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SNARLER ATV 2021 Series
Segway SNARLER ATV 2021 Series User Manual
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SER
VICE MANU
AL
A
TV SERIES PRODUCTS
20210804 V01
2
Table of Contents
General Information
7
Vehicle Identification Number
8
Technical Parameters of Vehicle
9
Unit Conversion Table
12
Torque
12
Maintenance
16
Table of Contents
16
Maintenance Periodic Table
18
Check and Adjust Free Play of Throttle Cable
21
Throttle Lever Free Play Inspection
21
Cleaning or Replacing Air Fi Lter
22
Brake System
23
Inspection of Front Brake Hose and Connection
23
Check Fl Uid Level of Front Brake Oil Cup
24
Replace Brake Hose
24
Check Rear Brake Oil Cup Liquid Level
25
Pump out Brake Fl Uid from Brake System
25
Replace Brake Fluid
25
Refill Brake Fluid
26
Discharge Air in the Brake System
27
Replace of Front Brake Disc
28
Replace of Rear Brake Disc
28
Check Cylinder
29
Check Free Play of Rear Brake Pedal
30
Adjustment of Free Play of Parking Handle
31
Check Rear Parking Handle Work Play
31
Cooling System
32
Radiator Cleaning
32
Radiator Hose and Connection Inspection
32
Adding Cooling Liquid
33
Engine Oil Level Check
34
Changing Engine Oil&Fi Lter
35
Oli Strainer Clean
35
Front/Rear Axle Gear Oil
36
Oil Fi Lter Change
36
Tire Inspection
37
Engine Lubrication System
38
Exploded View
39
Technical Parameter
41
Special Tools and Sealant
42
Engine Oil Flow Chart
43
Engine Oil and Oil Filter
44
Oil Level Inspection
44
Engine Oil Change
45
Oil Filter Change
45
Oil Pressure Measurement
46
Oil Pressure Valve
47
Oil Pressure Valve Inspection
47
Oil Pressure Valve Installation
47
Oil Pressure Valve Removal
47
Oil Pump
48
Oil Pump Installation
48
Oil Pump Removal
48
Oil Pump Gear
49
Oil Pump Gear Installation
49
Oil Pump Gear Removal
49
Oil Cooler
50
Oil Cooler Installation
50
Oil Cooler Removal
50
Crankshaft / Transmission
51
Exploded View
52
Crankcase
61
Crankcase Disassembly
61
Crankcase Assembly
64
Connecting Rod Big End Side Clearance
75
Crankshaft Main Bearing/Journal Wear
75
Crankshaft Runout
75
Transmission
76
Transmission Removal
76
Transmission Installation
78
Shift Fork Bending
79
Shift Fork/Gear and Shifter Groove Wear
79
Transmission and Shift Mechanism Inspection
80
Ball and Needle Bearing Replacement
82
Ball and Needle Bearing Wear
82
Ball Bearing, Needle Bearing, and Oil Seal
82
Oil Seal Inspection
83
Engine-Electrical System
84
Exploded View
85
Technical Parameter
87
Special Tools
88
Alternator Cover Installation
89
Alternator Cover Removal
89
Charging System
89
Alternator Rotor Removal
90
Alternator Rotor Installation
91
Alternator Stator Removal
91
Alternator Stator Installation
92
Alternator Inspection
93
Electric Starter System
95
Starter Motor Installation
95
Starter Motor Removal
95
Starter Gear Assembly
97
Engine-Cooling System
98
Exploded View
99
Technical Parameter
101
Special Tools
102
Water Pump
103
Water Pump Installation
103
Water Pump Removal
103
Impeller Removal
104
Water Pump Cover Removal
104
Water Pump Impeller Inspection
104
Mechanical Seal Replacement
105
Water Pump Shaft Removal
105
Water Pump Cover Installation
107
Thermostat
108
Thermostat Installation
108
Thermostat Inspection
109
Coolant Temperature Sensor
110
Coolant Temperature Sensor Inspection
110
Coolant Temperature Sensor Installation
110
Coolant Temperature Sensor Removal
110
Engine Top End
111
Exploded View
113
Special Tools
119
Spark Plug / Valve Cover / Throttle Body / Camshaft
120
Air Intake Pipe Installation
