Segway FUGLEMAN SGW1000F-U2 2022, Owner'S Manual

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Page 2: ...s Failure to follow the safety precautions could result in serious injury or death WARNING WARNING The engine exhaust from this product contains chemicals known to the State of California to cause can...

Page 3: ...ing This manual contains a large number of safety instructions operation instructions maintenance instructions and safety warnings Reading of this manual will help you quickly understand the vehicle a...

Page 4: ...oted trademarks are the property of Segway Powersports Inc Copyright 2020 Segway Powersports Inc All information contained within this publication is based on the latest product information at the tim...

Page 5: ...OF CONTENTS TABLE OF CONTENTS SAFETY INTRODUCTION VEHICLE DEVICE OPERATION MAINTENANCE STORAGE AND TRANSPORTATION SPECIFICATIONS EMISSION CONTROL SYSTEM TROUBLESHOOTING WARRANTY 1 26 67 94 160 177 16...

Page 6: ...ly even during routine maneuvers like turning driving on hills or over obstacles if you fail to take proper precautions Read the owner s manual that came with your vehicle Understand all safety warnin...

Page 7: ...impair judgement and reduce the operator s ability to react Complete the new operator driving procedures outlined this manual Never allow a guest to operate this vehicle until the guest has completed...

Page 8: ...ORTANT provides key reminders during disassembly assembly and inspection of components WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUT...

Page 9: ...sing alcohol or drugs 17 Vehicle modi cation 18 Passengers 19 Contact with exhaust 20 Seat Belts 21 Cab Net Doors 21 Loading on the vehicle 22 No Passengers in the cargo box 23 Operating on Pavement 2...

Page 10: ...ate an off road vehicle and is driven differently from other vehicles such as motorcycles and automobiles If proper precautions are not taken a collision or rolled over may occur during normal maneuve...

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Page 12: ...4 SAFETY INTRODUCTION SAFETY INTRODUCTION...

Page 13: ...m the label on your vehicle the label on the vehicle shall prevail If any label becomes illegible or falls off contact the dealer to purchase a new label for replacement If you purchased a used Segway...

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Page 18: ...ditions and your experience Always inspect your vehicle each time you use it to be sure it is in safe operating condition Never operate on excessively rough slippery or loose terrain until you have le...

Page 19: ...g to turn at faster speeds Do not attempt turns on steep inclines Always follow proper procedures for going uphill If you lose control and cannot continue up a hill back down the hill with the engine...

Page 20: ...should be as far forward in the bed as possible and distributed evenly from side to side Be sure cargo is secured so that it cannot move around during operation Reduce your speed and follow the instru...

Page 21: ...he driver must know how to drive the vehicle correctly in different situations and on different terrain Before driving the vehicle all drivers must complete the required driving safety training Please...

Page 22: ...riving age for this vehicle is 16 years Children under the age of 16 must not drive this vehicle Not to drive the vehicle without proper driving training Training courses are required Please ensure th...

Page 23: ...eets basic safety standards when driving Both U S and Canadian qualified helmets bear a U S Department of Transportation label ECE 22 05 marks are available in Europe Asia and Oceania The ECE mark con...

Page 24: ...NING Driving Vehicle after drinking or taking drugs may adversely affect a driver s judgment reaction time balance and feelings Do not drink alcohol or take drugs before or during driving RRWV SSURYHG...

Page 25: ...Using alcohol or drugs WARNING WARNING Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or dr...

Page 26: ...pment that increases 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 all terrain vehicle wa...

Page 27: ...hours and have completed the new operator driving instructions outlined on page 71 Passengers must always sit in the passenger seat with the seat belt secured Carrying more than two passenger in a th...

Page 28: ...oxic and can 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 cause cancer birth defects or...

Page 29: ...ity of injury in these circumstances The operator must wear the seat belt at all times Cab Net Doors Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or...

Page 30: ...vehicle is listed in the instruction section of this manual and on the vehicle label As more passenger weight is added the cargo weight may need to be reduced accordingly Do not exceed the vehicle s...

Page 31: ...for use on pavement Operating this vehicle on paved roads including sidewalks paths parking lots and driveways may adversely affect the handling of the vehicle and may increase the risk of loss of con...

Page 32: ...edures for turning as described in this owner s manual Avoid sharp turns Never turn while applying heavy throttle Never make abrupt steering maneuvers Practice turning at slow speeds before attempting...

Page 33: ...lutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in this owner s manual See page 78 Fuel safety Gasoline is very flammable under certain conditions Y...

