grease

filling label is placed nearby.

Grease ﬁlling label:

All  these  parts  need  sufficient  lubrication,  see  Periodic
maintenance  table.  Sufficient  lubrication  can  reduce  the
wear  of these parts, and increase the service life.

Summary of Contents for Snarler AATT66 LL

Page 1: ...1 A A AT T T6 6 6 S S S A A AT T T6 6 6 L L L USER MANUAL OBSLUZE T3b L7e...

Page 2: ...eful reading of this manual will help you to quickly understand the vehicle and will help your driving Periodic maintenance procedures are included in this manual They must be performed regularly to m...

Page 3: ...t described in the manual may be not installed on your vehicle If your vehicle needs service or repair please contact our dealer He willprovide you professional service in a timely manner All specific...

Page 4: ...4 TABLE OF CONTENTS SAFETY INTRODUCTION VEHICLE DEVICE OPERATION MAINTENANCE SPECIFICATIONS TROUBLESHOOTING EMISSION CONTROLSYSTEM 8 30 75 107 173 181 190...

Page 5: ...is not a toy and can be hazardous to operate ATVs handle differently from cars trucks or the off road vehicles A collision or rollover can occur quickly even during routine maneuvers like turning dri...

Page 6: ...r drugs before or while operating this vehicle as these they impair judgment and reduce the operator s ability to react Complete the New Operator Driving Procedures outlined this manual Never allow a...

Page 7: ...son inspecting or repairing the machine CAUTION YOU CAN be HURT if you don t follow these instructions NOTE NOTE provides key information by clarifyinginstructions The Prohibition Safety Sign indicate...

Page 8: ...RNING LABELS 11 GENERAL SAFETY PRECAUTIONS 18 IMPORTANT SAFETY INFORMATION 22 Reading the manual 22 Safe driving age 23 Riding equipment 24 Vehicle modifications 26 Passengers 27 Exhaust gases are dan...

Page 9: ...that is not regulated and drives differently from other vehicles such as motorcycles and cars If proper precautions are not taken a collision or roll over may occur during normal maneuvers such as tu...

Page 10: ...ion Read and follow the instructions on the labels carefully If any of the labels depicted in this manual differ from the labels on your vehicle always read and follow the instructions on the vehicle...

Page 11: ...SAFETY INTRODUCTION 12 Model AT6 S...

Page 12: ...SAFETY INTRODUCTION 13 Model AT6 L...

Page 13: ...SAFETY INTRODUCTION 14 5 6...

Page 14: ...SAFETY INTRODUCTION 15 7 8 9...

Page 15: ...SAFETY INTRODUCTION 16 10 11 12...

Page 16: ...SAFETY INTRODUCTION 17 13 14...

Page 17: ...s or a face shield gloves over the ankle boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this vehicle Never attempt jumps wheelies or other s...

Page 18: ...f you Never go over the top of a hill at speed if you cannot see what is on other side Always keep hands arms feet and legs inside the vehicle at all times during operation Keep your feet on the floor...

Page 19: ...that are too steep for it or for your abilities Go straight up and down the hills where possible Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model Reme...

Page 20: ...Cargo should be distributed evenly on front and rear rack Be sure that cargo is secured so that it cannot move around during t h e ride Reduce speed and follow instructions in this manual for carrying...

Page 21: ...know how to drive the vehicle correctly in different situations and on differentterrain Before driving the vehicle all drivers must complete the required driving safety training Please ensure that eac...

Page 22: ...this vehicle is 16 years Children under the age of 16 must not drive this vehicle Do not drive the vehicle without proper driving training training courses are required Please ensure that every driver...

Page 23: ...proper gear can reduce the chance of injury when you ride Helmet Wearing a helmet can prevent head injuries When driving you must wear an approved helmet that meets safetystandards ECE22 05 Additiona...

Page 24: ...TY INTRODUCTION 25 WARNING Driving ATV after drinking or taking drugs may adversely affect a driver s judgment reaction time balance and senses Do not drink alcohol or take drugs before or during driv...

Page 25: ...creases the power of the vehicle If any equipment is added to the vehicle or if any modifications are made to the vehicle to increase the vehicle speed or power the warranty may be influenced The addi...

Page 26: ...ith passenger largely reduces driver s ability to control an ATV which can lead to accidents or rollovers Do not ride with this ATV carrying more riders passengers than is this vehicle designed for Ne...

Page 27: ...n cause loss of consciousness or death in a short time Do not start or run a motor in a closed space The engine exhaust of this product contains chemicals that can cause cancer birth defects or other...

