Replacing the Brake Assembly on the Segway Max Plus (2.3)

 

 

 

 

Tool Preparation

 

•Screwdriver

•PH1, T10, T15, T20, T25, T30 bits

•Nipper pliers

•Scissors

•Wire ties

•New brake handle parts

 

Remove the Stem Assembly

 

1.Remove 1 M5x12 screw on the front side of the front tube with a T25 bit.

2.Remove 2 M7x20 screws on the side of the front tube with a T30 bit.

3.Pull out the stem, disconnect the control bus, and remove the two brake wire boxes.

4.Remove the plastic part of the brake wire from the slot of the brake wire box.

5.Pass the two brake wires through the open slot of the vertical tube separately.

6.Remove the connection block from the head end of the brake line and take out the stem.

 

Remove the Dashboard

 

1.Remove 3 M3x12 screws with a PH1 bit and take off the dashboard cover.

2.Remove 3 M2x5 screws on the dashboard.

3.Remove the cable retaining ring.

4.Disconnect the electric throttle, electric brake, and light from the dashboard.

5.Remove the dashboard.

 

Remove the Decorative Cover of Stem

 

1.Remove 1 M4x8 bolt on the decorative cover with a T20 bit.

2.Remove the small plate cover.

3.Remove 6 ST2.9x9.5 screws with a T10 bit (torque: 0.75±0.02 N·m).

4.Fasten 2 M4x8 bolts with a T20 bit and install the upper and lower decorative covers.

5.Fasten 1 M4x8 bolt with a T20 bit.

 

Remove the Brake Handle Parts

 

1.Remove the anti-theft screws on the handle with a T30 bit and take out the bottom of the stem.

2.Hold the brake handle tightly and use pointed nose pliers to remove the brake thread head from the claw.

3.Remove the brake wire head from the round hole of the brake handle and take out the brake handle assembly.

 

Install the Brake Handle Assembly

 

1.Take a new brake assembly and clench the brake handle to expose the jaw.

2.Install the brake wire end into the round hole of the brake handle and expose it from the jaw.

3.Install the head of the brake line into the jaw with nipper pliers.

4.Install the brake line into the slot of the brake handle.

5.Install the parts into the handlebar and trim the wire harness.

6.Fasten the anti-theft bolts of the brake handle parts with a T30 bit (torque: 6-8 N·m).

7.Pass the brake line through the bottom of the stem and trim the wire harness, avoiding crossing and overlapping.

 

Install the Decorative Cover of Stem

 

1.Install the decorative cover onto the handlebar by fastening 6 ST2.9x9.5 bolts with a T10 bit (torque: 0.75±0.02 N·m).

2.Install the small plate cover by fastening 1 M4x8 bolt with a T20 bit (torque: 0.6±0.1 N·m).

 

Install the Dashboard

 

1.Pass the dashboard cable through the stem and connect the throttle, electric brake, and headlight harness to the dashboard.

2.Trim the wire harness and secure it with wire ties.

3.Fasten 3 M2x5 screws with a PH1 bit (torque: 0.24±0.02 N·m).

4.Install the dashboard decorative cover and fasten 3 M3x12 hexagonal countersunk screws with a T10 bit (torque: 0.8±0.1 N·m).

 

Install the Stem

 

1.Insert the brake wire through the open slot of the front tube and connect the control bus.

2.Insert the cuboid block into the connection of the brake line box at the end of the brake.

3.Install the brake wire plastic into the slot of the brake wire box.

4.Install the cover plate of the brake box and trim the controlling harness.

5.Insert the stem into the front tube.

6.Fasten 2 M7x20 screws with a T30 bit (torque: 8-10 N·m).

7.Fasten 1 M5x12 screw with a T25 bit (torque: 5-6 N·m).

 

Function Detection

 

1.Power on the scooter and confirm there are no issues with the operation.

 

Adjusting the Brake

 

1.Hold the brake handle three times to ensure there are no problems with the brake handle.

2.Loosen the jam nut with a #8 wrench and nipper.

3.Adjust the brake by rotating the adjusting nut.

 

Final Function Detection

 

1.Power on the scooter and lock the brake handle with a 33mm jig. Ensure the rear light is flashing.

2.Push the scooter while holding the stem, ensuring the wheel can rotate.

3.Adjust the brake with a 30mm jig using the same method as the previous step.

4.Push the scooter; the front wheel should lock, and the rear wheel should lift.

5.After adjusting the brake, fasten the jam nut with a #8 wrench and nipper (torque: 5.5±0.5 N·m).

 

This should make the instructions clearer and easier to follow.