121
Air Intake Pipe Removal
121
Throttle Body Installation
121
Throttle Body Removal
121
Fuel Injector Installation
122
Fuel Injector Removal
122
Spark Plug Inspection
123
Spark Plug Installation
123
Spark Plug Removal
123
Valve Cover Installation
124
Valve Cover Removal
124
Crank Position Sensor Removal
125
Camshaft Chain Tensioner Installation
126
Camshaft Chain Tensioner Removal
126
Camshaft Carrier Removal
127
Automatic Compression Release
128
Automatic Compression Release Installation
129
Automatic Compression Release Removal
129
Camshaft Sprocket Inspection
129
Camshaft Sprocket Installation
129
Cam Wear
130
Cylinder Head
131
Cylinder Head Inspection
131
Cylinder Head Removal
131
Cylinder Head Warp
131
Cylinder Head Disassembly
132
Valve Guide / Valve Inspection
133
Combustion Chamber Cleaning
134
Valve Seat Inspection
135
Valve Seat Reconditioning
135
Valve Seat Repair (Valve Lapping)
136
Cylinder and Piston
139
Cylinder Removal
139
Cylinder, Piston Installation
140
Piston Wear
141
Piston Ring Groove Width
142
Piston Ring Thickness
142
Piston Ring, Piston Ring Groove Wear
142
Piston/Cylinder Clearance
142
Piston Ring End Gap
143
Cylinder Head Installation
144
Camshaft Installation / Timing
145
Camshaft Chain Tensioner Installation
146
Valve Clearance Adjustment
147
Valve Lash - Tappet Selection
149
Cylinder Compression Measurement
150
Valve Cover Installation
150
Cvt System
152
Exploded View
153
Special Tools
158
CVT Cover
159
CVT Inner Cover Disassembly
160
CVT Inner Cover Installation
160
CVT Inner Cover Removal
160
Drive Belt
161
Drive Belt Inspection
161
Drive Belt Installation
161
Drive Pulley and Driven Pulley
162
Drive Pulley and Driven Pulley Removal
162
Drive Pulley Disassembly
163
Drive Pulley Inspection
164
Drive Pulley Assembly
166
Driven Pulley Disassembly
168
Driven Pulley Inspection
169
Driven Pulley Assembly
170
Drive Pulley and Driven Pulley Installation
172
Front and Rear Differential
174
Add Gear Oil
193
Drain Gear Oil
193
Rear Diff Erential Gear Oil Replacement
193
Assemble
197
Disassemble
197
Inspection of Parts Wear
197
Oil Seal 37×55×7
197
Assemble
198
Assemble
199
Disassemble
199
Tooth Gap Adjustment
199
Assemble
200
Disassemble
200
Solenoid Valve Assembly Inspection and Replacement
200
Fuel System
201
Exploded View of Fuel System
202
Assembly
203
Disassembly
203
Fuel Tank
203
Disassembly
204
Fuel Pump
204
Inspection
204
Assembly
205
Assembly
206
Disassembly
206
Fuel Filter
206
Cooling System
207
Exploded View of Cooling System
208
Coolant Flow
209
Technical Parameter
211
Coolant
213
Coolant Deterioration Inspection
213
Coolant Level Check
213
Pressure Test
214
Radiator Removal
215
Radiator Fan Installation
216
Radiator Fan Removal
216
Radiator Cap Inspection
217
Radiator Cleaning
217
Radiator Inspection
217
Intake / Exhaust System
218
Exploded View of Intake System
219
Disassemble Air Filter
220
Exploded View of Exhaust System
221
Muffl er and Exhaust Pipe
222
Muffl er Disassembly
222
Assembly
223
Exhaust Pipe Disassembly
223
Inspection
223
Front & Rear Suspension
229
Exploded View of Front Suspension
230
Exploded View of Rear Suspension
232
Technical Parameter
234
Absorber Inspection
236
Normal Hydraulic Damping Absorber Preloading Adjustment
236
Shock Absorber
236
Absorber Damping Adjustment
237
Measure Free Length of Spring
237
Absorber Disassembly
238
Rebound Damping Adjustment
238
Suspension
240
Rocker Arm Assembly
241
Rocker Arm Disassembly
241
Rocker Arm Maintenance
242
Rear Stabilizer Bar Maintenance
244