Page 28: ...must be shut off and must be done outdoors or in a well ventilated area At or near the refueling or gasoline storage place do not smoke avoid open flame or sparks Do not overflow the tank when refueli...

Page 29: ...cation of parts and controls 36 Handlebar switches 37 Ignition switch 38 Engine Start Stop switch 39 Headlight switch 40 Turn signal switch 41 Hazard Switch 42 Force multiplier Override switch 43 Winc...

Page 30: ...Parking brake lever free play 54 Foot brake 55 Front auxiliary brake 57 Fuel tank cap 58 Storage box 59 INSTRUMENTS 60 Indicators Warning lights 61 LCD Display 64 Diagnostic trouble codes 67 Display...

Page 31: ...understand the application operation First Activation Download the APP from the APP Store in your mobile phone before you try to activate the ATV for the first time Search for Segway Powersports in t...

Page 32: ...and step on the foot brake at the same time Note If the VIN number cannot be scanned by the phone for example due to the low light you can enter the VIN number manually The vehicle VIN number you wil...

Page 33: ...within the Bluetooth distance the vehicle Bluetooth module will automatically activate the vehicle when receiving Bluetooth signal of your mobile phone and automatically switch off the vehicle when y...

Page 34: ...VEHICLE DEVICE 35 APP FUNCTION Main features Driving control analysis vehicle data analysis etc For detailed information please see theAPP User Manual...

Page 35: ...CE 36 FEATURES AND CONTROLS Location of parts and controls 1 Shift Lever 2 Engine 3 Seat 4 Rear Shock Absorber 5 Backrest 6 Front Shock 7 Handlebar Switch 8 Fuel tank cap 5 4 3 2 1 7 8 6 5 4 3 2 1 7 8...

Page 36: ...es 1 Headlight Switch 2 Starter Button 3 Turn Signal Switch 4 Engine Stop Switch 5 Emergency Stop Switch 6 Horn Switch 7 Drive Select Switch 8 Throttle lever 9 Winch Switch 10 Ignition Switch 1 2 3 9...

Page 37: ...s located in the centre of the handlebars LOCK position Steering is locked in this position ON position All electrical circuits are on all electrical systems are working The key cannot be removed in t...

Page 38: ...ton Green 2 Engine stop button Red Starting the engine 1 Step on the foot brake Turn the ignition key into ON position see Page 38 2 Press the Engine start button green the engine will start To stop t...

Page 39: ...ument panel will lit 2 Low Beam Select to turn on Low Beam 3 Lights off 4 Position lights Turn on the position light and the indicator on the instrument panel will lit When the ignition switch is ON p...

Page 40: ...to the left to turn left turn signal on The indicator on instrument panel flashes Slide to the right to turn left turn signal on The indicator on instrument panel flashes Turn off the turn signal by r...

Page 41: ...in to deactivate hazard warning lights When the hazard warning lights are on all turn signal lights and both turn signal indicators on the instrument panel are flashing When to use hazard warning ligh...

Page 42: ...icle speed is limited Anyway if you need more engine power in muddy conditions on the hill or in other troubles you can keep pressing this switch and the vehicle will increase the speed limit and engi...

Page 43: ...nch is used to pull vehicles out of mud snow sand water and over obstacles and to control ATV accessories such as snow plow Understand the correct methods how to use the winch Pay attention to the saf...

Page 44: ...tial are equipped with 2x4 rear wheel drive only and 4x4 all wheel drive drive mode switch Select the appropriate 2x4 4x4 drive mode according to the situation and current terrain conditions In additi...

Page 45: ...wheels symbol is displayed on the LCD gauge The vehicle will limit maximum speed to 30 km h This mode is suitable for rough terrain muddy or hilly conditions and other difficult conditions 4 4 Lock Mo...

Page 46: ...table drive mode for you see page 48 Note The selection lever can only be shifted into the Differential lock position if the drive select switch is in the 4x4 position WARNING Operating the drive sele...

Page 47: ...en wheels Note In rough terrain where you expect that 2x4 LOCK drive will not be sufficient For driving with loads and in hills On soft and slippery surfaces If the rear wheels are slipping If you nee...

Page 48: ...s When driving with locked front differential reduce your speed and allow for greater maneuvering distances Locking the front differential can unexpectedly change the handling characteristics of the A...

Page 49: ...ine speed release the throttle lever When you release the thumb completely engine speed returns to idle Throttle lever WARNING Check whether the throttle lever function is normal before driving If the...

Page 50: ...rt Power socket for 12V accessories with rated current less than 10A and two USB ports are available on this ATV 12V Accessory outlet 2x USB port Open the accessory outlet cover Accessory plug and USB...

