Werkstatthandbuch Segway I2 SE - EnG - Level 1 & 2

Segway® Personal Transporter
Service Manual

i2 SE
i2 SE Patroller
x2 SE
x2 SE Turf
x2 SE Patroller
March 2014
24019-00001 aa
WARNING!
To replace parts on the Segway Personal Transporter, you must read and follow all instructions
and warnings in this Service Manual. Failure to do so could result in serious injury or death.
ii Segway Personal Transporter SE Service Manual

Copyright, Disclaimer, Trademarks, Patent, and Contact Information
Copyright © 2014 Segway Inc. All rights reserved.
Trademarks
Segway owns a number of trademarks including, but not limited to, Segway and the Segway "Rider Design" logo that have been
registered in the United States and in other countries. Those trademarks followed by ® are registered trademarks of Segway.
All other marks are trademarks or common law marks of Segway. Failure of a mark to appear in this guide does not mean that
Segway does not use the mark, nor does it mean that the product is not actively marketed or is not significant within its relevant
market. Segway reserves all rights in its trademarks. All other trademarks are the property of their respective companies.
Segway Patent Information

The Segway PT is covered by U.S. and foreign patents.
For a patent listing, see http://www.segway.com/downloads/pdfs/patents.pdf.
Contact Information
For support, please contact the company from which you bought the Segway product. For a listing of Authorized Segway Dealers
and Distributors, refer to the Segway website at http://www.segway.com.
Segway Customer Care: 866-4SEGWAY (866-473-4929)

Fax: 603-222-6001
E-mail: technicalsupport@segway.com
Website: http://www.segway.com
Segway Personal Transporter SE Service Manual iii

iv Segway Personal Transporter SE Service Manual
Contents
Copyright, Disclaimer, Trademarks, Patent, and Contact Information........................................................ iii
General Safety Precautions..................................................................................................ix

Safety Conventions........................................................................................................................................ ix
Important Safety Notices.............................................................................................................................. ix
Introduction....................................................................................................................... 0–1
Purpose...................................................................................................................................................... 0–1
Audience..................................................................................................................................................... 0–1
Certification............................................................................................................................................... 0–1
Organization...............................................................................................................................................0–2
Terminology................................................................................................................................................0–3
Customer Replaceable Kits and Technician Replaceable Parts...............................................................0–3
Related User Materials...............................................................................................................................0–3
Parts Diagram............................................................................................................................................0–4
1 LeanSteer.......................................................................................................................1–1
Handlebar....................................................................................................................................................1–4
LeanSteer Frame.........................................................................................................................................1–5
LeanSteer Stem..........................................................................................................................................1–6
InfoKey Controller.......................................................................................................................................1–7
InfoKey Dock...............................................................................................................................................1–7
InfoKey Controller Battery..........................................................................................................................1–8
2 Mats............................................................................................................................... 2–1
Mats............................................................................................................................................................ 2–2
3 Batteries....................................................................................................................... 3–1
Batteries..................................................................................................................................................... 3–2
4 Tire/Wheel Assembly.................................................................................................. 4–1

i2 SE Wheel Assembly................................................................................................................................ 4–2
x2 SE Wheel Assembly............................................................................................................................... 4–3
x2 SE Turf Wheel Assembly........................................................................................................................4–4
x2 SE Turf Hub Adapter.............................................................................................................................. 4–5
i2 SE Tire Tube............................................................................................................................................4–6
Segway Personal Transporter SE Service Manual v

Contents
5 Fenders.......................................................................................................................... 5–1
i2 SE Fender................................................................................................................................................ 5–2
x2 SE Fender............................................................................................................................................... 5–3
x2 SE Fender Frame................................................................................................................................... 5–4
6 Powerbase Trim............................................................................................................ 6–1

Gearbox Cover............................................................................................................................................ 6–2
Console Cover............................................................................................................................................ 6–3
Front and Rear Fascia.................................................................................................................................6–4
7 Gearbox..........................................................................................................................7–1
Gearbox...................................................................................................................................................... 7–2
8 Serviceable Powerbase................................................................................................ 8–1

Establishing a Serviceable Powerbase...................................................................................................... 8–2
9 Console......................................................................................................................... 9–1
Console Components................................................................................................................................ 9–2
Radio Board................................................................................................................................................ 9–3
Console.......................................................................................................................................................9–4
Power Board............................................................................................................................................... 9–5
Interconnect Board.................................................................................................................................... 9–6
AC Input Filter............................................................................................................................................ 9–7
Pivot Assembly........................................................................................................................................... 9–9
Front Light Pipe........................................................................................................................................ 9–10
10 Chassis Cover............................................................................................................. 10–1

Chassis Cover........................................................................................................................................... 10–2
11 CU Board...................................................................................................................... 11–1
CU Board................................................................................................................................................... 11–2
12 Balance Sensor Assembly..........................................................................................12–1

Balance Sensor Assembly........................................................................................................................12–2
13 Motor............................................................................................................................13–1
Motor.........................................................................................................................................................13–2
Elastomer Bushing................................................................................................................................... 13–4
14 Powerbase Chassis.....................................................................................................14–1
Powerbase Chassis...................................................................................................................................14–2
vi Segway Personal Transporter SE Service Manual

Contents
A Post-Service Tests........................................................................................................ A–1

Startup Test................................................................................................................................................ A–1
Standard Check.......................................................................................................................................... A–1
Operational Test......................................................................................................................................... A–1
B Parts List....................................................................................................................... B–1

Customer Replaceable Kits....................................................................................................................... B–1
Technician Replaceable Parts....................................................................................................................B–2
C Fasteners....................................................................................................................... C–1
D Tools and Equipment...................................................................................................D–1
E Glossary........................................................................................................................ E–1
Segway Personal Transporter SE Service Manual vii

Contents
viii Segway Personal Transporter SE Service Manual

General Safety Precautions
Safety Conventions
The following safety messaging conventions are used throughout this document:
WARNING! Warns you about actions that could result in death or serious injury.
CAUTION! Warns you about actions that could result in minor or moderate injury.
Indicates information considered important, but not related to personal injury. Examples
NOTICE
include messages regarding possible damage to the PT or other property, or usage tips.
Important Safety Notices

Read and follow all safety notices.
General
WARNING!
• Failure to follow these safety precautions could lead to electrical shock, serious injury, death, or damage to property.
• To replace parts on the Segway PT, you must read and follow all instructions and warnings in this Service Manual.
• Always power off the Segway PT before performing any maintenance or installing any part or accessory.
• Always unplug the AC power cord before performing any maintenance or installing any part or accessory.
Batteries
WARNING!
• Do not use the battery if the battery casing is broken or if the battery emits an unusual odor, smoke, or excessive
heat, or leaks any substance. Avoid contact with any substance seeping from the battery. Batteries contain toxic and
corrosive materials that could cause serious injury.
• As with all rechargeable batteries, do not charge near flammable materials. When charging, the batteries heat up and
could ignite a fire.
• Keep out of reach of children and pets. Exposure to battery voltage could result in death or serious injury.
• Observe and follow all safety information on the warning label found on the battery.
• Use only Segway-approved charging devices to charge the batteries.
• Do not attempt to open batteries. Do not insert any object into the batteries or use any device to pry at the battery
casing. If you insert an object into any of the battery ports or openings you could suffer electric shock, injury, burns,
or cause a fire. Attempting to open the battery casing will damage the casing and could release toxic and harmful
substances, and will render the battery unusable.
• Do not submerge the PT, batteries, or powerbases in water. Do not use a power washer or high-pressure hose to clean
a PT. Avoid getting water into any of the connectors. Avoid exposing the Segway PT to heavy downpours or extended
periods of heavy rain. If you suspect the batteries or powerbase have been submerged or experienced water intrusion,
call Segway Technical Support immediately at 1-866-473-4929, prompt #2. Until you receive further instructions, store
the PT upright, outdoors, and away from flammable objects. Failure to do so could expose you to electric shock, injury,
burns, or cause a fire.
• Comply with all local and federal or individual country laws when disposing of and transporting Segway PT batteries.
• Failure to adhere to these warnings could lead to serious injury, death, fire, or damage to property.
Segway Personal Transporter SE Service Manual ix

General Safety Precautions
Fasteners
WARNING!
• Use only Segway-approved fasteners. Other fasteners may not perform as expected and may come loose.
• Do not tighten or reuse any fastener except the screws used to attach the batteries, wheel nuts, and LeanSteer frame.
Instead, when any other fastener is loose or removed, replace the fastener with a new Segway-approved fastener. See
“Fasteners,” page C–1, for more information.
• Before using a fastener, make certain the fastener is the correct size and type with any necessary washer and thread
lock in place (see Table C–1, p. C–2).
• Since the pre-applied thread lock compound is intended for single use only, reuse of fasteners is not permitted with the
exception of the wheel nuts, battery fasteners, and LeanSteer frame fasteners.
• Do not attempt to repair any stripped or damaged screw hole. Instead, replace the part. If a replacement part is not
available, do not reassemble.
• Insert fasteners slowly and carefully. Do not cross-thread or over-tighten fasteners. Tighten only to the prescribed
torque.
• At the factory, Segway installs self-tapping fasteners intended for one-time use only. Service replacement fasteners are
not self-tapping and, therefore, may differ slightly in appearance from the comparable factory-installed fasteners.
• Failure to adhere to these warnings could lead to serious injury or death or damage to property.
Eye Protection
WARNING!
• When procedures require the use of safety glasses (such as those in which a mallet or solvent is used), failure to wear
eye protection could result in serious injury.
ESD Procedures
CAUTION!
• When a repair involves opening the console or chassis cover, best-practice electrostatic discharge (ESD) control
procedures must be followed. Failure to follow ESD procedures could result in personal injury or damage to property.
SOLVENTS
CAUTION!
• This manual refers to the use of isopropyl alcohol and ammonia or ammonia-based window cleaner in certain cleaning
procedures. Use of any other type of solvent is not allowed.
Questions
WARNING!
• If you have any questions about the instructions in this guide, please contact a Segway Service Representative to avoid
confusion leading to serious injury or death or damage to property.
x Segway Personal Transporter SE Service Manual