Page 34: ...witchs 34 Combination Switch 36 Toggle switch for Two wheel drive or Four wheel drive 37 Electronic power steering EPS 39 12V Socket 40 SEAT 41 Driver seat adjustment 41 Driver seat removal installati...

Page 35: ...ap 50 Gear Shift Selector 51 Brake pedal and accelerator pedal 52 Parking brake 54 Roll Overprotective Structures ROPS 55 INSTRUMENT PANEL 56 Instrument Indicator Light Warning Light 57 Diagnostic dis...

Page 36: ...rom APP STORE Android mobile phone first download Google play and then search Segway powersports to download application in Google Play After the successful installation of the APP the vehicle will be...

Page 37: ...ective connection distance of the Bluetooth signal the vehicle Bluetooth module will automatically unlock the vehicle after acquiring the mobile phone Bluetooth signal and automatically lock the vehic...

Page 38: ...LE DEVICE APP Function This app is a program designed for users who have the Segway Powersports vehicle Main features driving control analysis vehicle data analysis Detail information see Segway Power...

Page 39: ...31 VEHICLE DEVICE VEHICLE DEVICE PARTS AND CONTROL 1 Front Bumper 2 Handrails 3 ROPS 4 Cargo Box 5 Muffler 6 Tailgate 7 Rear Bumper 8 Cargo Box Flip Handle 9 Fuel Cap 10 Cab Net Door...

Page 40: ...LE DEVICE VEHICLE DEVICE 1 Light Switch 2 AWD Switch 3 Instrument Cluster 4 Gear Shifter Selector 5 Storage Box 6 Storage Box 7 DC Socket 8 Switch 9 Ignition 10 Parking Brake 11 Start Button 12 12 Vol...

Page 41: ...Turn the key to the ignition switch ON position Press the Engine Start Stop press the start switch and the vehicle will start MODE2 Turn the key to the position ON the vehicle is energized and the ele...

Page 42: ...Command Four Wheel Drive Switch Emergency shutdown Switch Engine Stop Engine Start Vehicle launch 1 Depress the brake pedal when the gear is in P gear or N gear 2 Turn the ignition key into ON positio...

Page 43: ...cy light off Use this switch when the vehicle is in an emergency Temporary parking of vehicles The vehicle is malfunctioning The vehicle encounters other emergencies Mode Switch S Sport mode This mode...

Page 44: ...36 VEHICLE DEVICE VEHICLE DEVICE Toggle switch forTwo wheel drive or Four wheel drive 1 Handle switch On Command Four Wheel Drive Switch if equipped Rear wheel differential lock 4WD Unlock...

Page 45: ...state of 4 wheel drive with power output of the front wheel and power output of the rear wheel This mode is suitable for muddy conditions mountainous conditions and other bad road conditions 4 4 locki...

Page 46: ...s Front position lights tail lights license plate lights and dashboard lights are turned on Turn the switch to this position the headlights are placed on the low beam Turn the switch to this position...

Page 47: ...ion the EPS system is energized NOTICE When the key is turned to the on position the EPS warning indicator lights up briefly Please refer to P59 After the key switch is turned to the OFF position the...

Page 48: ...s Located in the middle of the front panel of the vehicle The power socket can be used for 12V accessories with a working current of less than 10A Output power 120W Top USB interface Bottom DC interfa...

Page 49: ...t back and the driver s feet can step on the brake pedal and accelerator pedal Driver seat adjustment There is a U shaped adjusting handle at the front end of the seat Pull the U shaped adjusting rod...

Page 50: ...ard and pull out the cable connector under the seat 3 Remove the seat from the vehicle Driver seat installation 1 Plug the cable connector under the seat 2 Insert the two fixing pins behind the seat i...

Page 51: ...the front end of the seat to remove the seat from the vehicle The seat cover is located under the passenger seat After the passenger seat is removed hold the seat cover with both hands Move it upwards...

Page 52: ...CLE DEVICE Seat Headrest Adjustment The seat headrest can be adjusted When the upper row of headrest holes are fixed the headrest position is low When the lower row of headrest holes are fixed the hea...

Page 53: ...ard the steering wheel do not loosen it Move the steering wheel up or down to adjust to a suitable position hold the steering wheel and release the adjustment pole After adjusting the angle of the ste...

Page 54: ...risk of injuries Fasten seat belts correctly Stretch the shoulder buckle so that it covers the entire shoulder but do not touch the neck or slipping off the shoulder Place the waist buckle as low as p...