Page 51: ...sired gear has really been shifted Shifting scheme L Low speed H High speed N Neutral R Reverse P Parking NOTE You need to step on the brake pedal abd stop the vehicle whenever you change the gears If...

Page 52: ...ace the shifter in P and squeeze the parking brake lever and hold Press the parking brake lock downward After hearing the click sound the brake lock gets stuck in theslot To release the parking brake...

Page 53: ...rake lever firmly squeeze and release it several times The parking brake lever shall not be stuck 2 Measure the distance the parking brake lever moves before the brake is engaged Free play measured on...

Page 54: ...system of the vehicle The foot brake is located on the right floorboard When you need to slow down or stop step on the foot brake pedal gradually Warning Emergency braking can cause the vehicle to ski...

Page 55: ...adjusting nut is located at the bottom near the foot brake lever The stroke height of the foot brake lever can be adjusted by turning the foot brake lever nut Turn nut in direction R to lower the foot...

Page 56: ...is located on your right handlebar Use the auxiliary brake to brake all wheels If the rear wheels start to slip when using the auxiliary brake briefly release the lever and immediately depress it aga...

Page 57: ...ten the fuel tank cap in direction R WARNING Always use only the fuel type specified for your vehicle Do not smoke when refueling as you may ignite the fuel and cause fire Do not touch other persons o...

Page 58: ...he centre of the handlebars lift the glove compartment cover upwards The glove compartment is under the cover 2 Underseat storage box Storage box is under the seat Seat removal see Page 118 3 Rear sto...

Page 59: ...indicators warning lights and display information on the instrument panel so as to immediately understand vehicle status NOTE LCD display may be damaged by using a high pressure washer Do not clean th...

Page 60: ...VEHICLE DEVICE 61 Indicators Warning lights Indicators and warning lights indicate vehicle status The figurebelow shows all indicator and warning lights...

Page 61: ...an EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result 5 Oil Pressure warning This symbol appears when oil pressure is too low Do not operate...

Page 62: ...EPS system if equipped 13 ABS warning light ABS Indicates failure in any ofthe following system ABS if equipped Brake assist system if equipped 14 Coolant temperature warning lamp Indicator light sho...

Page 63: ...time 2 Bluetooth The icon will lit when the Bluetooth is on 3 Remote access Confirms mobile phone connection for vehicle settings 4 Segway logo Logo lights up after power is on 5 Speed Displays the a...

Page 64: ...arking 7 RPM Displays actual engine rpm 8 Drive mode 2 x 4 mode 2 x 4 lock mode 4 x 4 mode 4 4 lock mode 9 Coolant temperature Displays coolant temperature H High temperature C Low temperature 10 Batt...

Page 65: ...ault codes 13 Engine hours Displays total engine running time 14 Total mileage Displays the total mileage the vehicle has traveled 15 EPS Power steering On EPS mode was set in the APP and the preferre...

Page 66: ...m Please contact your dealer when trouble code appears on your dashboard 1 Trouble code display area System Failure Code Failure description ECU P0123 Throttle position sensor High Voltage P0122 Throt...

Page 67: ...0 System Voltage Not plausible P0132 O2 Sensor Circuit High Voltage Bank 1 Sensor 1 P0131 O2 Sensor Circuit Low Voltage Bank 1 Sensor 1 P0134 O2 Sensor Circuit Bank 1 Sensor 1 P0130 O2 Sensor Circuit...

Page 68: ...ntrol Circuit Not plausible P0692 Fan 1 Control Circuit High P0691 Fan 1 Control Circuit Low P0480 Fan 1 Control Circuit P0322 Ign Distributor Eng Speed Inp Circ No Signal P0459 Evaporative Emission S...

Page 69: ...ormal output of secondary torque sensor E0008 The difference between main and secondary torques is too large E0009 The difference between the main torque before and after amplification is too large E0...

Page 70: ...eering wheel Angle is not right E0024 Abnormal voltage at electrical machinery end T BOX T0001 GPS module failure T0002 4G module failure T0003 Bluetooth module failure T0004 Sensor failure T0005 Powe...

Page 71: ...VEHICLE DEVICE 72 ABS A0006 Voltage of ABS module is too low A0007 Vehicle speed single failure A0008 CAN single failure...

Page 72: ...dark to bright Press SELECT button Change the units MPH or KPH Press and hold SELECT key Reset the single trip mileage Press and hold MODE and SELECT at the same time Clock setting the hour digit blin...

Page 73: ...then tighten the two rear bolts Leave a gap of 3 mm at the back of the clamp block 4 Tighten all screws and check that handlebars do not restrict the steering WARNING Improper adjustment of the handl...