Introduction
Purpose
The purpose of this manual is to provide instructions for servicing the Segway
Personal Transporter (Segway PT) models i2 SE/Patroller, x2 SE/Patroller, and
x2 SE Turf.
Audience
Chapters 1 – 8 of this manual are written for either customers or Segway
Certified Service Technicians working under agreement with Segway Inc.
Chapters 9 – 14 of this manual are written only for Segway Certified Service
Technicians working under agreement with Segway Inc. See page 8–3 for
more information.
Certification
Becoming a Segway Certified Service Technician involves a four-level
certification process. The service technician will be required to undergo
training at each level. Upon satisfactory completion of this training, the service
technician becomes certified to repair the Segway PT parts and assemblies
according to the following scheme:
Table 0–1: Certification Levels
Level Parts and Assemblies Certified to Maintain Instructions
1 • Customer Replaceable Parts
−− LeanSteer Frame Chapter 1
−− Mats Chapter 2
−− Batteries Chapter 3
−− Tire/Wheel Assembly Chapter 4
−− Fender Chapter 5
−− Powerbase Trim Chapter 6
−− Gearbox Chapter 7
• Serviceable Powerbase Chapter 8
2 • All Level 1 (see above) See above
• Console Chapter 9
−− Radio Board “
−− Console “
−− Power Board “
−− Interconnect Board “
−− AC Input Filter “
−− Pivot Assembly “
−− Front Light Pipe “
Segway Personal Transporter SE Service Manual 0–1

Introduction
Table 0–1: Certification Levels (cont.)

Level Parts and Assemblies Certified to Maintain Instructions
3 • All Level 1 and Level 2 (see above) See above
• Embedded Systems
−− Chassis Cover Chapter 10
−− CU Board Chapter 11
−− Balance Sensor Assembly (BSA) Chapter 12
−− Motor Chapter 13
−− Powerbase Chassis Chapter 14
4 • All Level 1, Level 2, and Level 3 (see above) See above
• Diagnostics (with special tools)
Organization
This manual organizes service instructions into two general categories:
• Instructions intended for both customers and service technicians
(Chapter 1 – Chapter 8)
• Instructions intended for service technicians only
(Chapter 9 – Chapter 14)
The instructions in Chapter 9 – Chapter 14 describe procedures for replacing parts
after having established a Serviceable Power Base (SPB), which is described in
Chapter 8.
Table 0–2: Chapter Descriptions
Chapter Description
page ix Safety information. Read before servicing the Segway PT.
page 0–4 Exploded view of the Segway PT component parts.
Chapter 1 LeanSteer Frame and LeanSteer Stem installation and removal procedures.
Chapter 2 Mat installation and removal procedures.
Chapter 3 Li-ion Battery installation, removal, and troubleshooting procedures.
Chapter 4 Tire/Wheel Assembly installation and removal procedures.
Chapter 5 Fender and Fender Frame installation and removal procedures.
Chapter 6 Powerbase Trim (Fascia) installation and removal procedures.
Chapter 7 Gearbox installation and removal procedures.
Chapter 8 Serviceable Power Base definition and description.
Chapter 9 Console and related components installation and removal procedures.
Chapter 10 Chassis cover installation and removal procedures.
Chapter 11 CU Boards installation and removal procedures.
Chapter 12 Balance Sensor Assembly installation and removal procedures.
Chapter 13 Motor installation and removal procedures.
Chapter 14 Powerbase Chassis replacement procedure.
Appendix A Post-Service Tests to be performed after servicing the Segway PT.
Appendix B Parts Lists for the Segway PT.
Appendix C Fastener descriptions and specifications.
Appendix D Tools and diagnostic equipment necessary to properly service a Segway PT.
Appendix E Definitions of product-specific words used in this manual.
0–2 Segway Personal Transporter SE Service Manual

Introduction
Terminology
Throughout this manual, the term “model x2” refers to both the x2 and x2 Turf
models unless otherwise noted. All i2/x2 procedures are valid in all SE and
Patroller models unless otherwise noted.
Customer Replaceable Kits and Technician Replaceable Parts

Subassemblies qualified in this manual as Customer Replaceable may be
installed by the customer. Otherwise, subassemblies are qualified as installable
only by a Certified Service Technician.
A subassembly that is available as a replaceable kit is shipped in a box and
includes all parts and fasteners needed to install the subassembly. These kits
are listed under the heading Replaceable Kits on the first page of each chapter.
All parts included in a Replaceable Kit should be replaced.
When individual parts of a subassembly are available for replacement, these
parts are shipped without fasteners and are intended for installation only by a
Certified Service Technician. These parts are listed under the heading Technician
Replaceable Parts on the first page of each chapter.
Related User Materials

The following additional materials may be needed for reference during service:
• User Manual: Segway Personal Transporter (PT) i2 SE, x2 SE, x2 SE Turf
Please check the Segway website (www.segway.com) for updates to the User
Manual, or contact Segway to confirm you have on hand the most recent service
publications.

Introduction
Parts Diagram
Handlebar Clamp InfoKey
21861-00001 (Patroller) 21064-00001 (Programmed)
21065-00001 (Unprogrammed)
Handlebar Handlebar Clamp

20443-00001 20046-00001 (Standard)
InfoKey Dock
20533-00001
x2 Fender x2 Components
x2 Fender Frame 20798-00002 (Left)
23489-00001 20798-00001 (Right)
LeanSteer Frame
23512-00001 (Standard) x2 Wheel
(Patroller) 23548-00001 23725-00001
x2 Hubcap
23537-00001
Mat
23554-00001 (Standard)
23578-00001 (Comfort)
Gearbox Cover Console Trim

20152-00001 23478-00001 LeanSteer Stem
23508-00001 (Standard)
23507-00001 (Patroller)
Stem Cap
23519-00001
Front Console Trim

23399-00001
Front Fascia
23550-00001
i2 Fender
20190-00001
Rear Fascia
23550-00002
i2 Hubcap
20325-00001
i2 Wheel
Battery
20162-00001
20967-00001

1 LeanSteer
This chapter describes installation and removal procedures for the LeanSteer Applies to Models
Frame, LeanSteer Stem, and handlebar. The LeanSteer assembly pivots at the
i2 SE, x2 SE, x2 SE Turf
base to control left/right movement of the PT.
WARNING! Qualifications
• Failure to follow these safety precautions could lead to electrical shock,
Customer Replaceable
serious injury, death, or damage to property.
• Read all instructions. Customer Replaceable Kits
• Power off the Segway PT. Handlebar Clamp Kit (20954-00001)
• Unplug the Segway PT. 1 Handlebar Clamp
• The LeanSteer Frame and LeanSteer Stem must be properly attached 3 Fasteners
and secured. Failure to properly attach the LeanSteer components
and/or maintain proper torque on the fasteners could result in Handlebar Kit (20955-00001)
machine malfunction and could cause personal injury or damage to
1 Handlebar
the Segway PT. Using the Segway PT without properly assembling
the LeanSteer components and/or maintaining proper torque on the
fasteners could lead to an unexpected change in steering and could
result in serious injury and/or damage to the Segway PT from loss of
control, collisions, and falls.
• Check the tightness of the fasteners connecting the LeanSteer Stem
to the Pivot Base every time the LeanSteer Stem is removed and
reinstalled.
When to Replace
You need to replace the LeanSteer frame if any part is bent or otherwise broken.

LeanSteer
Standard LeanSteer Frame
M4 x 20 SHCS
20306-00001
Grip Trim
Handlebar Clamp
18892-00001
20046-00001 (Standard)
Handlebar Tube
20045-00001
Upper LeanSteer Tube

20048-00001 (Standard)
Tube Bushing
Handlebar Stop 23511-00001
20041-00001
Height Adjust Knob

20753-00001
Washer
20751-00001
Lower LeanSteer Tube
Wedge 23509-00001
20042-00001
#6-19x19mm PHCS
Bolt Trim 23558-00001
23516-00001 (Standard)
Washer Plate End Cap

23545-00001 (Standard) 23541-00001
Figure 1–1: Standard LeanSteer Frame Components

LeanSteer
Patroller LeanSteer Frame
M4 x 20 SHCS
20306-00001
Grip Trim
18892-00001
Handlebar Clamp
21861-00001 (Patroller) Handlebar Tube
20045-00001
Upper LeanSteer Tube

21791-00001 (Patroller)
Handlebar Stop
20041-00001
Tube Bushing
23511-00001
Height Adjust Knob
20753-00001
Washer
20751-00001
Lower LeanSteer Tube Wedge

23509-00001 20042-00001
#6-19x19mm PHCS
Bolt Trim 23558-00001
23545-00002 (Patroller)
Washer Plate End Cap

23545-00002 (Patroller) 23541-00001
Figure 1–2: Patroller LeanSteer Frame Components

LeanSteer
Handlebar
Removal Handlebar
Tool Required: 3 mm hex wrench
1. Make sure the Segway PT is powered off and
unplugged.
2. Using a 3 mm hex wrench, remove the three
fasteners that secure the Handlebar Clamp to the
LeanSteer Frame. See Figure 1–3.
3. Remove the Handlebar and Handlebar Clamp from Handlebar Clamp
the LeanSteer Frame.
20306-00001
Installation 2.0 N-m (18 in-lbf)
Tools Required: 3 mm hex wrench
Torque wrench Figure 1–3: Installing and Removing the Handlebar
1. Make sure the Segway PT is powered off and

unplugged.
2. Align the Handlebar in place against the LeanSteer
Frame using the alignment guides. See Figure 1–4.
3. Position the Handlebar Clamp against the
Handlebar.
4. Insert the three fasteners through the Handlebar
Clamp and into the LeanSteer Frame.
5. Using a 3 mm hex wrench, alternate between
the three fasteners, evenly tightening in small
increments.
6. Check to ensure that the gap between the Handlebar
Clamp and the LeanSteer Frame is even and is
Figure 1–4: Aligning the Handlebar
equidistant between top and bottom. Torque to
2.0 N-m (18 in-lbf).
7. Perform post-service tests (page A–1).

