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VILLIAN SSV Series
Segway VILLIAN SSV Series User Manual
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1
GENERAL
INFORMA
TION
VEHICLE
IDENTIFICA
TION
NUMBER/ENGINE
SERIAL
CODE……
1-2
TECHNICAL
P
ARAMETERS
OF
VEHICLE
…………………………
1-
3
UNIT CONVERSION T
ABLE
……………………………………………
… 1-6
T
ORQUE
…………………………………………………………………
…1-7
GENERAL
INFORMA
TION
5
7
Table of Contents
General Information
6
Vehicle Identification Number/Engine Serial Code
7
Technical Parameters of Vehicle
8
Unit Conversion Table
11
Torque
12
Maintenance
16
Table of Contents
16
Maintenance Reference
21
Grease
23
Frame, Nuts, Bolts, and Fasteners
24
General Vehicle Inspection and Maintenance
24
Pre-Ride / Daily Inspection
24
Shift Cable Inspection / Adjustment
25
Fuel Filter
26
Fuel System
26
Fuel System and Air Intake
26
Fuel Lines
27
Air Filter Service
28
Engine Intake Pre-Filter Service
28
Engine
29
Engine Oil Level
29
Engine Oil Change
30
Replace Oil Fi Lter/Oil Strainer
31
Add Engine Oil
32
Engine / Oil Tank Breather Hose Inspection
33
Engine Cylinder Leakdown Test
33
Spark Arrester
34
Check the Level of Rear Gear Box
35
Transmission and Front Gearcase
35
Check the Level of Front Gear Box
36
Front/Rear Gearbox Oil Discharge
36
Cooling System
38
Cooling System Hoses
38
Cooling Bottle Coolant
39
CVT Belt
40
Pvt / Final Drive / Wheel and Tire
40
Drive Shaft Boot Inspection
41
The CVT Dry
41
Wheel
42
Wheel Installation
42
Wheel Removal
42
Battery Charging
43
Battery Disassembly
43
Electrical and Ignition System
43
Battery Installation
44
Spark Plug
44
Spark Plug Inspection
45
Brake System
47
Brake Oil
48
Engine Lubrication System
49
Exploded View
50
Technical Parameter
52
Special Tools
53
Engine Oil Flow Chart
54
Oil and Oil Filter
55
Oil Level Check
55
Clean the Oil Fi Lter Combination
56
Engine Oil Change
56
Remove the Oil Filter
56
Measure Oil Pressure
57
Oil Pressure
57
Install the Oil Filter Assembly
58
Install the Oil Pump Assembly
58
Oil Pump
58
Remove the Oil Fi Lter Assembly
58
Remove the Oil Pump Assembly
58
Install the Main Engine Oil Pump Rotor
59
Remove the Main Engine Oil Pump Rotor
59
Install the Auxiliary Oil Pump Rotor
60
Install the Oil Pump Shaft and Oil Seal
60
Remove the Auxiliary Oil Pump Rotor
60
Remove the Oil Pump Shaft and Oil Seal
60
Install the Oil Cooler Assembly
61
Oil Cooler Assembly
61
Remove the Oil Cooler Assembly
61
Starting System
66
Exploded View
67
Special Tools
69
Install the Starter Motor
70
Remove the Starter Motor
70
Starting System
70
Disassemble the Starting Overload Protector and the Double Gear Assembly
71
Install Starting Overload Protector and Double Gear Assembly
71
Check the Starting Overrunning Clutch
72
Disassemble the Magneto Rotor
72
Install the Magneto Rotor
72
Disassemble the Starting Overrunning Clutch
73
Install the Starting Overrunning Clutch
73
Crankcase\Crankshaft\Balance Shaft
74
Explosive View
75
Explosive View of up and down the Case Sub-Assembly
76
Explosive View of Left Crankcase Cover Sub-Assembly
78
Explosive View of Upper Crankcase Cover Sub-Assembly
80
Explosive View of Lower Crankcase Cover Sub-Assembly
81
Explosive View of Oil Pan Sub-Assembly
82
Technical Parameter
83
Special Tools
84
Left Crankcase Cover
85
Left Crankcase Cover Disassembly
85
Check Left Crankcase Cover
86
Crankcase\Crankshaft\Balance Shaft
86
Install Left Crankcase Cover
86
Crankcase Assembly
87
Remove Balance Shaft
89
Check Balance Shaft
90
Remove the Crankshaft
90
Check the Crankshaft
91
Install the Crankshaft
92
Mounting Balancing Shaft
92
Crankcase Assembly
93
Bearing Selection
96
Bearing Shell Group
96
Group Identifi er
96
Balancing Shaft Bearing Bush Optional