Page 74: ...Brake Pads 78 CVT clutch Drive belt 79 Mounting the ATV 79 Starting the engine 80 Parking 80 Turns 80 Riding in reverse 81 Turning around on a hill k turns 82 Riding on slippery surfaces 83 Riding th...

Page 75: ...ing on an incline 90 Braking 91 Parking the vehicle 91 Break in 92 PRE RIDE INSPECTION 93 Pre ride checklist 93 LOAD LIMITS GUIDELINES 95 Maximum loading capacities 97 Loading Guidelines 98 Trailer 99...

Page 76: ...ce between your vehicle and other vehicles operating in the same area Communicate to oncoming riders by signaling the number of vehicles in your group When stopping park your vehicle at the edge of th...

Page 77: ...ing club or local officials Break in period Break in period is the first 300 km of operation Careful break in of new engine and drivetrain components will improve the performance and service life of y...

Page 78: ...en be sure to clean also the intake and outlet ducts Take out any debris from the clutch and engine compartment when belt is replaced Mounting the ATV 1 Wear protective riding gear See the Safe Riding...

Page 79: ...on red to stop the engine P 39 3 Turn the key to the OFF position P 38 the key can be taken out of the main switch 4 Lock the Parking brake lever P 53 Turns Turning on ATV involves moving your body Yo...

Page 80: ...al wheel speed is required for vehicle movement Use the Override button with caution as it greatly increase rearward speed Do not operate at wide open throttle Operate the throttle just enough to main...

Page 81: ...ehicle on the uphill side or on the left if the vehicle is pointing straight uphill While staying uphill of the vehicle turn the handlebars fully to the left 5 While holding the brake lever release th...

Page 82: ...3 Engage 4x4 drive before wheels begin to lose traction 4 Maintain high level of alertness reading the trail and avoiding quick turns which can cause slides 5 Never apply the brakes during the slide...

Page 83: ...Periodic Maintenance Chart Following areas need special attention engine oil transmission oil and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after o...

Page 84: ...ter leaving the water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads If it s unavoidable to enter water deeper than to the footrests Proc...

Page 85: ...oach the obstacle reduce your speed be prepared to stop 4 Never try to ride over large obstacles such as large rocks or fallen logs 5 Always have a passenger dismount when you approach the obstacle th...

Page 86: ...ight uphill 3 Avoid steep hills Maximum incline is AT6 S 25 AT6 L 15 4 Always check the terrain carefully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Ke...

Page 87: ...e while riding downhill or other irregular terrain 2 Avoid steep hills Never operate up or down hills steeper than AT6 S 25 AT6 L 15 3 Always check the terrain carefully before descending a hill 4 Alw...

Page 88: ...far backward as possible A passenger should also shift his her body weight uphill 8 Apply the brakes slightly Applying the brakes too much may cause the rear wheels to lock which could result in loss...

Page 89: ...e keeping your feet on the footrests 4 If the vehicle begins to tip quickly turn the handlebar downhill if possible or get off on the uphill side immediately Parking on an incline Avoid parking on an...

Page 90: ...ress the brake pedal evenly and firmly Practice starting and stopping using the brakes until you re familiar with the controls Parking the vehicle 1 Stop the vehicle on a level surface When parking in...

Page 91: ...needs 300 km break in period During break in Avoid using full throttle Always use less than 3 4 throttle Do not pull or carry heavy loads Avoid hard or continuous acceleration Vary the engine RPM The...

Page 92: ...on before they become a problem Correct any problem that you discover to reduce the risk of a breakdown or crash Pre Ride Checklist Item Remarks Page Brake system pedal stroke Check correct operation...

Page 93: ...131 Indicator lights Check P63 Switches Check operation P38 Ignition switch Check operation P39 Headlights Check operation P41 Brake light taillight Check operation Riding equipment Wear approved helm...

Page 94: ...ecured loads can create unstable operating conditions which could result in loss of control of the vehicle WARNING Strictly follow instructions in the operator s manual of the mounted or towed machine...

Page 95: ...ns that may result in backing downhill Take extra care when riding with load beyond the edges of the rack Stability and maneuverability may be adversely affected causing the vehicle to tip over Do not...

Page 96: ...AT6 S AT6 L Front Rack 40 kg 40 kg Rear Rack 60 kg 60 kg Towing capacity see Specifications Tongue weight see Specifications Note Load capacity and towing capacity may vary according to your model ver...

Page 97: ...e with a passenger on the front or rear rack 3 Cargo weight distribution should be 1 3 on the front rack and 2 3 on the rear rack 4 Make sure that the cargo is firmly secured to the rack before drivin...

