Replacing the Brake Assembly on the Segway Max Plus X (2.4)

Remove the Turn Signal Control

1.Use a TT20 bit to remove the 4 screws from the back of the forehead decorative cover plate and the front of the decorative cover plate.

2.Remove the 2 screws on the back of the forehead decorative cover plate using a TT20 bit.

3.At the same time, remove the turn signal switch and disconnect its connecting wire.

Remove the Left Brake Assembly

1.Use an 8mm ratchet wrench and needle-nose pliers to remove the front brake line locknut (M5) and the adjusting nut (P3).

2.Remove the anti-theft screw from the brake handle assembly using a T30 bit.

3.Remove the left brake handle assembly by gripping the brake handle and using needle-nose pliers to remove the brake wire head from the claw and the round hole of the brake handle.

Install the Left Brake Assembly

1.Prepare the new left brake handle assembly. Grip the handle to reveal the claw.

2.Insert the brake wire head into the round hole of the brake handle and then into the claw, using needle-nose pliers.

3.Ensure the brake line is installed in the brake handle slot, with the metal of the brake line sleeve pressed against the steps in the slot.

4.Attach the brake handle assembly to the cross pipe, making sure the wiring harness is not squeezed by the brake handle.

5.Fasten the M6 anti-theft screw of the brake handle assembly with a T30 bit, applying a torque of 7-9 N·m.

6.Tighten the front brake line locknut next to the adjusting nut using an 8mm ratchet wrench and needle-nose pliers, with a torque of 5.5 ± 0.5 N·m.

Install the Turn Signal Control

1.Connect the turn signal switch wiring harness.

2.Attach the back of the decorative cover plate to the forehead, securing it with two M4*12 inner hexagonal stainless steel screws using a TT20 bit. Apply a torque of 0.7-0.9 N·m.

3.Install the turn signal switch on the back of the decorative cover plate. Ensure the color order of the turn signal cables (white, black, and red from left to right) is correct and cannot be reversed.

4.Place the cables into the cover plate, attach the front of the cover plate, and secure it with 4 inner hexagonal stainless steel tapping screws from below.