97
Connecting Rod Bearing Bush Optional
97
Spindle Bushing Selection
97
Cylinder Head, Cylinder, Piston
98
Exploded View
100
Explosive View of Cylinder Head Cover Sub-Assembly
101
Explosive View of Cylinder Head Sub-Assembly
102
Explosive View of Cylinder Sub-Assembly
104
Explosive View of Valve Mechanism
105
Explosive View of Piston Connecting Rod Assembly
106
Technical Parameters
108
Technical Parameter
109
Special Tools
110
Cylinder Head Cover
111
Install the Cylinder Head Cover
111
Remove the Cylinder Head Cover
111
Camshaft Cover / Camshaft
112
Install the Tensioner
112
Remove the Tensioner
112
Disassemble Camshaft
113
Camshaft / Camshaft Lobe Inspection
114
Camshaft Sprocket Inspection
114
Install Camshaft Sprocket
115
Camshaft Installation / Timing Adjustment
116
Valve Clearance Adjustment
118
Optional Tappet Specifi Cations
119
Selection of Valve Tappet
119
Check the Cylinder Head Deformation
122
Cylinder Head
122
Cylinder Head Inspection
122
Install the Intake Pipe Assembly
123
Install Thermostat and Water Temperature Sensor
123
Remove the Intake Pipe Assembly
123
Disassemble the Spark Plug
124
Install Spark Plug
124
Thermostat Check
124
Remove the Valve
125
Valve Guide / Valve Inspection
126
Combustion Chamber Cleaning
127
Seat Ring Inspection
128
Seat Ring Repair
128
Seat Ring Repair (Valve Grinding)
129
Cylinder Head Assembly
131
Cylinder Block and Piston
132
Cylinder Block Inspection
132
Cylinder Block Removal
132
Disassemble the Piston
133
Piston Measurement
134
Measure the Gap of the Piston Ring Groove
135
Connecting Rod Measurement
136
Measure the Closed Gap of the Piston Ring
136
Measure the Piston Pin
136
Piston Connecting Rod Assembly
137
Piston Ring Installation
137
Cylinder Block Assembly
138
Cylinder Pressure Measurement
139
Cvt System
140
Exploded View
141
Special Tools
144
Disassemble the CVT Cover
145
Install the CVT Cover
145
Disassemble the CVT Inner Cover
146
Install the CVT Inner Cover
146
Check the Drive Belt
147
Disassemble the Drive Belt
147
Install the Drive Belt
147
Transmission Belt
147
Disassemble the Drive Pulley and the Driven Pulley
148
Install Drive Pulley and Driven Pulley
149
Water Pump Assembly
150
Exploded View
151
Special Tools
153
Water Pump Assembly
153
Disassemble the Water Pump
154
Install the Water Pump
155
Front Axle and Rear Gearbox
156
Exploded View of Front Axle
158
Special Tools
161
Add New Gear Oil
162
Drain the Old Gear Oil
162
Replacement of Front Axle Gear Oil
162
Disassemble
163
Inspection of Parts Wear
163
Install
163
Adjustment of Gear Clearance
164
Disassemble
164
Install
164
Exploded View of Rear Gearbox
165
Add Gearbox Oil
168
Drain the Gearbox Oil
168
Replacement of Gearbox Gear Oil
168
Dismantling the Driven Bevel Gear Cover Assembly
169
Dismantling the Driving Bevel Gear
169
Dismantling the Gearbox
169
Dismantling the Shift Shaft Cover Assembly
169
Gear Setting
169
Dismantling the Connecting Nut between the Shaft and the Box Body
170
Dismantling the Oil Pump Components
170
Dismantling the Shift Mechanism
170
Dismantling the Reverse Gear Idler Shaft Assembly and Main Shaft Assembly
171
Dismantling the Right Gearbox Assembly
171
Dismantling the Right Gearbox Connector
171
Dismantling the Box Connector
172
Dismantling the Gear Transmission Parts
172
Dismantling the Parking Mechanism
172
Dismantling the Shifting System
172
Dismantling the Countershaft Assembly
173
Assemble the Gearbox
174
Install the Left Box Bearing
174
Install the Right Gearbox Combined Bearing
174
Install the Bearing Plate of the Left Box Body
175
Install the Parking Mechanism
175
Assemble the Rear Axle Output Gear Assembly
176
Install the Countershaft Assembly