Page 98: ...ar rack The total load weight of the operator passenger accessories cargo and trailer shall not exceed the maximum capacity of the vehicle If a designated attachment point is provided on the tow hitch...

Page 99: ...e of improper hitch or exceeding the maximum tongue weight capacity may cause serious damage to your vehicle In this case your ATV will not be covered by warranty Never install car accessories on this...

Page 100: ...ies meet or exceed working load limit of the cable We recommend using an optional pulley block and double rope winching to reduce the load on the winch cable and battery When using double rope winchin...

Page 101: ...capacity on the first layer only only the first layer can be pulled in max winch capacity Do not overload the winch Never hook the cable back to itself otherwise the cable will be damaged Use trunk p...

Page 102: ...motor When the winch is under load do not approach or cross the cable When using the winch to move the load place the vehicle transmission in neutral apply park brake and plug all wheels with chocks...

Page 103: ...the steel cable before use Crushed pinched worn or kinked areas seriously reduce cable working load limit Damaged wire cable should be replaced The clutch should be disconnected first and then the wi...

Page 104: ...the vehicle engine and set the gear position to N to make sure battery is charged When the winch is working the current is large You must start the engine and apply throttle lightly to avoid damage t...

Page 105: ...ing the wire rope from the winch under power WARNING When releasing or retrieving the winch cable both ends of the cable must be left with sufficient length to prevent the cable from being over rolled...

Page 106: ...AL 118 TANK COVER 119 FRONT MAINTENANCE PANEL REMOVAL 120 INSTRUMENT COVER REMOVAL 121 ENGINE OIL 122 Oil recommendation 123 Engine oil level check 124 Changing engine oil and filter 126 Front Rear Di...

Page 107: ...Wheels removal 138 Tire replacement 140 SHOCKABSORBERSADJUSTMENT 141 Oilshockabsorber 141 Adjustable shock absorber 142 SUSPENSION LUBRICATION 144 FRONT AND REAR AXLE BOOTS 145 AIR FILTER 146 LIGHTS...

Page 108: ...Battery removal 161 Battery charging 162 Battery installation 163 Jump starting 164 FUSES 165 Fuse box 166 Fuse relay ratings and location 167 Fuse replacement 170 APPEARANCE CARE 171 Cleaning the veh...

Page 109: ...edge and basic tools many maintenance items can be completed by yourself However we suggest to ask for certain maintenance a S e gw a y Powersports service Some maintenance may require special tools a...

Page 110: ...Act The user is responsible for performing the regular maintenance specified in this manual Careful regular maintenance will help keep your vehicle in safe and reliable condition Check clean lubricate...

Page 111: ...uthorized dealer Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a quali ed dealer perform these operations M...

Page 112: ...s more often for vehicles subjected to severe use D Have an authorized dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and...

Page 113: ...or schedule repairs when required Front suspension Pre Ride Rear suspension Pre Ride Tires Wheels fasteners Pre Ride Brake uid level Pre Ride Brake system Pre Ride Throttle lever Pre Ride Engine oil l...

Page 114: ...neral lubrication 50 H 3 M 800 Lubricate all ttings pivots cables etc Throttle Body Intake Duct 50 H 6 M Inspect duct for proper sealing air leaks Drive belt 50 H 6 M 800 Inspect adjust replace as nee...

Page 115: ...t clean replace worn parts D Spark plug 100 H 12 M 1600 Inspect replace as needed D Clutches drive and driven 100 H 12 M 1600 Inspect clean replace worn parts D Front wheel bearings 100 H 12 M 1600 In...

Page 116: ...lubrication However if these components are heavily used the user may perform additional lubrication as required Item Recommended lubricant Capacity Procedure Engine oil 10W 40 SJ 2 4L Maintain level...

Page 117: ...with your fingers and move upward 2 Lift the seat upward after it bounces off 3 Remove the OPC wiring connector from the seat 4 Take the seat off NOTE There is OPC wire harness connector under the sea...

Page 118: ...118 2 Remove the two expansion screws in front of the tank cover 3 Remove the two hexagon screws behind the tank cover 4 Lift the tank cover up NOTE There are two wire harness connectors at the botto...

Page 119: ...nt of the panel up by hand When lifting up the maintenance panel do not apply too much force to avoid the panel and the rack support bar collision as this could damage maintenance panel paint Coolant...

Page 120: ...ENT COVER REMOVAL 1 Bolts 2x 2 Front maintenance panel 3 Instrument cover To remove the instrument cover 1 Remove the front maintenance panel 2 See Page 120 2 Remove 2 screws of the instrument cover 1...