LeanSteer
LeanSteer Frame
Removal 23517-00001
Tool Required: 5 mm hex wrench 11.0 N-m (8.1 ft-lbf)
LeanSteer Frame
1. Make sure the PT is powered off and unplugged.
2. Using a 5 mm hex wrench, remove the two fasteners LeanSteer
holding the LeanSteer Frame to the LeanSteer Stem Stem
(see Figure 1–5), while supporting the LeanSteer
Frame.
3. Remove the LeanSteer Frame.
Installation
Torque wrench
2. Place the LeanSteer Frame onto the LeanSteer Stem
(see Figure 1–5).
3. Using a 5 mm hex wrench, install the two fasteners.
Torque to 11.0 N-m (8.1 ft-lbf).
Figure 1–5: LeanSteer Frame
4. With the PT powered down (OFF), lean the LeanSteer
Frame fully left and right, until it touches each
fender (see Figure 1–6).
5. Ensure the LeanSteer Frame returns to a straight,
upright position. If it is not vertical, follow the
instructions on page 1–6 to remove and install the
LeanSteer Stem.
6. Check the fasteners to be sure they are tight.
NOTICE
Check the fasteners at least monthly to be sure they
remain tight. If they are loose, tighten the fasteners
to 11.0 N-m (8.1 ft-lbf).
Figure 1–6: Check LeanSteer Frame

LeanSteer
LeanSteer Stem
Removal
Tool Required: T-30 6-lobe wrench
LeanSteer Stem
2. Remove the LeanSteer Stem Cap (see Figure 1–7).
3. Using a T-30 6-lobe wrench, remove the four
fasteners.
4. Slide the LeanSteer Stem off the pivot base.
LeanSteer
Stem Cap
Installation
Tools Required: T-30 6-lobe wrench Pivot Base
Torque wrench
20539-00001
1. Make sure the PT is powered off and unplugged. 11 N-m (8.1 ft-lbf)
2. Slide the LeanSteer Stem onto the pivot base (see Figure 1–7: LeanSteer Stem
Figure 1–7).
NOTICE
The Standard LeanSteer Stem must be used Standard Patroller
with the Standard LeanSteer Frame, and the
Patroller LeanSteer Stem must be used with the
Patroller LeanSteer Frame. Standard and Patroller
components cannot be used together.
3. Using a T-30 6-lobe wrench, install the four

fasteners, but do not tighten completely.
4. Make sure the LeanSteer Stem is vertical.
5. Tighten the fasteners to 11 N-m (8.1 ft-lbf).
6. Verify that the LeanSteer Stem is still vertical.
7. Place the LeanSteer Stem Cap over the front of the
LeanSteer Stem and press until it snaps in place.
Figure 1–8: LeanSteer Stem Comparison

LeanSteer
InfoKey Controller
Removal
1. Press the release tab at the bottom of the InfoKey
Dock. See 1 in Figure 1–9.
2. Slide the InfoKey Controller out of the Dock.
See 2 in Figure 1–9.
InfoKey Controller
Installation
1. Make sure the InfoKey Dock is installed (see
page 1–7).
2. Place the InfoKey Controller onto the Dock and slide
into place until the release tab (1 in Figure 1–9) is
engaged.
InfoKey Dock
Figure 1–9: Remove InfoKey Controller
InfoKey Dock
Removal
Tool Required: 3 mm hex wrench 20306-00003
2.0 N-m (18 in-lbf)
2. Using a 3 mm hex wrench, remove the fastener that
holds the InfoKey Dock to the LeanSteer Frame. InfoKey Dock
See Figure 1–10.
3. Remove the InfoKey Dock.
Installation
Torque wrench
2. Place the InfoKey Dock against the upper LeanSteer
Frame with the release tab oriented toward the
bottom. See Figure 1–10.
3. Using a 3 mm hex wrench, install the fastener
through the hole in the InfoKey Dock and into
the upper LeanSteer Frame. Torque to 2.0 N-m
(18 in-lbf).
Figure 1–10: InfoKey Dock

LeanSteer
InfoKey Controller Battery

Removal
Tool Required: Coin or flathead screwdriver
2. Rotate the InfoKey Controller 45 degrees
counterclockwise to separate it from the InfoKey
Dock Adapter. See Figure 1–11.
3. Using a coin or a flathead screwdriver, unscrew the
back cover of the InfoKey Controller and remove the
battery. See Figure 1–12.
Installation
Tool Required: Coin or flathead screwdriver
2. Verify that the new battery is type CR2430, available
as part of the Segway InfoKey Kit.
3. Insert the InfoKey Controller Battery with the
positive (+) side showing. See Figure 1–12. Figure 1–11: Connect/Disconnect InfoKey Controller to Dock Adapter
4. Using a coin or flathead screwdriver, reattach the
back cover of the InfoKey Controller.
5. Place the InfoKey Controller on the InfoKey Dock
Adapter and rotate clockwise until the InfoKey
Controller clicks into position. See Figure 1–11.
Figure 1–12: InfoKey Controller Battery

2 Mats
This chapter describes removal, inspection, and installation of Mats on a Applies to Models
Segway PT.
Your Segway PT comes with two Mats installed to the right and left of the
console. Mats are a functional component of the Rider Detect feature; Mats
Qualifications
permit a wide range of foot positions to achieve rider detection. These
Mats protect the rider detect sensors located beneath them and provide a Customer Replaceable
comfortable surface on which to stand. Mats should be secured in place prior to
riding. Customer Replaceable Kits
WARNING! Standard Mat Kit (23874-00001)
• Failure to follow these safety precautions could lead to electrical shock, 1 Standard Mat
Comfort Mat Kit (23875-00001)
• Read all instructions.
2 Comfort Mats
• Power off the Segway PT.
• Unplug the Segway PT.
• Always ensure that the top of the Powerbase and bottom of the Mat
are clean, dry, and free of debris. These Mats protect the rider detect
sensors located beneath them. Mats should be secured in place prior
to riding. Failure to follow these instructions could interfere with the
operation of the Segway PT leading to serious injury, death, or damage
to property.
When to Replace
It is appropriate to replace a Mat if any worn edges or tears are observed.

Mats
Mats
Removal
2. Lift the Mat off the Powerbase. See Figure 2–1.
Installation
2. Verify that the top of the Powerbase and the bottom
of the Mat are clean, dry, and free of debris.
3. Place the Mat on the Powerbase.
4. Fit the Mat’s rubber tabs into the slots formed by
the gap between the front and rear fascia and the
Powerbase. See Figure 2–1.
5. Visually confirm that the Mat is properly aligned and
all rubber tabs are tucked in prior to riding.
Figure 2–1: Mat Installation

3 Batteries
This chapter describes removal and installation procedures for the Li-ion Applies to Models
batteries used on a Segway PT. For information on using the batteries, including
charging, maintenance, safety, specification, and general care please refer
to the Segway PT User Manual and the Li-ion Battery Important Information
document. Qualifications
WARNING!
serious injury, death, or damage to property. Customer Replaceable Kit
• Read all instructions. Battery Kit (20878-00001)
• Power off the Segway PT. 1 Li-ion Battery
• Unplug the Segway PT. 4 Fasteners
• Do not use the battery if the battery casing is broken or if the battery
emits an unusual odor, smoke, or excessive heat, or leaks any
substance. Avoid contact with any substance seeping from the battery.
Batteries contain toxic and corrosive materials that could cause
serious injury.
• As with all rechargeable batteries, do not charge near flammable
materials. When charging, the batteries heat up and could ignite a fire.
• Keep out of reach of children and pets. Exposure to battery voltage
could result in death or serious injury.
• Observe and follow all safety information on the warning label found on
the battery.
• Use only Segway-approved charging devices to charge the batteries.
• Do not attempt to open batteries. Do not insert any object into the
batteries or use any device to pry at the battery casing. If you insert
an object into any of the battery ports or openings you could suffer
electric shock, injury, burns, or cause a fire. Attempting to open the
battery casing will damage the casing and could release toxic and
harmful substances, and will render the battery unusable.
• Do not submerge the PT, batteries, or powerbases in water. Do not
use a power washer or high-pressure hose to clean a PT. Avoid getting
water into any of the connectors. Avoid exposing the Segway PT to
heavy downpours or extended periods of heavy rain. If you suspect the
batteries or powerbase have been submerged or experienced water
intrusion, call Segway Technical Support immediately at 1-866-473-
4929, prompt #2. Until you receive further instructions, store the PT
upright, outdoors, and away from flammable objects. Failure to do so
could expose you to electric shock, injury, burns, or cause a fire.
• Comply with all local and federal or individual country laws when
disposing of and transporting Segway PT batteries.
• Use only Segway-approved fasteners.
• Insert fasteners slowly and carefully. Do not cross-thread or over-
tighten fasteners. Tighten only to the prescribed torque.
When to Replace
Replace batteries as advised by a Segway Service Representative.