176
Install the Left Box Connector
176
Assemble the HR Shift Fork Shaft Assembly
177
Assemble the L Gear Shift Fork Shaft Assembly
177
Install the Gear Set
177
Install the HR Shift Fork Shaft Assembly
178
Install the L Gear Shift Fork Shaft Assembly
178
Install the Parking Shaft and Shift Drum Assembly
179
Install the Gear Assembly
180
Install the Main Shaft Assembly
180
Install the Right Box Body Combination
180
Install the Countershaft Low-Speed Gear
181
Install the Driven Bevel Gear Shaft
181
Install the Driven Bevel Gear Cover
182
Install the Driven Bevel Gear Cover Oil Seal
182
Install the Gear Sensor and Rotary Shaft Oil Seal
183
Install the Gear Set Nut
183
Install the Oil Pump Assembly
184
Install the Rear Axle Output Shaft Oil Seal
184
Install the Needle Bearing and Locating Pin
185
Install the Shift Mechanism
185
Fuel System
186
Exploded View of Fuel System
187
Assembly
188
Disassembly
188
Fuel Tank
188
Disassembly
189
Fuel Pump
189
Inspection
189
Assembly
190
Assembly
191
Disassembly
191
Fuel Filter
191
Cooling System
192
Exploded View of Cooling System
193
Coolant Flow
194
Technical Parameter
196
Special Tools and Sealants
197
Coolant
198
Coolant Deterioration Inspection
198
Coolant Level Check
198
Pressure Test
199
Radiator Removal
200
Remove the Engine Raditor
200
Remove the Oil Radiator
200
Radiator Fan Installation
201
Radiator Fan Removal
201
Radiator Cap Inspection
202
Radiator Cleaning
202
Radiator Inspection
202
Intake / Exhaust System Intake/Exhaust System
203
Exploded View of Intake System
204
Air Filter Element Replacement
205
Air Inlet Filter Disassembly
205
Air Cleaner Disassembly
206
Disassemble
206
Muffler
208
Air Exhaust Disassembly
209
Air Exhaust System Inspection
210
Drive System
211
Exploded View of Drive System
212
Disassembly of the Rear Section of the Drive Shaft
213
Disassembly of the Front Section of the Drive Shaft
214
Disassembly of the Middle Section of the Drive Shaft
216
Bearing Replacement
217
Front Drive Shaft Removal
218
Drive Shaft Exploded View
219
Drive Shaft Removal
220
Installation of Drive Shaft
222
Inboard CV Joint Drive Shaft Repair
223
Front & Rear Suspension
226
Exploded View of Front Suspension
227
Exploded View of Rear Suspension
229
Technical Parameter
231
Dedicated Tools
232
Absorber Inspection
233
Shock Absorber
233
Absorber Scrapped
237
Front Suspension
238
Wheels and Tires
243
Exploded View of Wheels and Tires
244
Technical Parameters
246
Special Tools
247
Front Beam Inspection
248
Wheel Alignment
248
Front Bundle Adjustment
249
Wheel Check
250
Wheel Disassembly
250
Wheel（Rim
250
The Replacement of the Wheel
251
Tire
252
Tire Disassembly
252
Tire Disassembly (for Anti-Drop Rims)
254
Tyre Mounting (for Anti-Drop Rims)
255
Tire Check
256
Wheel Hub
257
Wheel Hub Assembly
257
Wheel Hub Disassembly/Assembly
257
Brake System
258
Specifications
260
Special Tools
261
Brake Fluid
262
Caliper
263
Caliper Installation
263
Caliper Assembly
264
Caliper Disassembly
264
Caliper Holder Shaft Wear Inspection
265
Piston and Cylinder Damage
265
Brake Discs
266
Brake Pad Installation
266
Brake Pad Removal
266
Brake Pad Wear Inspection
266
Brake Pads
266
Disc Cleaning
267
Disc Installation
267
Disc Removal
267
Disc Wear
267
Brake Hose Inspection
268
Brake Pedal
268
Brake Pedal Position Adjustment
268
Installation of Parking Cable
268
Parking Cable
268
Parking Cable Removal
268
Vehicle Body and Frame
278
Seat Removal
288
Power Switch
289
Battery Repair Cover
290
Electrical Repair Cover
290
Foot Pedal Drain Cover
290
Gasoline Pump Repair Cover
291
Regular Engine Maintenance
291
Roll Cage Removal
293
Frame Attachment Removal
295
Front Bumper Removal
299