Page 55: ...kle until it clicks 2 Pull out each seat belt and check for any damage including cutting grinding Damage wear or stiffness If any damage is found please contact a Segway Powersports dealer for replace...

Page 56: ...oor Before each use be sure to check the wear and tear of the door door latch or safety net and lock Replace any worn or damaged parts in time New parts can be obtained from your authorized Segway Pow...

Page 57: ...x can be removed Click the upper part of box and lift it out Meanwhile move upper left and right buckles of box to open this box 4 Middle lower storage box WARNING Keep the storage box closed if you d...

Page 58: ...r it may ignite the fuel and cause fire hazard Do not touch other people or stuff with static electricity or it may cause static electricity accumulation and ignite fuel Do not overfill the fuel when...

Page 59: ...the gear has been switched to the desired position See the table below for the tap position description CAUTION The transmission will be damaged when you change shift gear if the engine is running ov...

Page 60: ...edal Step on brake pedal 1 to select gear reduce speed or stop the vehicle Use this brake pedal when you start the engine If you want to reduce speed or stop the vehicle step on the brake pedal with y...

Page 61: ...peed loosen your accelerator pedal The accelerator pedal is spring load style It will return to balance position if no force is on it idle speed When released the spring pressure returns the pedal to...

Page 62: ...nd still and then hold the T shaped parking handle with your hand and pull it up until your foot releases the brake The vehicle is still in a reliable stationary state when pedaling and the parking br...

Page 63: ...e dealer thoroughly inspects the ROPS or replaces it No device can assure occupant protection in the event of a rollover When used with seat belts and cab nets or doors the ROPS helps prevent occupant...

Page 64: ...of the various indicators warning lights and display content information on the instrument table to understand the vehicle status NOTICE The combination meter may be damaged by using a high pressure...

Page 65: ...ode the indicator is switched on and all warnings on the indicator The light will be briefly lit for 1 second 1 Engine Tachometer shows Display the real time RPM of the vehicle 0 2 4 6 8 10 from low t...

Page 66: ...al mileage please clear the subtotal mileage through Segway Powersports APP 7 Engine Running Time Display engine running time 8 Dynamic Residual Mileage Display the mileage that can be driven by the c...

Page 67: ...PS System Indicates a failure in EPS system optional equipment if equipped Brake System Low brake fluid level The braking system is faulty Parking Brake This light is on after parking brake is applied...

Page 68: ...e light and instrument panel light are on Power icon on Bluetooth The icon will light on when the APP Bluetooth power is used Remote Power on When power on the Vehicle the APP in the mobile phone and...

Page 69: ...U P0108 17 Manifold Absolute Pressure Barometric Pressure Circuit High P0107 16 Manifold Absolute Pressure Barometric Pressure Circuit Low P010C 17 Mass or Volume Air Flow B Circuit Low P010D 16 Mass...

Page 70: ...P0414 11 Secondary Air Injection System Switching Valve A Circuit Shorted P0413 13 Secondary Air Injection System Switching Valve A Circuit Open P0262 12 Cylinder 1 Injector Circuit High P0261 11 Cyli...

Page 71: ...P1568 00 Idle Speed Contr Throttle Pos mechanical Malfunction P1545 00 Throttle Pos Contr Malfunction P1545 22 Throttle Pos Contr Malfunction P1545 21 Throttle Pos Contr Malfunction P1565 00 Idle Spe...

Page 72: ...ontrol Circuit Low Bank 1 Sensor 1 P0030 13 O2 Sensor Heater Control Circuit Bank 1 Sensor 1 P0132 17 O2 Sensor Circuit High Voltage Bank 1 Sensor 1 P0131 16 O2 Sensor Circuit Low Voltage Bank 1 Senso...

Page 73: ...rque before and after ampli cation is too large E0010 Electrical machinery unassisted E0011 Over electric current E0012 Abnormal busbar electric current E0013 CAN communication abnormal Output abnorma...

Page 74: ...er CAN failure T0006 Body CAN failure ABS A0001 Left front wheel speed error signal A0002 Right front wheel speed error signal A0003 Left rear wheel speed error signal A0004 Right rear wheel speed err...

Page 75: ...rator Driving Procedures 71 Driving with Passengers 72 Starting the Vehicle 73 Park the Vehicle 73 Braking 73 Parking the vehicle 74 Driving on Slippery Surfaces 74 Driving through water 75 Driving in...

Page 76: ...ION OPERATION PRE RIDE INSPECTION 80 HAULING CARGO 82 Belt life 84 Towing loads 84 Maximum loading capacity 85 Dumping the cargo box 85 Loading guidelines 86 Trailer 86 WINCH OPERATION 88 Winch Operat...