Batteries
Batteries
When replacing a Battery, consider replacing both Batteries,
and always use pairs of Batteries with the same chemistry.
Replacing only one Battery will not necessarily increase the
performance or range of the PT, because the PT is designed to
operate only at the level allowed by the lower-energy Battery.
Redundancy is a critical safety feature built into the Segway
PT that also applies to the Batteries. Therefore, you should
replace Batteries in pairs (except for the unusual situation
where a Battery is replaced because of damage or defect and
the other Battery is relatively new).
NOTICE
To isolate a problem in a specific battery, swap front and
rear Batteries to confirm that the error condition follows the
Battery.
Removal
1. Make sure the PT is powered off and unplugged. Battery
2. Tip the PT onto its side so the Wheel lies flat against
a smooth, clean surface.
3. Using a 3 mm hex wrench, remove the battery
fasteners (4 per battery). See Figure 3–1
4. Pull the Battery straight off the chassis.
5. Repeat steps 3 and 4 for the other Battery.
NOTICE
Consult your local recycling center for proper disposal of
Batteries.
Figure 3–1: Battery Removal

Batteries
Batteries (cont.)
Installation
Torque wrench
CAUTION!
To avoid risk of damage, do not use power tools.

2. Tip the PT onto its side so the Wheel lies flat against 20541-00002
a smooth, clean surface. 1.6 N-m (14 in-lbf)
3. Install one of the Batteries on the Powerbase, with
the curved edge of the Battery to the outside of the
Powerbase. See Figure 3–2.
4. Ensure the Battery is aligned straight against the
Powerbase edge trim, and there are no uneven gaps.
5. Install the two center fasteners first; do not tighten.
6. Install the two outer fasteners; do not tighten.
7. Torque the center fasteners first, then the outer
fasteners to 1.6 N-m (14 in-lbf).
8. Verify the battery is aligned and straight against the Battery
Powerbase edge trim and there are no uneven gaps. Figure 3–2: Torque the two center fasteners first.
9. Repeat Steps 1–8 for the second Battery.


Batteries

4 Tire/Wheel Assembly
This chapter describes the removal and installation procedures for the Tire/ Applies to Models
Wheel Assembly of a Segway PT. For general tire care information, refer to the
Segway PT User Manual.
There are two Tire/Wheel Assemblies per PT.
Qualifications
WARNING! Customer Replaceable
serious injury, death, or damage to property. Customer Replaceable Kits
• Read all instructions. i2 Tire and Wheel (20942-00001)
• Power off the Segway PT. 1 Tire and Wheel
• Unplug the Segway PT. 3 Wheel Nuts
• Wear safety glasses to avoid eye injury.
i2 Wheel Cap (20943-00001)
• Use only Segway-approved fasteners.
1 Wheel Cap
• Each model — i2, x2, and x2 Turf — has a unique type of Tire/Wheel
Assembly. Because of the differences in the software, i2, x2, and x2 x2 Tire and Wheel (23684-00001)
Turf wheels and tires are not interchangeable. Use only i2 wheels and
1 Tire and Wheel
tires on the i2 model, x2 and x2 turf wheels and tires on x2 and x2 Turf
models. 3 Wheel Nuts
x2 Turf Tire and Wheel (21162-00001)

When to Replace
1 Turf Tire and Wheel
You need to replace a Tire/Wheel Assembly or the tire tube (i2) under any of the
following conditions, including, but not limited to: 1 Spacer
• Persistent leak in tire after reinflation. 4 Fasteners, 40 mm
• Wheel is cracked or bent. x2 Turf Hub Adapter (20963-00001)

• Tire is flat, cracked, or excessively worn. Excess wear is determined as 1 Wheel Hub
follows:
4 Fasteners, 30 mm
−− i2: Center rib is worn flush with tire surface.
x2 Turf Wheel Trim (20965-00001)
−− x2: Diamond pattern on center rib is no longer visible.
1 Wheel Trim
−− x2 Turf: Tire tread depth is less than 3/32 in (2.38 mm).
4 Fasteners, 30 mm
Tire inflation pressure can dramatically affect range, traction, and tread wear.
Ensure tires are properly inflated as follows: x2 Turf Spacer (21370-00001)
• i2: 15 psi (1.03 bar) 1 Spacer
• x2: 4 psi (0.275 bar) 4 Fasteners, 40 mm
i2 Tube Replacement Kit (21193-00001)

5 Tubes
i2 Tire Replacement Kit (21471-00001)

5 Tires

Tire/Wheel Assembly
i2 SE Wheel Assembly
NOTICE
Support your Segway PT by means other than resting it
on its wheels. Support of the unit from below the batteries
is recommended. As an alternative, the Segway PT can be
positioned on its side on the opposite wheel. Do not rest the
Segway PT on an exposed gearbox.
Removal
Tool Required: 13 mm socket wrench
i2 Wheel
2. Support the PT or turn it on its side.
3. Remove the wheel cap. Push a screwdriver into the
notch on the side of the wheel cap and pry the wheel
cap off. See Figure 4–1.
4. Using a 13 mm socket wrench, remove the three
Wheel Nuts
wheel nuts and discard.
20158-00001
5. Remove the i2 SE Wheel Assembly. 30 N-m (22 ft-lbf)
Gearbox Flange
Installation
Tools required: 13 mm socket wrench
Torque wrench
1. Make sure the PT is powered off and unplugged. i2 Hubcap
2. Support the PT or turn it on its side. Figure 4–1: i2 SE Tire/Wheel Assembly
3. Place the i2 SE Wheel Assembly on the gearbox
flange. See Figure 4–1.
4. Using a 13 mm socket wrench, install the three wheel
nuts. Torque to 30 N-m (22 ft-lbf).
5. Install the wheel cap. Press the cap onto the wheel
until it snaps into place.

Tire/Wheel Assembly
x2 SE Wheel Assembly
Removal
wheel nuts and discard. See Figure 4–2. x2 Wheel
4. Remove the x2 SE Wheel Assembly.
Installation
Tools Required: Isopropyl alcohol wipes
13 mm socket wrench
Torque wrench
3. Inspect the mounting surfaces; use isopropyl Gearbox Flange
alcohol wipes to clean off all debris.
4. Place the x2 SE Wheel Assembly on the gearbox
flange. See Figure 4–2.
5. Holding the wheel to prevent rotation, use a 13 mm
socket wrench to install the three wheel nuts. Torque Wheel Nuts
to 30 N-m (22 ft-lbf). 20158-00001
30 N-m (22 ft-lbf)
Figure 4–2: x2 SE Tire/Wheel Assembly

Tire/Wheel Assembly
x2 SE Turf Wheel Assembly

Removal
Rubber mallet
3. If removing the x2 SE Turf Wheel Assembly and Hub
Adapter, proceed to page 4–5. x2 Turf Wheel
4. Using an 8 mm hex wrench, remove the four Hub Adapter
fasteners. See Figure 4–3.
5. Lift off the wheel trim.
6. Loosen the x2 SE Turf Wheel Assembly by tapping
the side of the wheel with a rubber mallet. Wheel
Trim
7. Lift off the x2 SE TurfWheel Assembly, including the
spacer.
Spacer
Installation
8 mm hex wrench
20991-00002
Torque wrench
35 N-m (26 ft-lbf)
Figure 4–3: x2 SE Turf Tire/Wheel Assembly
3. Inspect the wheel mounting surfaces; use isopropyl
alcohol wipes to clean off all debris.
4. Place the Spacer over the hub adapter; align the
mounting holes. See Figure 4–3.
5. Place the Wheel against the Spacer, with the valve
stem facing outward; align the mounting holes.
6. Place the wheel trim on the Wheel; align the
mounting holes.
7. Insert four fasteners through the wheel trim, Wheel,
and Spacer. Using an 8 mm hex wrench, thread the
fasteners into the Hub Adapter. Torque to 35 N-m
(26 ft-lbf).

Tire/Wheel Assembly
x2 SE Turf Hub Adapter

Removal
3. Remove the x2 SE Turf Wheel Assembly (page 4–4).
wheel nuts. See Figure 4–4. Wheel Nuts
5. Lift off the Hub Adapter. 20158-00001
30 N-m (22 ft-lbf)
Installation
13 mm socket wrench
Torque wrench
1. Make sure the PT is powered off and unplugged. Hub Adapter
2. Support the PT or turn it on its side. Figure 4–4: x2 SE Turf Hub Adapter
3. Inspect the mounting surfaces; use isopropyl alcohol
wipes to clean off all debris.
4. Align the three center holes in the Hub Adapter or
entire x2 SE Turf Wheel Assembly with the lugs on the
gearbox flange. See Figure 4–4.
5. Using a 13 mm socket wrench, thread the wheel nuts
onto the lugs. Torque to 30 N-m (22 ft-lbf).

Tire/Wheel Assembly
i2 SE Tire Tube
Removal
Tools Required: Pen
Bar clamp
2 Tire irons
3. Remove the i2 SE Tire/Wheel Assembly
(page 4–2).
4. Remove the valve stem cap and, using a pen or
other pointy object, release the air from the tire by
pushing down on the valve needle while squeezing
the tire to ensure tire is completely emptied of air.
See Figure 4–5.
Figure 4–5: Deflate the Tire
NOTICE
The i2 SE tire is tightly fitted to the wheel in a
manner similar to a motorcycle tire mounted to a
rim.
5. Using a bar clamp, break the tire bead by positioning

the clamp jaws against the inner and outer sidewalls
of the tire and tightening the clamp. Continue to
break the tire bead in this manner, shifting the
clamp over 6 inches each time. See Figure 4–6.
NOTICE
Carefully position the clamp to avoid puncturing the
tire. Insert the clamp on the tire wall, centering the
clamp at the tire specification label.
Figure 4–6: Break the Tire Bead
CAUTION!
The rim has sharp edges. Use caution when
handling. Avoid being pinched between the wheel
and the tire.
6. Finish separating the tire bead by hand. See

Figure 4–7.
Figure 4–7: Separate Bead by Hand

Tire/Wheel Assembly
i2 SE Tire Tube Removal (cont.)