Removal of Rear Bumper Assembly
302
Front Axle Disassembly
304
Engine Disassembly
307
Electrical System
311
Exploded View
314
Technical Parameters
318
Multimeter
319
Special Tools
319
Battery
320
Battery Installation
320
Remove the Battery
320
Battery Charging
321
Charging Condition Check
323
Generator Inspection
324
Circuit Diagram of Charging System
325
Remove
326
Voltage Regulating Rectifi er Inspection
326
Lighting System Circuit
327
Headlight
328
Replace
328
Replace
329
Tail Light
329
Licence Lamp
330
Remove
330
Replace
330
Flasher
331
Power Lock
332
Switch
332
Emergency Switch
334
Flameout Switch
334
2WD/4WD Drive Mode Switch
335
Start Switch
335
2WD/4WD Drive Mode Switch Removal and Installation
336
Starting System Layout
337
Schematic Diagram of Starting System
338
Starting System Troubleshooting
338
Switch Position Diagram
340
Electrical Wiring
341
Wiring Check
341
Disassembly of Power Lock, Start Button, Various Switches, Etc
342
Combination Fuse Box Cover Inner Part
343
Combination Fuse Box Main Body Segment
343
Fuse Box
343
Fuse Continuity Test
344
Disassemble
346
Start Relay Troubleshooting
346
Disassemble
347
Installation
347
Start Motor
347
Disassemble the ECU
348
Ecu
348
ECU Connector Removal Skills
348
Install ECU
348
Disassemble
349
Fuel Pump Assembly
349
Fuel Pump Assembly Inspection
350
Fuel Pump Assembly
351
Install Trailer Power Socket
352
Remove Trailer Power Socket
352
Trailer Power Socket
352
Efi System
353
Schematic Diagram of EFI System
353
Coolant Temperature Sensor
354
Function Description
354
Working Principle
354
Fault Diagnosis
355
Performance Parameter
355
Function Introduction
356
Oxygen Sensor
356
Working Principle
356
Electrical Characteristic Parameter
357
Performance Parameter
357
Electrical Characteristics
358
Electronic Control Unit（Ecu
359
Function Description
359
Electrical Characteristics
360
Fault Diagnosis
360
ECU Pin Defi Nition
361
Fuel Injector
363
Working Principle
363
Fault Diagnosis
364
Performance Parameter
364
Ignition Coils
365
Working Principle
365
Fault Diagnosis
366
Performance Parameters
366
Remove and Install Spark Plugs
367
Spark Plug
367
Engine Speed Sensor
368
Fault Diagnosis
368
Technical Performance Test
368
Disassembly Requirements
369
Electronic Throttle Valve Body Assembly
369
Inlet Pressure Temperature Sensor
370
Fault Diagnosis
371
Three-In-One Sensor Performance Characteristics
371
Throttle Position Sensor and Throttle Actuator
372
Throttle Position Sensor Performance Characteristics
372
Fault Diagnosis
373
Throttle Actuator (DC Motor) Technical Performance Parameters
373
Electronic Accelerator Pedal
374
Remove and Install the Accelerator Pedal
374
Fault Diagnosis
375
Technical Performance Parameters
375
Fault Code Reading
376
Troubleshooting Instrument Operation
376
Summary of Failure Codes
377
Eps
382
EPS System Wiring Schematic Diagram
383
EPS Trouble Removal
384
Display and Human-Computer Interaction Assembly
386
Instrumentation
387
Meter Dismantling
391
Technical Parameters
391
Central Control Display
393
Disassembly and Installation of Central Control
394
Function Introduced
395
AM Performance Index
396
Performance Parameter
396
Fault Diagnosis
397
FM Performance Index
397
Tbox
398
Tbox Fault Code Display Area
399
Winch Assebly
400
Removal of Winch Motor
402
Winch Motor Position
402
Install Winch Motor
403
Schematic Diagram of Trailer System
405
Color Comparison Table
406
Electric Schematic Diagram
407
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Segway VILLIAN SSV Series Specifications
General
Brand
Segway
Model
VILLIAN SSV Series
Category
Offroad Vehicle
Language
English
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