Page 77: ...the risk of an accident Always perform the Pre Ride Inspection outlined in the Operation chapter before each use of your vehicle to make sure it s in safe operating condition Always follow the inspect...

Page 78: ...ponents will improve the performance and service life of these components Follow these steps carefully Brake System Break In Period In order to achieve the best braking performance the brake must be n...

Page 79: ...all cab doors are closed and locked 8 Sit in the driver s seat fasten the seat belt and put the transmission in the P position 9 Depress the brake pedal and release the parking brake 10 Start the eng...

Page 80: ...le to sit with their backs on the seat with their feet flat on the floor and their hands on the steering wheel if driving or on the passenger armrest grab bar 5 The driver and all passenger must wear...

Page 81: ...at both passenger and passenger wear seat belts Park the Vehicle 1 Press the brake pedal and put the shifter in P 2 Turn the key to the OFF position P 33 and the key can be taken out of the switch 3 P...

Page 82: ...rfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slo...

Page 83: ...ine Your dealer can provide this service If it s impossible to bring the vehicle in before starting the engine perform the service outlined in the Vehicle Immersion section of this manual and take the...

Page 84: ...obstacles 2 Watch out for bumps potholes and other obstacles in the terrain 3 When you approach any obstacle reduce your speed and be prepared to stop 4 Never try to ride over large obstacles such as...

Page 85: ...r go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Driving downhill When driving downhill follow these precautions...

Page 86: ...n incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always block the rear wheel...

Page 87: ...tion or the riding mileage which used first two full tanks of fuel Avoid full throttle operation Avoid pressing the accelerator pedal past down Avoid continuous acceleration The brake needs a 124mi 20...

Page 88: ...proper operation P52 Brake fluid Ensure appropriate level P129 Front suspension Check and lubricate if necessary P136 Rear suspension Check and lubricate if necessary P136 Tire Check status and pressu...

Page 89: ...81 OPERATION OPERATION Seat belt Check the length of the seat belt for damage and check whether the latch is in normal operation P46 Net door Inspect doors and latches for wear or damage P48...

Page 90: ...exceed the maximum weight capacityof the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passenger s accessories and loads in the rack or box The...

Page 91: ...MENDED SPEEDS Vehicle should never exceed 10 MPH 16 km h while towing a load on a level grass surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering...

Page 92: ...on the towing bracket 2 When towing a disabled vehicle place the disabled vehicle s transmission in neutral Do not operate the vehicle faster than 10 MPH 16 km h when towing 3 Towing a trailer increas...

Page 93: ...ttempt to dump or unload the vehicle while parked on an incline 2 Apply the brakes 3 Set the parking brake 4 Turn the key to the off position 5 Dismountvehicle 6 Ensure that the cargo is positioned ev...

Page 94: ...will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position Loading guidelines When tra...

Page 95: ...and trailer shall not exceed the maximum capacity of the vehicle Where a designated attachment point is provided on the towbar Either Pass the cable through the attachment point and clip it back on i...

Page 96: ...ng range of the winch Do not overload Ensure that all equipment used meets the maximum rope pull force rating We recommend using an optional pulley block double rope using a pulley block double rope w...

Page 97: ...eck the rope to prevent kinks and uneven wire layers The rope slack must be properly tightened under a weight of about 220 lbs 100Kg When pulling the load be sure to place a protective layer on the wi...

Page 98: ...gloves Do not let the rope slip over your hands Check the rope before use Crushed pinched worn or kinked areas seriously reduce the carrying capacity A damaged rope should be replaced It must be re wo...

Page 99: ...winch is not used please remove the controller WARNING When releasing or retrieving the winch rope both ends of the rope must be left with sufficient length to prevent the rope from being over rolled...

Page 100: ...Winch When the winch manual release switch is turned clockwise the winch cable can be pulled out manually When the winch manual release is switched turned counterclockwise the winch can be controlled...

Page 101: ...Remote control operation 1 Release the winch cable 2 Reclaim the winch cable NOTICE When the remote control doesn t work it may be that the battery in the remote control is exhausted Replace the batt...

Page 102: ...gine Oil Level Check 108 Changing Engine Oil Filter 110 Drain the Engine Oil 111 Replace Oil Filter Oil Strainer 113 Oil Strainer Cleaning 114 Add Engine Oil 115 FRONT REAR GEARBOX DEMAND DRIVE FLUID...