7. Place the wheel face down on a clean, smooth
surface. With the inside of the wheel facing up, pry
one end of the tire iron underneath the lip of the tire
bead, pulling it up above the rim. See Figure 4–8.
CAUTION!
Improper placement of the tire iron can result in
pinching.
8. Insert a second tire iron under the tire bead about

6 inches away from the first tire iron and pry that
portion of the tire over the rim. See Figure 4–9.
9. Pull the first tire iron out and reinsert it under the Figure 4–8: Insert the First Tire Iron
bead about 6 inches away from the other tire iron.
Repeat until the entire side of the tire is lifted over
the rim.
10. Push the valve stem through the rim into the tire and
extract the tube. See Figure 4–10.
11. If replacing the tire, work the outside bead over the
inside of the wheel to remove the tire completely.
See Figure 4–11.
Figure 4–9: Insert the Second Tire Iron
Figure 4–10: Extract the Tube
Figure 4–11: Remove the Tire

Tire/Wheel Assembly
i2 SE Tire Tube (cont.)

Installation
NOTICE
Use only Segway-approved tubes. The 90-degree bend in the
valve stem is necessary for proper clearance.
Tools Required: Tire iron

Air pump
1. To install a new tire, seat the outside bead on the

wheel by hand before installing the tube.
Figure 4–12: Feed the Tube into the Tire
2. Inflate the tube with just enough air to give the tube
a circular shape.
3. Align the valve stem with the opening in the rim
and feed the tube into the tire around the rim. See
Figure 4–12. Make sure there are no kinks, bends,
or folds in the tube. Push the valve stem through the
opening in the rim.
4. By hand, work the outside bead back over the rim as
much as possible. See Figure 4–13.
5. Use a tire iron to lift the remaining bead over the rim,
being careful not to pinch or bind the tube or crack
the wheel. See Figure 4–14.
Figure 4–13: Work Outside Bead by Hand
CAUTION!
To avoid pinching, keep hands and fingers away from
the bead during inflation.
6. Using an air pump with a Schrader valve attachment

(or other source of forced air), inflate the tire enough
to seat the tire beads. See Figure 4–15. It may be
necessary to overinflate the tire to properly seat the
tire beads. When properly seated, the tire and wheel
will have an even, slight gap. Ensure the tire stem is
angled 45-degrees toward the chassis.
NOTICE
If the tire becomes overinflated when seating the Figure 4–14: Use a Tire Iron to Lift Remaining Bead
beads, release air until the pressure reaches 15 psi.
7. Install the Tire/Wheel Assembly (page 4–2).

Figure 4–15: Inflate the Tire

5 Fenders
This chapter describes the removal and installation procedures for the fenders Applies to Models
on a Segway PT. The fenders on the Segway PT are designed to protect the rider
from debris and to safeguard the rider while leaning into turns.
There are two fenders per Segway PT.
Qualifications
The i2 SE has one type of fender. The x2 SE and x2 SE Turf has another type of
fender that attaches to a fender frame.
WARNING! Customer Replaceable Kits

• Failure to follow these safety precautions could lead to electrical shock, i2 Fender Kit (20945-00001)
1 i2 Fender
4 Fender Fasteners
• Unplug the Segway PT. x2 Fender Kit (left side) (20961-00001)
1 x2 Fender
When to Replace 4 Fender Fasteners
You need to replace a fender for reasons that include, but are not limited to, if it
x2 Fender Kit (right side) (20962-00001)
is cracked or otherwise broken.
1 x2 Fender
4 Fender Fasteners
x2 Fender Frame Kit (23682-00001)

1 x2 Fender Frame
3 Fender Frame Fasteners
4 Fender Fasteners

Fenders
i2 SE Fender
Removal
1. Make sure the PT is powered off and unplugged. i2 Fender
2. Remove the Tire/Wheel Assembly (page 4–2).
fasteners holding the Fender to the gearbox. See
Figure 5–1.
4. Lift the Fender off the gearbox.
Installation
Tools Required: T-20 6-lobe wrench
Torque wrench
20538-00001
2. Orient and place the Fender on the gearbox. See 1.5 N-m (13 in-lbf)
Figure 5–1.
Figure 5–1: i2 SE Fender
fasteners. Torque to 1.5 N-m (13 in-lbf).

Fenders
x2 SE Fender
Removal
x2 Fender
3. Using a 4 mm hex wrench, remove the four fasteners
holding the Fender to the Fender Frame. See
Figure 5–2.
4. Remove the Fender from the Fender Frame.
NOTICE
The Fender and Fender Frame can be removed as a
unit by removing the Fender Frame fasteners (see
page 5–4).
20871-00001
Installation ½ turn – 1 full turn
after seated
Figure 5–2: x2 SE Fender
Torque wrench
2. Orient and place the left Fender on the left Fender
Frame. Orient and place the right Fender on the right
Fender Frame.
3. Ensure the grommets are in place on the Fender.
If grommets need to be installed, use a finger to
push the grommets into place. Grommets are
bidirectional and can be installed from either side of
the Fender.
4. Using a 4 mm hex wrench, install the four fasteners
until seated. Tighten one-half to one full turn. See
Figure 5–2.

Fenders
x2 SE Fender Frame
Removal
Tool Required: 4 mm hex wrench Fender Frame
3. Remove the Fender (page 5–3).
4. Using a 4 mm hex wrench, remove the three
fasteners holding the Fender Frame to the gearbox.
Gearbox
See Figure 5–3. Discard the fasteners.
5. Remove the Fender Frame.
NOTICE
20553-00002
The Fender and Fender Frame can be removed as a
6.0 N-m (4.5 ft-lbf)
unit (not shown). Fender Frame fasteners should be
discard and replaced with new ones.
Installation
Torque wrench
Figure 5–3: x2 SE Fender Frame
2. Place the Fender Frame on the Gearbox.
See Figure 5–3.
3. Using a 4 mm hex wrench, install three new Fender
Frame fasteners. Torque to 6.0 N-m (4.5 ft-lbf).
4. Install the Fender (page 5–3).

6 Powerbase Trim
This chapter describes removal and installation procedures for the powerbase Applies to Models
trim (fascia, gearbox cover, and console cover). Each Segway PT has front and
rear fascia.
WARNING! Qualifications
• Read all instructions. Customer Replaceable Kits
• Power off the Segway PT. Front Fascia Kit (23876-00001)
• Unplug the Segway PT. 1 Front Fascia
2 Fasteners
When to Replace
You need to replace front or rear fascia if either is physically damaged. Rear Fascia Kit (23876-00002)
1 Rear Fascia
2 Fasteners
Gearbox Cover Kit (20944-00001)

1 Gearbox Cover
3 Fasteners
Center Console Cover Kit (23913-00001)

1 Center Console Cover
1 Front Console Cover
4 Center Console Cover Fasteners
2 Front Console Cover Fasteners

Powerbase Trim
Gearbox Cover
This component is installed on i2 models only.
Removal Gearbox Cover

2a. x2 SE: remove the Fender and Fender Frame
assembly (page 5–4). Remove the Gearbox Cover.
2b. i2 SE: using a 4 mm hex wrench, remove the three
fasteners and discard them. See Figure 6–1.
3. Remove the Gearbox Cover.
Installation
20553-00001
6.0 N-m (4.5 ft-lbf)
Torque wrench Figure 6–1: Gearbox Cover
2. Align the holes in the Gearbox Cover with the holes
in the Gearbox. See Figure 6–1.
3a. x2 SE: install Fender and Fender Frame assembly
(page 5–4). Thread three new fasteners through
the holes in the Gearbox Cover.
3b. i2 SE: using a 4 mm hex wrench, install three new
fasteners.
4. Torque to 6.0 N-m (4.5 ft-lbf).

Powerbase Trim
Console Cover
Removal
T-20 6-lobe wrench Center Console Cover
2. Using a 4 mm hex wrench, remove the two fasteners
from the Front Console Cover and slide the Front
Console Cover off. See Figure 6–2.
fasteners on the Center Console Cover and lift the
Center Console Cover off. See Figure 6–3.
CAUTION!
Make sure the IEC connector (charge port) remains
clean and dry.
Front Console Cover
20554-00001
Installation Figure 6–2: Front Console Cover 1.5 N-m (13 in-lbf)
4 mm hex wrench
Torque wrench
20307-00002
1. Make sure the PT is powered off and unplugged. 1.5 N-m (13 in-lbf)
2. Place the Center Console Cover on the console.
fasteners. Torque to 1.5 N-m (13 in-lbf).
See Figure 6–3.
Center Console Cover
4. Slide the Front Console Cover over the legs of the
Center Console Cover.
5. Using a 4 mm hex wrench, install the two fasteners.
Torque to 1.5 N-m (13 in-lbf). See Figure 6–2.
Figure 6–3: Center Console Cover

Powerbase Trim
Front and Rear Fascia

Removal and installation instructions are identical for both
front and rear fascia.
Rear Fascia
Removal
Tool Required: 4 mm hex wrench 20554-00001
1. Make sure the PT is powered off and unplugged. 1.5 N-m (13 in-lbf)
2. Remove one Tire/Wheel Assembly.