Page 121: ...y special attention to the oil level If the oil level is low add the oil If the oil level starts to rise especially in cold weather stop using the machine and contact an authorized Segway Powersports...

Page 122: ...g 10W 40 SJ four cycle oil for this engine Please refer to the Lubricating guide section for oil recommendations and capacity Recommended oil Maxima ATV PREMIUM4 10W 40 CAUTION Mixing brands or using...

Page 123: ...ipstick clean 4 Reinsert oil dipstick completely 5 Put a piece of cotton cloth under the end of the oil dipstick then pull out the oil dipstick and check the oil level Note Oil level should be between...

Page 124: ...7 If the oil level is near or below the lower level mark remove the seat see Page 118 Remove the oil filler cap 3 on the front right crankcase cover and add the specified oil into the fill cap hole t...

Page 125: ...atitis and skin cancer Care should be taken to avoid prolonged and repeated exposure to the used oil Wash the skin thoroughly with soap and hot water to remove engine oil from your skin Used oil and u...

Page 126: ...Use recommended oil only see Specifications Use of other oils may cause improper operation of parts 1 Filling plug 2 O ring 3 Drain plug Checking front rear differential oil final drive oil 1 Place t...

Page 127: ...lling plug Torque to speci cation 6 Check for the leak Changing the front rear differential oil final drive oil Have the front rear differential oil final drive oil changed by an authorized Segway Pow...

Page 128: ...operating conditions If you use your ATV in extreme climatic conditions mixing ratio should be adjusted accordingly Use only distilled or demineralized water for mixing Adding coolant The recovery bot...

Page 129: ...MAINTENANCE 130 6 Reinstall the front maintenance panel 1 Maximum level 2 Minimum level...

Page 130: ...is in heavy use check it more frequently 1 Always keep the brake fluid at an correct level Please refer to master cylinder brake fluid section fordetails 2 Check the braking system for leakage 3 Chec...

Page 131: ...s If any damage crack excessive corrosion warping is found please visit Segway Powersports service before operation Brake fluid Recommended brake fluid No adjustment is required for the hydraulic brak...

Page 132: ...recommended brake fluid and check the fluid level 4 Check whether the brake pads are worn NOTE Brake fluid can damage plastic and painted surfaces and should be handled with caution If the brake fluid...

Page 133: ...ont brake fluid level is above the minimum level mark on the right handlebar When the fluid level is below the minimum add brake fluid LOWER mark minimum brake fluid level 1 Check brake fluid frequent...

Page 134: ...erating conditions Brake pads wear faster in wet and muddy conditions Periodically inspect brake pads for thickness according to maintenance periodic table If brake pad thickness is 1 00 mm or less br...

Page 135: ...Pa Check tire pressure only after the tire cools down If the vehicle has been parked for at least 3 hours or has not driven more than 1 5km checking at this time will get an accurate reading of the co...

Page 136: ...he Tread wear indicator T W I When the tire tread block wears to the wear limit mark exchange the tire Otherwise the tire can burst underway due to insufficient strength Always replace tires when the...

Page 137: ...e is damaged cuts delaminations deep cracks bulges indicating the tire carcass is damaged etc Tire has steady air leak and cannot be normally repaired due to the size or position of the puncture or ha...

Page 138: ...wheel to come off during ride which may cause an accident or rollover Always ensure that all nuts are tightened to 70 80 Nm Do not use lubricating oil or grease on wheel bolts nuts Lubricating oil gre...

Page 139: ...140 Tire replacement Recommended tire size Front Rear 25 8 12 26 8 12 25 10 12 26 10 12 WARNING Do not use wheels of different sizes than recommended in this manual as this can cause the vehicle to l...

Page 140: ...ust shock absorber according the actual type fitted to yourATV Oil shock absorber There are 5 spring preload positions for different loads and driving conditions on this shock absorber Position 1 For...

Page 141: ...TION When adjusting the shock absorbers always adjust absorbers on the left and right side to the same setting Change up or down only one position at a time when adjusting Do not try to make large adj...

Page 142: ...damping adjusting screw Use flat screwdriver to adjust the screw Increase rebound damping by turning the screw in the direction H Reduce rebound damping by turning the screw in the direction S 3 Sprin...

Page 143: ...hafts and stabilizer bar are provided with grease nipples A grease filling label is placed nearby Grease lling label All these parts need sufficient lubrication see Periodic maintenance table Sufficie...

Page 144: ...REAR AXLE BOOTS Front axle boots Rear axle boots Inspect the front and rear drive shafts ball joint boots for cracks tears perforations or grease leakage If needed contact an authorized Segway Powers...