Page 103: ...Replace the Tires 132 Wheel Removal 133 Tire Replacement Size 134 SHOCK ABSORBER ADJUSTMENT 135 LUBRICATION 136 Front Rear Drive Axle Dustcover 137 AIR FILTER 138 Replacing Air Filter element 138 Air...

Page 104: ...Charging 151 Battery Installation 152 FUSE 154 Fuse Box 155 Fuse Relay Distribution and Rated Amperage 156 Fuse Box Replacement 158 APPEARANCE CARE 159 Vehicle Washing 159 Vehicle Storage 159 MAINTENA...

Page 105: ...rts dealer Service and adjustments are important for proper vehicle operation If you re not familiar with the service and adjustment procedures have a qualified Segway Powersports dealer perform these...

Page 106: ...roperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized Segway Powersports dealer or other qualified person perform t...

Page 107: ...Ride Rear suspension Pre Ride Tires Wheels fasteners Pre Ride Brake uid level Pre Ride Brake system Pre Ride Accelerator Pre Ride Engine oil level Pre Ride Air lter pre lter Daily Inspect clean often...

Page 108: ...ral lubrication 50 H 3 M 3 M 500 800 Lubricate all ttings pivots cables etc Throttle Body Intake Duct 50 H 6 M 500 800 500 800 Inspect duct for proper sealing air leaks Drive belt 50 H 6 M 500 800 Ins...

Page 109: ...pipe Joints 100 H 12 M 1000 1600 Inspect clean replace worn parts D Spark plug 100 H 12 M 1000 1600 Inspect replace as needed D Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace wo...

Page 110: ...al lubrication as required Project Recommended model Capacity Inspection procedure Engine oil SAE10W 40 SJ Or higher grade 128 5 oz 3300 ml Maintain level in safe range on dipstick Front Di erential S...

Page 111: ...103 MAINTENANCE STORAGEANDTRANSPORTATION Front service lid Hold the front service lid and lift it upward Open the lid Fuse box coolant filling port located under the front service lid...

Page 112: ...tainer Whenloading the goods do not exceed the maximum load of the container do not exceed the maximum load of the container Cargo box tailgate Open the tailgate by lifting the handle of the rear door...

Page 113: ...rgo bed release handle to raise the cargo bed The lock hook of the container will spring open The cargo bed will slowly tilt upwards and stop automatically when it reaches the turning limit Push down...

Page 114: ...during cold weather can indicate contaminants collected in the oil sump or crankcase If the oil level starts to rise change the oil immediately Monitor the oil level if it continues to rise stop using...

Page 115: ...r oil for this engine Follow the manufacturer s recommendations for ambient temperature operation Please refer to the lubricant guide section for fluid recommendations capacity CAUTION Mixing brands o...

Page 116: ...Using a rag hold the end of the oil dipstick and remove the oil dipstick from the engine 5 Wipe the oil from the dipstick 6 Reinsert the dipstick completely 7 Pull the dipstick out and check the oil l...

Page 117: ...k insert and install it again 9 If the oil level is near or below the lower level mark Flip the cargo container see page 105 Remove the oil fill cap 3 from the front right crankcase cover Add the spec...

Page 118: ...d be taken to avoid prolonged and repeated exposure to such oils Wash the skin thoroughly with soap and water to remove the used engine oil The used oil and filter must be disposed in a safe and compl...

Page 119: ...ng 5 Oil Drain Plug There are two places on the engine where the oil can be drained and both places should be drained otherwise the waste oil cannot be drained completely Oil drain position 1 The oil...

Page 120: ...t oil can cause skin burns Don t let hot oil touch the skin 3 Place a suitable container under the oil drain plug 1 to collect the discharged waste oil 4 Remove the oil drain plug 1 remove the O ring...

Page 121: ...Refer to fluid recommendations for capacity and plug torque Always change the filter at the same time you change the engine oil 1 Using a oil filter wrench turn the filter counter clockwise to remove...

Page 122: ...eaning 1 Oil drain plug 2 O ring 3 Oil filter Torque Drain Plug 11 8 14 8ft lb 16 20N m 1 Remove the drain plug take off the O ring and remove the oil strainer 2 Clean the strainer and allow to dry 3...

Page 123: ...ul to do not overfill it The correct oil level is between the upper level and the lower level marks on the dip stick 3 Retighten Replace the oil cap 4 Put the gear shifter in park 5 Lock the parking b...

Page 124: ...s any of the following Continuous 4WD operations running in mountain or mountain areas for long periods of time in 4WD mode 4WD is the primary mode of all wheel drive operations NOTICE If the front ge...