−− i2 SE (page 4–2)
−− x2 SE (page 4–3)
−− x2 SE Turf (page 4–4)
3. Remove both fenders.
−− i2 SE Fenders (page 5–2)
−− x2 SE Fender Frames (page 5–4)
4. Remove the Console Cover (page 6–3).
5. Using a 4 mm hex wrench, remove the two fasteners
holding the Fascia. See Figure 6–4 and Figure 6–5.
6. Remove the Fascia.
Figure 6–4: Rear Fascia
Installation
Torque wrench
2. Place the front Fascia onto the front of the
powerbase (Figure 6–5) and the rear Fascia onto
the rear of the powerbase (Figure 6–4).
3. Using a 4 mm hex wrench, install the four fasteners.
Torque to 1.5 N-m (13 in-lbf).
4. Install the Console Cover (page 6–3).
5. Install the Fenders.
−− i2 SE (page 5–2) 20554-00001
−− x2 SE (page 5–4) 1.5 N-m (13 in-lbf)
6. Install the Tire/Wheel Assembly.
−− i2 SE (page 4–2) Front Fascia
Figure 6–5: Front Fascia
−− x2 SE (page 4–3)

7 Gearbox
This chapter describes troubleshooting, removal, and installation procedures for Applies to Models
the Gearbox assembly on a Segway PT. Each Segway PT has two Gearboxes.
WARNING!
• Failure to follow these safety precautions could lead to electrical shock, Qualifications
• Power off the Segway PT. Customer Replaceable Kits
• Unplug the Segway PT. Gearbox Kit (21367-00001)
• Wear safety glasses to avoid eye injury. 1 Gearbox
• Gearboxes are not field serviceable. Do not attempt to open the 3 Fasteners
gearbox for lubrication or repair. You must replace the entire gearbox
assembly if the gearbox is not operating normally. Servicing or Gearbox Gasket Kit (20292-00001)
modifying the gearbox in any way could lead to malfunction. 1 Gasket
CAUTION!
• When a repair involves opening the console or chassis cover, best
practice electrostatic discharge (ESD) control procedures must be
followed. Failure to follow ESD procedures could result in personal
injury or damage to property.
• Machined surfaces of the gearbox can be sharp. Use caution when
handling the gearbox and spacer to avoid injury.
When to Replace
It is appropriate to remove, inspect, or replace the gearbox for reasons that
include the following:
• Excessive wheel wobble that cannot be remedied by either changing
the wheel position on the gearbox, by rotating the mounting position
by 180 degrees, or by replacing the Tire/Wheel Assembly.
The wheel hub has three holes that correspond to the three gearbox
flange studs. The wheel can be mounted to the gearbox in any of three
positions, relative to these holes. Clocking the wheel (i.e. advancing
the wheel to the next of these three possible positions) might minimize
wheel wobble on some units.
• Excessive and progressively worsening noise and/or vibration that
cannot be remedied by removing potential obstructions of the wheel,
by properly inflating the tire, or by replacing the Tire/Wheel Assembly.

Gearbox
Gearbox
Removal
Rubber mallet Chassis

Gearbox
2. Remove the LeanSteer Frame (page 1–5).
3. Remove the LeanSteer Stem (page 1–6).
4. Remove the Mats (page 2–2).
5. Remove the Batteries (page 3–2).
6. Remove the Tire/Wheel Assemblies.
−− i2 SE (page 4–2)
−− x2 SE (page 4–3)
Gearbox Spacer
7. Remove the Fenders
−− i2 SE (page 5–2) 20537-00002
−− x2 SE (page 5–3) 40 N-m (30 ft-lbf)
8. Remove the Console Cover (page 6–3). Figure 7–1: Remove Gearbox and Fasteners
9. Remove the Front and Rear Fascia (page 6–4).

10. Using a T-45 6-lobe wrench, remove the three
gearbox fasteners and discard. See Figure 7–1.
NOTICE
Gearbox fasteners are installed with thread lock
compound and require significant leverage to loosen
for the duration of thread engagement. Use of new
gearbox fasteners with new thread lock compound is
required for proper installation.
11. Remove the gearbox. Using a rubber mallet,

gently tap the chassis side of the gearbox housing
alternating front and back. Repeat until the gearbox
is unseated. Lift the gearbox off the chassis and set
aside. See Figure 7–2.
Figure 7–2: Tap Gearbox to Remove

Gearbox
Gearbox (cont.)
Installation
CAUTION!
Machined edges can be sharp. To avoid pinching, keep hands
and fingers clear of mating surfaces while seating gearbox
and spacer to chassis.
Tools Required: Cotton swabs

Ammonia
Isopropyl alcohol
Vacuum
Rubber mallet
T-45 6-lobe wrench
Torque wrench
2. Inspect the motor coupling and elastomer bushing.
Replace the elastomer bushing if it is worn out. See
page 13–4. Elastomer Bushing
NOTICE
To prevent contamination, cover the motor cavity.
Figure 7–3: Remove the Thread Lock Compound
3. Completely remove the thread lock compound from
the gearbox fastener holes. Use cotton swabs to
thoroughly clean excess thread lock compound from
the internal threads. First use ammonia or ammonia-
based window cleaner, then isopropyl alcohol, to
remove the thread lock compound. See Figure 7–3.
NOTICE
Using a vacuum cleaner or similar tool, remove any
foreign material from the motor cavity prior to re-
installation.
4. Ensure the gasket is present and oriented properly

in the grooves of the gearbox spacer gasket. See
Figure 7–4.
Gasket
Figure 7–4: Align the Gearbox Spacer Gasket

Gearbox
Gearbox Installation (cont.)

5. Align the couplings and gearbox housing roll pins
with the chassis. See Figure 7–5 (only one roll pin
Roll Pin
shown).
NOTICE
Although the motor is shown out of position in
Figure 7–5 (to make couplings and roll pins visible),
motor is still in place during this procedure.
6. Check to ensure both gaskets are in good condition

and properly located.
7. Inspect the roll pins to ensure they are in place and
free of residue.
8. Using a rubber mallet, gently tap the gearbox
outer cover at the locations indicated by arrows in
Figure 7–6 to seat the gearbox against the chassis
until the mating surfaces are flush. Alternate strike
points from side to side to seat the gearbox evenly.
CAUTION! Figure 7–5: Align the Roll Pins with the Chassis

Do not strike the gearbox flange. Striking the flange
could knock it out of alignment, damaging the
gearbox. Gearbox Flange
NOTICE
Do not use the gearbox fasteners to seat the
gearbox to the chassis. Make sure the gearbox and
spacer are completely seated prior to tightening
the gearbox to the specified torque. Failure to do so
could result in stripped chassis holes.
9. Using a T-45 6-lobe wrench, install three new

gearbox fasteners. Torque to 40 N-m (30 ft-lbf).
10. Install the Front and Rear Fascia (page 6–4).
11. Install the Console Cover (page 6–3).
12. Install the Fenders
−− i2 SE (page 5–2)
−− x2 SE (page 5–3)
13. Install the Tire/Wheel Assemblies.
−− i2 SE (page 4–2)
−− x2 SE (page 4–3)
14. Install the Batteries (page 3–2). Figure 7–6: Tap Gearbox to Seat Against Chassis
15. Install the Mats (page 2–2).

16. Install the LeanSteer Stem (page 1–6).
17. Install the LeanSteer Frame (page 1–5).

8 Serviceable Powerbase
This chapter describes the Serviceable Powerbase in a Segway PT. Applies to Models
WARNING! i2 SE, x2 SE, x2 SE Turf
serious injury, death, or damage to property. Qualifications
• Read all instructions. Customer Serviceable
• Unplug the Segway PT.
CAUTION!

Serviceable Powerbase
Establishing a Serviceable Powerbase

The Serviceable Powerbase is the launch point for many
service procedures. Throughout this Service Manual you
will be instructed to “establish a Serviceable Powerbase” or
“reassemble from a Serviceable Powerbase,” which means
to remove (or reassemble) the following components on the
Segway PT:
• LeanSteer Frame (page 1–5)
• LeanSteer Stem (page 1–6)
• Mats (page 2–2)
• Batteries (page 3–2)
• Tire/Wheel Assemblies
−− i2 SE (page 4–2)
−− x2 SE (page 4–3) Figure 8–1: Serviceable Powerbase
• Fenders
−− i2 SE (page 5–2)
−− x2 SE (page 5–3)
• Powerbase Trim
−− Gearbox Cover (page 6–2)
−− Console Cover (page 6–3)
−− Fascia (page 6–4)
• Gearbox (page 7–2).
NOTICE
In some cases, the Serviceable Powerbase will be used as
a replaceable module. Note that the unit serial number
and InfoKey Controller are associated with the Serviceable
Powerbase.

NOTICE
The following sections in this Service Manual are intended for use by Segway Certified Service Technicians only.
Segway does not recommend that non-certified individuals replace any of the components described in the
following sections. The warranty will be void if components in any of the following sections are replaced by an
individual other than a Segway Certified Service Technician.


9 Console
This chapter describes removal and installation procedures for the console and Applies to Models
related components on a Segway PT.
WARNING!
Certified Service Technician
• Power off the Segway PT. Technician Replaceable Parts
• Unplug the Segway PT. Light Pipe (23483-00001)
• Wear safety glasses to avoid eye injury. 1 Light Pipe
CAUTION! Radio Board (23451-00001)

• When a repair involves opening the console or chassis cover, best 1 Radio Board
followed. Failure to follow ESD procedures could result in personal Power Board (23483-00001)
1 Power Board
When to Replace Power Supply Harness (23593-00001)

Replace a console component when diagnostic testing determines that the 1 Power Supply Harness
component is defective. For diagnostic procedures, contact a Segway Service
Representative. Interconnect Board (23411-00001)
1 Interconnect Board
AC Input Filter (23405-00001)

1 AC Input Filter
Pivot Assembly (23502-00001)

1 Pivot Assembly
Front Light Pipe (23402-00001)

1 Front Light Pipe
Console Base (23990-00001)

1 Console Base

Console
Console Components
Light Pipe
23483-00001
Radio Board
23451-00001
Pivot Assembly Gasket

23502-00001 23393-00001
Gap Pad
23699-00001
Console Base
Front Light Pipe 23390-00001
23402-00001
Insulator
23575-00001
AC Input Filter
23405-00001
Interconnect Board
23411-00001
Power Board
23371-00001
Insulator
23598-00001
Figure 9–1: Console Components

Console
Radio Board
Removal
T-10 6-lobe wrench 20203-00002
1.8 N-m (16 in-lbf)
1. Make sure the PT is powered off, unplugged, and the
batteries have been removed.
Light Pipe
2. Establish a Serviceable Powerbase (page 8–2).
3. Using a T-20 6-lobe wrench, remove the six
20567-00001 (self-tapping)
fasteners holding the Light Pipe in place. Discard the
20973-00001 (non-tapping)
fasteners.
1.6 N-m (14 in-lbf)
4. Remove the light pipe.
5. Using a T-10 6-lobe wrench, remove the six fasteners
holding the Radio Board in place. Discard the
fasteners. Radio Board
6. Remove the Radio Board.
7. Using ESD best practices, place the Radio Board in
an ESD bag for return shipment to Segway.
Installation
T-20 6-lobe wrench
1. Orient the Radio Board on the Console Base.
2. Install the Radio Board. Press it onto the
Interconnect Board. Figure 9–2: Light Pipe and Radio Board
3. Using a T-10 6-lobe wrench, install six new fasteners.
NOTICE
Original fasteners are self-tapping. Replace with
non-tapping fasteners.
4. Orient the Light Pipe on top of the Radio Board.