Page 145: ...nt for inspection If the filter element is seriously soaked with oil or dust do not clean it and instead replace it with a new filter element If there is no oil or heavy dust put the air filter elemen...

Page 146: ...element 4 Air filter plug Air filter cover is located in front of the seat Seat removal see Page118 1 Press and lift the air box cover clamps 2 Pull up the front of air filter cover 3 Take out the air...

Page 147: ...sible damage we recommend that these parts are better to be replaced by the dealer When there are big beads of water inside the lens or water condensation inside the headlamp contact your dealer for m...

Page 148: ...1 Front headlamps cover 2 Expansion screw 2 Turn the rear headlamp cover clockwise and take it off CAUTION Hot parts can cause skin burns Allow the lights to cool before performing any maintenance DO...

Page 149: ...n lamp 4 Reinstall the new light into the headlight and turn on the lights Test whether light is working properly 5 Press the fixed spring on both sides to make the spring pop out of the slot 6 Remove...

Page 150: ...ngproperly Taillight rear turn light replacement To change taillight Remove rear light cover 1 Unscrew the rear light holder 2 Turn the bulb to be replaced counter clockwise When the limit bead at the...

Page 151: ...ight Use following procedure for adjustment 1 Place the vehicle on a flat ground with a headlight approximately 10 m from the wall CAUTION The following image is for reference only Your model may be s...

Page 152: ...ght aim on the wall The most intense part of the headlight beam should be 5cm below the mark on the wall Measure the headlight aim with the weight of the driver on the front seat Adjusting the headlig...

Page 153: ...ht beam can be adjusted slightly to the left or right 1 Horizontal adjusting screw To adjust the headlight beam to the left turn the headlight adjustment screw in direction L Toadjust the headlight be...

Page 154: ...and spark plug gap specifications Spark plug torque to specifications Spark plug Type Spark plug gap NGK CPR7EA 0 6 0 8 mm 0 6 0 8 mm CAUTION Using non recommended spark plugs can cause serious engine...

Page 155: ...the engine is running Check or change the spark plug according to periodic maintenance chart 1 Bolt 2 Ignition coil 3 Spark plug 4 Spark plug sleeve CAUTION Remove the spark plug for inspection need...

Page 156: ...turn the spark plug sleeve 1 4 turn and remove it from the spark plug 4 Rotate spark plug counter clockwise and remove it 5 Inspect spark plug Spark plug normal status The insulator tip is light gray...

Page 157: ...deposits delayed maintenance will reduce engine performance WARNING Make sure the engine has stopped running and the exhaust pipes are cool Let pipes completely cool down to avoid heavy burns To reduc...

Page 158: ...s 1 Bolt M6x16 3x 2 Spark arrestor 1 Remove 3 bolts M6x16 2 Start the engine and rev it up about 20 times At the same time use a towel to plug the end of the muffler instantly generating pressure in t...

Page 159: ...gine Charge the battery every 30 days This will maintain the battery life WARNING 12V batteries contain toxic and corrosive sulfuric acid and may produce flammable explosive hydrogen gas To reduce the...

Page 160: ...Battery is located under the seat Refer to the Page 118 for seat removal Switch the ignition key to OFF position before removing the battery 1 Bolt M8 x 12 2x 2 Battery plate 3 Terminal rubber covers...

Page 161: ...attery from the ATV Battery Charging CAUTION When charging the 12V batteries produce hydrogen combustible and explosive gas Therefore please follow thefollowing precautions before battery charging If...

Page 162: ...and tighten the red positive cable 4 Connect and tighten the black negative cable 5 Install a clear battery vent from the vehicle to the battery vent For conventional batteries only 6 Install the bat...

Page 163: ...our ATV 2 Connect the other clamp of the jumper cable to the positive terminal of the battery in another vehicle 3 Connect negative clamp of the jumper cable to the negative terminal of the battery in...

Page 164: ...re are several spare fuses in the fuse box Check all other fuses for possible cause Replace all blown fuses and check the electrical system All fuses are located in the fuse box In the event of a syst...

Page 165: ...al see Page 120 After the front maintenance cover is removed the fuse box is located at the bottom Move the locking tabs on the sides of the fuse box cover to the outside Loosen the tabs and open the...

Page 166: ...se relay ratings and location There is a fuse location and rating scheme on the top of the fuse box cover Refer to this scheme when finding a fuse for replacement Fuse relay ratings and location Norma...

Page 167: ...F3 IGNTE 10A F4 2WD 4WD 10A F5 Light speaker 15A F6 ICU IG 7 5A F7 DTS IG 5A F8 DTS 5A F9 KEY 5A F10 EPS IG 5A F11 12V Auxiliary outlet USB Port 15A F12 Pos Lamp L 7 5A F13 Fuel pump 10A F14 Head lig...