Page 125: ...Put the vehicle to a stop 2 With a rag remove and pull out the oil dipstick 3 Clean the dipstick 4 Re insert the dipstick completely 5 Check the oil level as shown in the figure above The oil should...

Page 126: ...the vehicle oil drain to collect the waste oil 2 Position the vehicle on a horizontal surface and remove the drain plug and o ring 3 After the oil is drained reinstall the drain plug using new washer...

Page 127: ...the vehicle on a horizontal plane 2 Place the drain tray under the differential 3 Remove the drain plug Allow the fluid to drain completely 4 Clean and reinstall the drain plug 5 Torque to desired va...

Page 128: ...RNING WARNING Failure to remove all debris when the belt is replaced can result in vehicle damage loss of control and serious injury or death Stop the engine before replacement and allow the vehicle t...

Page 129: ...completely Install the drive belt The installation steps are basically the reverse of the removal 1 Wrap the drive belt around the CVT driving wheel 2 Use the CVT belt replacement tool to open the CV...

Page 130: ...B7RTC Spark Plug Gap 0 7 0 9 mm Spark Plug Torque 8 8 ft lbs 12 N m 1 Remove the CVT clutch drain plug 2 Wait for the water to drain out and reinstall the water drain plug 2 Start the engine 3 Increas...

Page 131: ...ne is running Check or change the spark plugs within the maintenance time shown in the periodic maintenance schedule CAUTION Allow the engine to cool before attempting to remove the spark plug for ins...

Page 132: ...ition coil The spark plug is located below the ignition coil 3 Using the spark plug wrench provided in the took kit remove the plugs by rotating them counterclockwise 4 Reverse the procedure for spark...

Page 133: ...rate at normal operating temperature Maintaining the coolant will allow the cooling system to work properly and prevent freezing overheating and corrosion Therefore the coolant should be frequently ch...

Page 134: ...the vehicle 2 If the liquid level is low add the corresponding type of coolant Coolant should be in the bottle remain level between minimum MIN and maximum mark MAX on the liquid as the liquid cools...

Page 135: ...allowed to cool down before the pressure cap is removed Use fresh antifreeze when any cooling system fluid is removed for maintenance or repair 50 50 premix to replace coolant If the recycling bottle...

Page 136: ...nspection is recommended to keep the braking system in good working condition If the brake is in heavy use during normal operation check it frequently 1 Always keep the brake fluid at an appropriate l...

Page 137: ...ake Oil DOT4 No adjustment is required for the hydraulic assisted braking system Check the brake oil level of the auxiliary braking system frequently If the level is shown to be low perform the follow...

Page 138: ...ontact with the skin or eyes flush with plenty of water immediately If you feel sick seek medical attention immediately Brake Pads Brake pad wear will depend on the severity of the operator and operat...

Page 139: ...e checking pressure If the vehicle has been parked for at least 3 hours or has not driven more than 1 mi 1 5km the check at this time can get an accurate reading of the cold tire inflation pressure Ti...

Page 140: ...such as a cut delamination or a deep crack of the sidewall or a bulge is all indications that the tire is damaged Tires can have air leaks and cannot be normally repaired due to the size or position...

Page 141: ...que Mounting nuts 74 88ft lbs Mounting nuts 74 88ft lbs 100 120N 100 120N m m 1 Stop the engine 2 Put the gear shifter in P position 3 Lock parking brake 4 Lift the side of the vehicle by placing a su...

Page 142: ...xcessive tightening of wheel nuts resulting in damage to bolt or spoke wheels In addition lubricating oil or grease can cause wheel nuts to become loose and wheels may fall off which can lead to accid...

Page 143: ...ard it can be adjusted by the spring table adjustment Position 1 Standard position Position 2 5 When vehicle load is heavy it can be adjusted to this position Use crescent wrench 6 to adjust the impac...

Page 144: ...installed with grease fitting If you see the label below there is a grease spot nearby These parts on the vehicle need sufficient lubrication Lubrication can reduce the wear of these parts and increas...

Page 145: ...NSPORTATION Front Rear Drive Axle Dustcover Check for cuts damage or grease leakage in the front and rear drive Axle dust boots If you find an damage or grease leakage please contact your Segway Power...

Page 146: ...y meets the needs of the engine The air filter core shall be replaced regularly according to the periodic maintenance table The primary filter screen must be cleaned every bime the air filter core is...

Page 147: ...er cover and pull out the air filter cover 1 2 Pull out the air filter box 3 Take out the filter element 3 from the box clean or replace the filter element according to the cleanliness of the filter e...