5. Using a T-20 6-lobe wrench, install six new fasteners.
6. Reassemble the PT from the Serviceable Powerbase
(page 8–2).

Console
Console
20540-00005
Removal 11.0 N-m (8.1 ft-lbf)
Tool Required: T-27 6-lobe wrench 20540-00006
batteries have been removed. 20540-00005
3. Remove the Radio Board (page 9–3).
fasteners holding the Console in place. See
Figure 9–3. Discard the fasteners.
5. Tip the Console on its side and disconnect the four
Powerbase harnesses. See Figure 9–4.
6. Remove the Console.
Installation
Torque wrench
1. Orient the Console on the Powerbase so the end
with the Pivot Base is toward the front.
2. Tip the Console on its side and connect the
Powerbase harnesses. See Figure 9–4. Each
harness is a different size/shape and fits into only
one of the connectors.
3. Tip the Console upright, being careful not to pinch
the harnesses.
4. Using a T-27 6-lobe wrench, install the three shorter
fasteners to the front and rear of the Console. Install
Figure 9–3: Console Fasteners
the longer fastener in the center. Torque to 11.0 N-m
(8.1 ft-lbf).
5. Install the Radio Board (page 9–3).
(page 8–2).
Figure 9–4: Console Harnesses

Console
Power Board
Removal
1. Make sure the PT is powered off, unplugged, and the Insulator
4. Detach the Console from the Powerbase
(page 9–4).
5. Remove the insulator covering the Power Board. See Power Supply Harness
Figure 9–5.
6. Disconnect the Power Supply Harness from the
Power Board. Press down on the tab while gently
pulling the connector out of the socket.
7. Using a T-10 6-lobe wrench, remove the eight
fasteners holding the Power Board in place. Discard
the fasteners. See Figure 9–6.
8. Remove the Power Board. Lift the board out of Figure 9–5: Power Board Insulator
the Console Base, leaving the Interconnect Board
behind.
9. Using ESD best practices, place the Power Board in
an ESD bag for return shipment to Segway. 20567-00001 (self-tapping)
20973-00001 (non-tapping)
1.6 N-m (14 in-lbf)
Installation
Torque Wrench
1. Install the Power Board. Press the board onto the
Interconnect Board. Power Board
2. Using a T-10 6-lobe wrench, install eight new Thermal
fasteners. Torque to 1.6 N-m (14 in-lbf). Gap Pad
NOTICE
3. Connect the Power Supply Harness. See Figure 9–5.

4. Install the insulator. First fold the tabs under, as Interconnect Board
shown. Then install the insulator so the tabs fit
around the Power Board, holding the insulator in
place.
5. Install the Console onto the Powerbase
(page 9–4).
(page 8–2). Figure 9–6: Power Board

Console
Interconnect Board
Removal
batteries have been removed. Interconnect Board
Pivot Harnesses
(page 9–4).
5. Remove the Power Board (page 9–5).
6. Disconnect the two Pivot Assembly Harnesses. For
each harness, press down on the tab while gently
pulling the connector out of the socket.
Pivot Assembly
7. Remove the Interconnect Board.
8. Using ESD best practices, place the Interconnect
Board in an ESD bag for return shipment to Segway. Figure 9–7: Interconnect Board
Installation
1. Orient the Interconnect Board so the notched side
protrudes through the hole in the Console Base, and
the Pivot Harness connectors are toward the Pivot
Assembly. See Figure 9–7.
1. Install the Interconnect Board.
2. Connect the Pivot Harnesses to the Interconnect
Board.
3. Install the Power Board (page 9–5).
(page 9–4).
(page 8–2).

Console
AC Input Filter
Removal
23591-00001
Tools Required: 4 mm hex wrench 20567-00001 (self-tapping) 3.0 N-m (27 in-lbf)
T-20 6-lobe wrench 20973-00001 (non-tapping)
T-10 6-lobe wrench 1.6 N-m (14 in-lbf)
AC Input Filter AC Input
Socket
4. Detach the Console from the Powerbase Insulator
(page 9–4).
5. Disconnect the Power Supply Harness from the
AC Input Filter. Press down on the tab while gently
pulling the connector out of the socket. See
Figure 9–10.
6. Using a 4 mm hex wrench, detach the ground lug
Console Base
from the Console Base. See Figure 9–10.
23559-00001
7. Using a T-20 6-lobe wrench, remove the two 1.0 N-m (9 in-lbf)
fasteners holding the AC Input Socket in place. Figure 9–8: AC Input Filter
Discard the fasteners. See Figure 9–8.
8. Using a T-10 6-lobe wrench, remove the five
fasteners holding the AC Input Filter in place.
Discard the fasteners.
9. Remove the AC Input Filter.
10. Using ESD best practices, place the AC Input Filter in
an ESD bag for return shipment to Segway.
11. Remove the insulator.

Console
AC Input Filter (cont.)

Installation
T-20 6-lobe wrench
4 mm hex wrench
Torque wrench
1. Fold the tabs of the insulator and place the insulator
in the Console Base. Fold the tabs under the
insulator to act as springs holding the insulator
against the board. See Figure 9–8.
Figure 9–9: Ground Lug
2. Orient the AC Input Filter in the Console Base. Orient
the AC Input Socket against the hole in the rear of
the Console Base.
Power Supply Harness Socket
NOTICE
Make sure the AC Socket is oriented correctly. Check
orientation by plugging in a power cord.
3. Using a T-10 6-lobe wrench, install the five fasteners

that hold the AC Input Filter in place. Torque to 1.6
N-m (14 in-lbf).
NOTICE
4. Using a T-20 6-lobe wrench, install the two fasteners

that secure the AC Input Socket. Torque to 1.0 N-m
Figure 9–10: Ground Lug Orientation
(9 in-lbf).
5. Assemble the ground lug and fastener as shown in
Figure 9–9.
6. Using a 4 mm hex wrench, fasten the ground lug to
the Console Base. Orient the ground lug as shown in
Figure 9–10. Torque to 3.0 N-m (27 in-lbf).
7. Connect the Power Supply Harness. See
Figure 9–10.
(page 9–4).
(page 8–2).

Console
Pivot Assembly
Removal
Pivot Assembly
(page 9–4).
5. Remove the AC Input Filter (page 9–7).
7. Remove the Interconnect Board (page 9–6). Gasket
fasteners and discard. See Figure 9–11.
9. Remove the Pivot Assembly.
Installation
Torque wrench
1. Install the gasket into the groove on the underside of 20205-00001
the Pivot Assembly. 11 N-m (8.1 ft-lbf)
2. Thread the Pivot Assembly harnesses through the
hole in the Console Base and position the Pivot
Assembly on the Console Base.
Figure 9–11: Pivot Assembly
3. Using a T-30 6-lobe wrench, install four new
fasteners. Torque to 11 N-m (8.1 ft-lbf).
4. Install the Gap Pad. See Figure 9–12.
5. Install the Interconnect Board (page 9–6).
7. Install the AC Input Filter (page 9–7).
(page 9–4).
9. Install the Radio Board (page 9–3). Gap Pad
(page 8–2).
Figure 9–12: Gap Pad

Console
Front Light Pipe

Removal 20566-00001 (self-tapping)
Tool Required: T-10 6-lobe wrench 20972-00001 (non-tapping)
1. Make sure the PT is powered off, unplugged, and the 1.6 N-m (14 in-lbf)
batteries have been removed. Front Light Pipe
3. Remove the Radio Board (page 9–3). Gasket
(page 9–4).
6. Remove the Interconnect Board (page 9–6).
7. Remove the Pivot Assembly (page 9–9). Console Base
8. Using a T-10 6-lobe wrench, remove the two
fasteners holding the Light Pipe in place. Discard the
fasteners. See Figure 9–13. Figure 9–13: Front Light Pipe
Installation
Torque wrench
1. Slide the gasket onto the Light Pipe with
the adhesive side toward the Light Pipe. See
Figure 9–13.
2. Orient the Light Pipe on the Console Base.
3. Using a T-10 6-lobe wrench, install the two fasteners.
NOTICE
4. Install the Pivot Assembly (page 9–9).