Page 168: ...12V 20A R2 DTS relay 12V 20A R3 IG relay 12V 20A R4 Main relay 12V 20A R5 4WD relay 2 12V 20A R6 ECU 4WD relay 12V 20A R7 Low Beam relay 12V 20A R8 High Beam relay 12V 20A R9 Auxiliary start relay 12V...

Page 169: ...To check or replace the fuse pull out the blown fuse with a fuse puller in the box cover Using this tool will help you take out thefuse Fuse box cover is also fitted with a spare fuses which can be r...

Page 170: ...towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime 4 After washing rinse your ATV thoroughly with plenty of clean water to remove any residues Deter...

Page 171: ...ur vehicle Clean and polish regularly with a clean cloth and mat Old or reused cloth and mats can contain dirt particles that can scratch the finish Vehicle storage When the vehicle is not used for a...

Page 172: ...173 SPECIFICATIONS TECHNICAL SPECIFICATIONS 174 VEHICLE IDENTIFICATION NUMBERS 179 IDENTIFICATION PLATE 180...

Page 173: ...2200 mm 2350 mm Width 1280 mm 1280 mm Height 1430 mm 1430 mm Wheelbase 1320 mm 1450 mm Ground clearance 270 mm 270 mm Turning radius 7000 mm 8000 mm Curb weight no oil and gasoline 390 kg 398 kg Fron...

Page 174: ...ssion ratio 10 6 1 Maximum power 32 5 kW 7000 rpm Maximum torque 48 Nm 5500 rpm Idle speed 1400 140 rpm Starting system Electric Lubrication Wet Sump Engine oil type 10W 40 SJ Engine oil capacity with...

Page 175: ...ype Flame retardant plastic fuel tank Fuel tank capacity 23L Fuel reserve 4 5L Spark plug type NGK CPR7EA Spark plug gap 0 6 0 8 mm Transmission CVT Gearbox Shifting sequence L H N R P CVT ratio 0 648...

Page 176: ...ation Brake fluid type DOT4 Front suspension Double A Arm Rear suspension Double A Arm with stabilizer Front shock absorber Hydraulic shock Adjustable hydraulic piggyback shock see your model Rear sho...

Page 177: ...Headlights LED 13 2W H4 55W 60W Front turn signal lights LED 2 64W 4 8W DRL lights LED 28 8W 4 2W Front position lights LED 12W 0 5W Rear turn signal lights LED 2 64W 10W Brake lights LED 3 96W 21W 5W...

Page 178: ...l number in the spaces provided for ordering spare parts from a dealer or for reference in case the vehicle is stolen Vehicle identification number is stamped on the frame under the seat Engine serial...

Page 179: ...PLATE Vehicle s identification plate is located on the left side of the vehicle under the rear rack Identification plate contains basic vehicle information including VIN number You will need VIN numbe...

Page 180: ...t turn over 184 Engine pings or knocks 184 Engine stops or loses power 185 Engine turns over fails to start 185 Engine backfires 186 Engine runs irregularly stalls or misfires 187 Engine runs irregula...

Page 181: ...trailer in high range Shift transmission to low range prior to loading ATV to prevent belt burning Starting out going up a steep incline When starting out on an incline use low range Driving at low R...

Page 182: ...essive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low...

Page 183: ...t breaker Reset the breaker Low battery voltage Recharge battery Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine pings o...

Page 184: ...on Out of Fuel Refuel Clogged fuel valve or lter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is out of use Replace Old or non recommended fuel Rep...

Page 185: ...ble Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug Incorrect spark plug gap or heat range Set gap to specs or replace plug Old or non recommended fuel Replace with n...

Page 186: ...ange Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery Engine runs irregula...

Page 187: ...e Contact your dealer for service Possible Lean or Rich Fuel Mixture Contact your dealer for service Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with reco...

Page 188: ...rn or defective spark plug wires Contact your dealer for service Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose connections Check tighten all connections Low battery vol...

Page 189: ...190 EMISSION CONTROLSYSTEM SOURCE OF EXHAUST EMISSIONS 191 EXHAUST EMISSION CONTROL SYSTEM 191 CRANKCASE EMISSION CONTROL SYSTEM 192 NOISE CONTROL SYSTEM 192...

Page 190: ...ons they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system...

Page 191: ...a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner NOISE CONTROL SYSTEM Do not modify th...

Page 192: ...time of publication Due to constant improvements in the design and quality some depictions information and specifications may differ from those presented in this publication Depictions and or procedu...

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