Page 148: ...replace it if damaged WARNING When assembling the filter element please make sure that the buckles of the filter element and the end cover are installed in place otherwise it will cause the engine to...

Page 149: ...ns out please send the vehicle to the dealer for replacement Halogen lamp If the halogen bulb is damaged it can be replaced You can replace the following lamps yourself The ease of replacement varies...

Page 150: ...adlight shade bulb glass Fingerprints on the glass can to cause premature failure Execute the following procedure 1 Remove the headlamp shade expansion screw and remove the headlamp cover with the too...

Page 151: ...ring pop out of the slot 6 Remove the broken light bulb CAUTION Please replace lamp with the recommended power Reinstall the new lamp into the new headlight assembly The installation procedure is oppo...

Page 152: ...t of the lamp seat the damaged bulb can be taken out and replaced with a new bulb with the same power 3 Test whether the lamp works normally High beam adjustment The headlight beam can be adjusted sli...

Page 153: ...ights and mark the walls at the same height 3 Apply the brakes Start the engine Turn on the headlights 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 9 5 24 cm...

Page 154: ...wise To lower the headlight beam turn the headlight speed adjustment screw clockwise Adjust the headlight beam left and right The headlight beam can be adjusted from left or right To turn the headligh...

Page 155: ...maintenance will reduce engine performance if the maintenance is not done WARNING WARNING Make sure the exhaust pipes are cool Ensure that there are no combustible materials in the area when maintain...

Page 156: ...ler spark suppressor 3 Use a non synthetic brush to clean the arrester screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 4 Inspect t...

Page 157: ...ry life cycle WARNING 12V batteries contain toxic and corrosive sulfuric acid and may produce flammable explosive hydrogen gas To reduce the risk of serious injury or death the following precautions s...

Page 158: ...prevent damage to the vehicle The battery is located under the middle of the seat If you want to replace or maintain the battery please remove the passenger seat and cover see page 43 for details Turn...

Page 159: ...f charging the 12V battery is still installed in the vehicle be sure to disconnect the ground cable Make sure the power switch on the charger is off when connecting and disconnecting the charger cable...

Page 160: ...allation NOTICE To reduce the chance of sparks disconnect the black negative cable first When reinstalling the battery install the black negative cable last 1 Clean battery cables and terminals with a...

Page 161: ...da Rinse well and dry thoroughly 2 Put the battery in the tray 3 Connect and tighten the red positive cable 4 Connect and tighten the black negative cable 5 Install the battery press plate 6 Tighten t...

Page 162: ...t is found to have blown replace the blown fuse There is a spare fuse in the fuse box Check all fuses for other possible causes Replace all blown fuses and check the working condition of components Al...

Page 163: ...ir cover as shown in page 103 After the front panel repair cover has been removed the fuse box is located at the bottom Move the clasp on the left and right sides of the fuse box cover Loosen the clas...

Page 164: ...TATION Fuse Relay Distribution and Rated Amperage There is a You can refer to the fuse distribution label on the top of the fuse box cover to find a fuse of the same power for replacement Rated ampera...

Page 165: ...10A F17 EPS IG fuse 5A F20 MAIN FUSE 50A F23 ECU FUSE 15A F24 EPS fuse 40A F31 FAN FUSE 20A R1 REMOTE POWER ON RELAY 12V 20A R2 AUXILIARY START RELAY 12V 20A R3 IG1 RELAY 12V 20A R4 MAIN RELAY 12V 20A...

Page 166: ...fuse s To check or replace the circuit fuse pull out the old fuse with a puller The fuse box cover is equipped with a puller Using this tool will help you take out the fuse The fuse box cover is fitt...

Page 167: ...ve the grime 4 After washing rinse your vehicle thoroughly with plenty of clean water to remove any residue Detergent residue can corrode alloy parts 5 Dry your vehicle with a chamois or a soft towel...

Page 168: ...SPECIFICATIONS SPECIFICATIONS TECHNICAL PARAMETERS OF VEHICLE 161 VEHICLE IDENTIFICATION NUMBER 165 The frame nameplate 167...

Page 169: ...ance 12 6 in 320 mm Turning circle diameter 335 in 8500 mm Height of seat cushion from the ground 19 6 in 500 mm Steering wheel diameter 13 8 in 350 mm Maximum weight capacity 1500 Ibs 680 kg Axle loa...