Wheels and Tires
245
Exploded View of Wheels and Tires
246
Technical Parameters
248
Special Tools
249
Front Beam Inspection
250
Wheel Alignment
250
Wheel Check
252
Wheels (Rims)
252
Wheels Assembly
252
Wheels Disassembly
252
Tire
254
Tire Check
258
Take the Wheels Apart
259
Wheel Hub
259
Brake System
260
Exploded View of Parking Brake
263
Specifications
263
Special Tools
264
Brake Fluid
265
Disassembly
266
Installation
266
Master Cylinder
266
Master Cylinder Disassembly
267
Caliper
268
Caliper Assembly
269
Caliper Disassembly
269
Caliper Holder Shaft Wear Inspection
270
Piston and Cylinder Damage
270
Brake Pad Installation
271
Brake Pad Removal
271
Brake Pad Wear Inspection
271
Brake Pads
271
Brake Discs
272
Disc Cleaning
272
Disc Installation
272
Disc Removal
272
Disc Wear
272
Vehicle Body and Frame
282
Rear Light Panel
291
Left and Right Pedals
292
Rear Fender
292
Rear Storage Box
292
Headlight Mask and Front Grille
293
Left and Right Front Mudguards
293
Disassembly
296
Disassembly
302
Disassembly
305
Front Shelf Repair
305
Rear Shelf Repair
305
Disassembly
307
Front Bumper Repair
307
Disassembly
308
Electrical System
309
Exploded View
311
Technical Parameters
314
Battery
316
Remove the Battery
316
Turn off Ignition Switch
316
Battery Charging
317
Charging Condition Check
319
Generator Inspection
320
Circuit Diagram of Charging System
321
Remove
322
Voltage Regulating Rectifi er Inspection
322
EFI System
323
Schematic Diagram of EFI System
323
Function Introduction
324
Temperature Sensor
324
Working Principle
324
Fault Diagnosis
325
Performance Parameter
325
Function Introduction
326
Oxygen Sensor
326
Working Principle
326
Electrical Characteristic Parameter
327
Performance Parameter
327
Troubleshooting
328
Electrical Characteristics
329
Electronic Control Unit（Ecu
329
Fault Diagnosis
329
Function Introduction
329
Fuel Injector
331
Working Principle
331
Fault Diagnosis
332
Performance Parameters
332
Ignition Coils
333
Working Principle
333
Fault Diagnosis
334
Performance Parameters
334
Remove and Install Spark Plugs
335
Spark Plug
335
Engine Speed Sensor
336
Fault Diagnosis
336
Technical Performance Test
336
Fault Diagnosis
337
Oil Pressure Sensor
337
Three-In-One Sensor
338
Throttle Valve Body Assembly
338
Three-In-One Sensor Performance Characteristics
339
Idle Motor
340
Fault Diagnosis
341
Idle Motor Fault Check
341
Idle Motor Fl Ow Characteristics
341
Fault Code Reading
342
Troubleshooter Operation
342
Summary of Failure Codes（Ecu
343
Lighting System Circuit
345
Headlamps
346
Replace
346
Replace
347
Tail Lamp
347
License Plate Lamp
348
Remove
348
Replace
348
Disassembly
349
Flasher
349
EPS-Brushless
350
EPS System Wiring Schematic Diagram
351
EPS Trouble Removal
352
EPS Fault Code
353
EPS-Brush
354
Dashboard
356
Display
356
Dashboard Indicator Light Description
357
Instrument Information Display
359
Dashboard (Meter)Button Function Introduction
362
Dashboard (Meter)Disassembly
362
T-Box
364
T-BOX Fault Code Display Area
364
Power Lock
366
Switch
366
Left Handlebar Switch
368
Disassembly and Assembly of Left Handlebar Switch
372
Right Handlebar Switch
373
Assembly and Disassembly of Right Handlebar Switch
374
Removal
375
Fuse Box
378
Wire Harness
380
Color Comparison Table
385
Wiring Diagram
385
Wiring Diagram
386
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Segway SNARLER ATV 2021 Series Specifications
General
Brand
Segway
Model
SNARLER ATV 2021 Series
Category
Offroad Vehicle
Language
English
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