Replacing the Back Tire / Wheel on the Segway Max Plus (2.3) Fleet Scooter

Tool Preparation

•Mobile phone

•Torque screwdriver

•H2.5, H3, H4, T20, PH2 bits

•8mm, 10mm, 18mm wrenches

•Nipper pliers

•New rear wheel

•2 reflective stickers

Remove the Tail Light Cover Plate

1.Turn over the scooter.

2.Remove 2 M4x14 bolts with a T20 bit and take off the cover plate.

Open the Battery Compartment Cover and Remove the Cover Plate

1.Remove 4 M4x8 screws with the H3 bit and take out the front cover plate.

2.Disconnect the motor wire (red) and the controller.

Remove the Rear Wheel

1.Remove the M5 bolt of the rear brake cable using an 8mm wrench and nipper pliers.

2.Remove the M5 adjusting nut, collar clamp, and dust cover.

3.Remove 1 M6 bolt with a 10mm wrench and pull out the brake cable from the limit hole.

4.Remove the reflective sticker on the right side.

5.Remove 2 M3x6 bolts with an H2.5 bit and take off the right decorative cover.

6.Remove the M6x16 bolt of the drum brake with an H4 bit.

7.Remove the M12 nut and washer on the right side with an 18mm wrench.

8.Remove the reflective sticker on the left side.

9.Remove 2 M3x6 bolts with an H2.5 bit and take off the left decorative cover.

10.Remove the ST3.9x13 bolt of the drum brake with a PH2 bit.

11.Remove the M12 nut and washer on the left side with an 18mm wrench.

12.Pull out the motor line from the slot and remove the motor assembly.

Install the Rear Wheel

1.Install the rear wheel into the frame, ensuring the proper position of the drum brake.

2.Fasten 2 ST3.9x13 bolts (torque: 0.55-0.65 N·m) and fix the cable cover plate of the motor.

3.Install the M12 nut and washer on the left side and fasten them with an 18mm wrench (torque: 45 N·m).

4.Install the left decorative cover, fasten 2 M3x6 screws with an H2.5 bit (torque: 0.55±0.15 N·m), and attach the reflective sticker.

5.Install the M12 nut and washer on the right side and fasten them with an 18mm wrench (torque: 45 N·m).

6.Fasten the M6x16 bolt (torque: 4-5 N·m).

7.Install the right decorative cover, fasten 2 M3x6 screws with an H2.5 bit (torque: 0.55±0.15 N·m), and attach the reflective sticker.

8.Pass the brake line through the limit hole, fasten the M6 nut with a 10mm wrench (torque: 4-5 N·m), and install the dust cover and collar clamp.

9.Pass the brake cable through the hole of the collar clamp, install the M5 adjusting nut, and fasten it with an 8mm wrench and nipper pliers (torque: 0.55±0.5 N·m).

Install the Front Cover Plate

1.Connect the controller and motor wires.

2.Install the front cover plate and fasten 4 M4x8 screws with an H3 bit (torque: 1.8-2.2 N·m).

Install the Battery and Battery Compartment Cover

1.Insert the fully charged battery into the battery compartment.

2.Lift the power plug of the controller to avoid damage.

3.Connect the power cable and install the pedal.

4.Install the battery compartment cover, ensuring the latch aligns with the e-lock, and press it into place.

Install the Tail Light Cover Plate

1.Turn over the scooter and install the tail light cover plate.

2.Fasten 2 M4x14 bolts with a T20 bit (torque: 1.5±0.2 N·m).

Function Detection

1.Power on the scooter and confirm that it functions properly.

Adjust the Brake

1.Hold the brake handle three times.

2.Loosen the M5 nut and adjust the turn adjusting nut.

3.Power on the scooter and clamp the brake handle with the 33mm end of a brake jig. The outside of the jig should be flush with the root of the round head at the top of the brake handle. The rear light should flash.

4.Hold the stem and push the scooter backward; the rear wheel should turn.

5.Power off the scooter and clamp the brake handle with the 30mm end of the brake jig in the same location. Hold the stem and push the scooter backward; the rear wheel should not turn, and the front wheel will lift.

6.Finally, fasten the M5 nut with an 8mm wrench and needle-nose pliers (torque: 5.5±0.5 N·m).