Page 170: ...n method Liquid Cooling method Liquid Lubricating oil Engine SAE10W 40 SJ or Higher Gearbox SAE 75 80W 90 GL5 Front Axle SAE 75 80W 90 GL5 Lubricating oil Lubricating oil volume volume Engine 128 5 oz...

Page 171: ...11 00R14 Tire pressure Fr Wheel 15 0 PSI 103 Kpa Rr Wheel 16 0 PSI 110 Kpa Driving brake Type Hydraulic Disc Operation method Right feet Parking brake Type Mechanic Automatic compensation type Operat...

Page 172: ...55W 2 32000cd H4 Fr Position light LED 2 Daytime Running Light LED 2 Tail light Rr Brake light Red 21W P21 5W Rr Position light Red 5W P21 5W Battery Capacity Maintenance free lead acid 12V 32Ah Dashb...

Page 173: ...ICLE IDENTIFICATION NUMBER Record the frame identification code and engine serial code in the spaces provided for assistance when ordering spare parts from a dealer or for reference in case the vehicl...

Page 174: ...166 SPECIFICATIONS SPECIFICATIONS QJLQH VHULDO FRGH Engine serial code...

Page 175: ...clude VIN code It needs the VIN when the vehicle requires activate in the first time 6 7HFKQRORJ R WG FHUWL HV WKDW WKLV 529 FRPSOLHV ZLWK 16 52 9 6WDQGDUG 7KLV YHKLFOH LV GHVLJQHG DQG PDQXIDFWXUHG IR...

Page 176: ...ine doesn t turn over 171 Engine pings or knocks 171 Engine stops or loses power 172 Engine turns over fails to start 172 Engine backfires 173 Engine runs irregularly stalls or misfires 174 Engine run...

Page 177: ...ng up a steep incline When starting out on an incline use low range see page 77 Driving at low RPM or low ground speed at approximately 3 5 mph 5 10 km h Drive at a higher speed or use low range more...

Page 178: ...ion stopped position Shift the transmission to low range Shift the transmission to low range and carefully use fast brief aggressive and carefully use fast brief aggressive throttle application to eng...

Page 179: ...tery to 12 5 VDC Recharge battery to 12 5 VDC Loose battery Loose battery connections connections Check all connections and tighten Check all connections and tighten Loose solenoid Loose solenoid conn...

Page 180: ...uel Drain the fuel system and refuel Drain the fuel system and refuel Fuel valve is out of use Fuel valve is out of use Replace Replace Old or non Old or non recommended fuel recommended fuel Replace...

Page 181: ...plugs plugs Inspect clean and or replace spark Inspect clean and or replace spark plugs plugs Incorrect spark plug gap Incorrect spark plug gap or heat range or heat range Set gap to specs or replace...

Page 182: ...wires plug wires See your dealer See your dealer Incorrect spark plug gap Incorrect spark plug gap or heat range or heat range Set gap to specs or replace plugs Set gap to specs or replace plugs Loose...

Page 183: ...r See your dealer Other mechanical failure Other mechanical failure See your dealer See your dealer Possible Lean or Rich Possible Lean or Rich Fuel Mixture Cause Fuel Mixture Cause Solution Solution...

Page 184: ...ctive spark plug wires plug wires See your dealer See your dealer Incorrect spark plug gap Incorrect spark plug gap or heat range or heat range Set gap to specs or replace plugs Set gap to specs or re...

Page 185: ...EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM SOURCE OF EXHAUST EMISSIONS 178 EXHAUST EMISSION CONTROL SYSTEM 178 CRANKCASE EMISSION CONTROL SYSTEM 178 NOISE CONTROL SYSTEM 178...

Page 186: ...The exhaust emission control system includes a PGM F system and oxygen sensor No adjustments to this system should be made although periodic inspection of the components is recommended The exhaust emi...

Page 187: ...WARRANTY WARRANTY WARRANTY 180 LIMITED WARRANTY POLICY 181...

Page 188: ...OWNER S WARRANTY RESPONSIBILITIES As the UTV owner you are responsible for the performance of the required maintenance listed in our owner s manual SEGWAY POWERSPORTS INC recommends that you retain a...

Page 189: ...components of your new SEGWAY vehicle against defects in material or workmanship when properly set up and operated in accordance with the recommendations set forth in the SEGWAY Operator s Manual SEGW...

Page 190: ...ent nor to any vehicle not operated in accordance with SEGWAY s instructions SEGWAY may elect to have an area representative evaluate the condition of the machine before warranty is considered In addi...

Page 191: ...special damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise This exclusion of consequential incidental and specia...

Page 192: ......