5. Install the Interconnect Board (page 9–6).
(page 9–4).
(page 8–2).

Motor
Elastomer Bushing
Inspection
Check to see if the Elastomer Bushing is worn or damaged.
Presence of excessive particles of elastomer material
indicates that replacement is necessary. See Figure 13–3.
Removal
2. Pull the Elastomer Bushing off the motor coupling.
Installation
Tools Required: Cotton swabs
Ammonia
Isopropyl alcohol Figure 13–3: Worn Elastomer Bushing
1. Use cotton swabs to clean all residue from the motor
coupling and cavity. First use ammonia or ammonia-
based window cleaner, then isopropyl alcohol, to
remove the residue.
2. Align the new Elastomer Bushing with the coupling,
making sure the tabs go on first. See Figure 13–4.
CAUTION!
Do not remove the coupling from the Motor. If
damaged, replace the entire Motor assembly.
If the Motor assembly is modified, the PT could
malfunction causing injury or damage to property.
Figure 13–4: Elastomer Bushing Alignment

14 Powerbase Chassis
This chapter describes the disassembly and reassembly procedures for the Applies to Models
Powerbase Chassis on a Segway PT.
WARNING!
Certified Service Technician
• Power off the Segway PT. Technician Replaceable Parts
• Unplug the Segway PT. Powerbase Chassis (17124-00003)
• Remove batteries before servicing. 1 Powerbase Chassis
CAUTION!
When to Replace
Replace the Powerbase Chassis when diagnostic testing or inspection
determines that the assembly is defective. For diagnostic procedures, contact a
Segway Service Representative.
The Segway PT Chassis is serialized and may only be replaced with
permission from Segway. A new serial number may be issued, and the
serialized replacement Chassis may be shipped to order from Segway Service
Headquarters.
You should replace a Powerbase Chassis under any of the following conditions:
• Stripped screw holes
• Visible cracks
• Ingress of moisture or dirt is evident
• Battery vent is damaged

Powerbase Chassis
Powerbase Chassis
The inset in Figure 14–1 shows the numeral 2 and an arrow
stamped on the Chassis to indicate the front of the Chassis.
Disassembly
Rear
3. Remove both Gearboxes (page 7–2).
5. Remove the Console (page 9–4).
Front
6. Remove the Chassis Cover (page 10–2).
7. Remove both CU Boards (page 11–2).
Figure 14–1: Powerbase Chassis
8. Remove the Balance Sensor Assembly (page 12–2).
9. Remove both Motors (page 13–2).
Reassembly
1. Install both Motors (page 13–2).
2. Install the Balance Sensor Assembly (page 12–2).
NOTICE
Use self-tapping fasteners when installing the BSA
into a new Powerbase Chassis.
3. Install both CU Boards (page 11–2).
NOTICE
Use self-tapping fasteners when installing the CU
Boards into a new Powerbase Chassis.
4. Install the Chassis Cover (page 10–2).

5. Install the Console (page 9–4).
7. Install both Gearboxes (page 7–2).
(page 8–2).

A Post-Service Tests
This chapter describes standard tests to perform after servicing a Segway PT.
WARNING!
• Read all instructions. Failure to do so could lead to electrical shock,
CAUTION!
Startup Test
1. Make sure the Wireless InfoKey Controller properly powers on the PT
without any error messages.
Standard Check
1. Check that fasteners are in place, secure, and torqued correctly.
2. Check wheels for wear, tightness, and tire pressure.
3. Check that the Mats are intact, secure, and free of debris.
4. Check the LeanSteer Frame for tightness. Make sure the LeanSteer
Frame returns to center.
5. Check to make sure that no part is damaged or loose.
Operational Test
1. Check for obstruction under the Mats.
2. Check the LeanSteer Frame for tightness and centered orientation.
3. Turn on and power off the PT twice.
4. Confirm adequate battery levels.
5. Turn on the PT and test the rider detect. Make sure that the display
does not indicate that the rider detect button is on at startup. Tilt the
PT back and press each rider detect button.
6. While holding the PT level, tap the Mat with a foot to enter balance
mode.
7. Step on and ride the PT. Move forward and backward. Turn 360 degrees
to the left and to the right.
Segway Personal Transporter SE Service Manual A–1

Post-Service Tests
A–2 Segway Personal Transporter SE Service Manual

B Parts List
This appendix lists parts and kits by part number.
• Table B-1 lists customer replaceable kits.
• Table B-2 lists technician replaceable parts.
Customer Replaceable Kits

Table B–1: Customer Replaceable Kits
Kit Kit Number Component Qty. Part Number
Standard Mat Kit 23847-00001 Standard Mat 1 23554-00001
Comfort Mat Kit 23857-00001 Comfort Mat 2 23875-00001
Li-ion Battery 1 20967-00001
Battery Kit 20878-00001
Fastener 4 20541-00002
Tire/Wheel 1 20162-00004
i2 Tire/Wheel Kit 20942-00001
Wheel Nut 3 20158-00001
i2 Wheel Cap Kit 20943-00001 Wheel Cap 1 20325-00001
Tire/Wheel 1 23725-00001
x2 Tire/Wheel Kit 23684-00001
Wheel Nut 3 20158-00001
Tire/Wheel 1 20816-00002
x2 Turf Tire/Wheel Kit 21162-00001 Spacer 1 20802-00001
Fastener 4 20991-00002
Hub Adapter 1 20749-00001
x2 Turf Hub Adapter Kit 20963-00001
Fastener 4 20991-00001
Wheel Trim 1 21034-00001
x2 Turf Wheel Trim Kit 20965-00001
Fastener 4 20991-00001
Spacer 1 20802-00001
x2 Turf Spacer Kit 21370-00001
Fastener 4 20991-00002
i2 Tube Kit 21193-00001 Tube 5 21926-00001
i2 Tire Kit 21471-00001 Tire 5 21801-00001
Fender 1 20190-00001
i2 Fender Kit 20945-00001
Fastener 4 20538-00001
Fender 1 20798-00002
x2 Fender Kit (Left) 20961-00001
Fastener 4 20871-00001
Fender 1 20798-00001
x2 Fender Kit (Right) 20962-00001
Fastener 4 20871-00001
Fender Frame 1 23489-00001
x2 Fender Frame Kit 23682-00001 Fastener 3 20553-00002
Fastener 4 20871-00001
Segway Personal Transporter SE Service Manual B–1

Parts List
Table B–1: Customer Replaceable Kits (cont.)

Kit Kit Number Component Qty. Part Number
Front Fascia 1 23550-00001
Front Fascia Kit 23876-00001
Fastener 4 20554-00001
Rear Fascia 1 23550-00002
Rear Fascia Kit 23876-00002
Fastener 4 20554-00001
Console Cover 1 23478-00001
Front Console Cover 1 23399-00001
Center Console Cover Kit 23913-00001
Fastener 4 20307-00002
Fastener 2 20554-00001
Gearbox 1 20152-00001
Gearbox Cover Kit 20944-00001
Fastener 3 20553-00001
Gearbox 1 20919-00001
Gearbox Kit 21367-00001
Fastener 3 20537-00002
Gearbox Gasket Kit 20292-00001 Gasket 1 15409-00001
Technician Replaceable Parts

Table B–2: Technician Replaceable Parts
Part Part Number
Light Pipe 23483-00001
Radio Board 23451-00001
Power Board 23483-00001
Power Supply Harness 23593-00001
Interconnect Board 23411-00001
AC Input Filter 23403-00001
Pivot Assembly 23502-00001
Front Light Pipe 23402-00001
Console Base 23990-00001
Chassis Cover 20316-00001
CU Board 23244-00001
Balance Sensor Assembly 19457-00003
Motor with Coupling 22252-00001
Drive Hub 21783-00004
Elastomer Bushing 21461-00001
Powerbase Chassis 17124-00003
B–2 Segway Personal Transporter SE Service Manual

C Fasteners
This appendix provides information about the fasteners used in the Segway PT.
WARNING!
• Use only Segway-approved fasteners. Other fasteners may not perform
as expected and may come loose.
• Do not tighten or reuse any fastener except the screws used to attach
the batteries, wheel nuts, and LeanSteer frame. Instead, when any
other fastener is loose or removed, replace the fastener with a new
Segway-approved fastener.
• Before using a fastener, make certain the fastener is the correct size
and type with any necessary washer and thread lock in place (see
Table C–1, p. C–2).
• Since the pre-applied thread lock compound is intended for single
use only, reuse of fasteners is not permitted with the exception of the
wheel nuts, battery fasteners, and LeanSteer frame fasteners.
• Do not attempt to repair any stripped or damaged screw hole.
Instead, replace the part. If a replacement part is not available, do not
reassemble.
• Insert fasteners slowly and carefully. Do not cross-thread or over-
tighten fasteners. Tighten only to the prescribed torque.
• At the factory, Segway installs self-tapping fasteners intended for
one-time use only. Service replacement fasteners are not self-tapping
and, therefore, may differ slightly in appearance from the comparable
factory-installed fasteners.
• Failure to adhere to these warnings could lead to serious injury or
death or damage to property.
Segway Personal Transporter SE Service Manual C–1

Fasteners
Table C–1: Fasteners
Part Number Fastener Type Application Qty/PT Drive Torque
Nut, M8 x 1.25 Wheel 6 13 mm 30 N-m (22 ft-lbf)
20158-00001
SHCS, M4 x 0.7 x 12 Light Pipe 6 T-20 1.8 N-m (16 in-lbf)

20203-00002
SHCS, M6 x 1.0 x 20 Pivot Assembly 4 T-30 11 N-m (8.1 ft-lbf)

20205-00001
SHCS, M4 x 0.7 x 20 Handlebar Clamp 3 3 mm 2.0 N-m (18 in-lbf)

20306-00001
SHCS, M4 x 0.7 x 20 InfoKey Dock 1 3 mm 2.0 N-m (18 in-lbf)

20306-00003
BHCS, M4 x 0.7 x 8 Console Cover 4 2.5 mm 1.6 N-m (14 in-lbf)

20307-00002
SHCS, M5 x 0.8 x 12 Motor 4 T-25 5.0 N-m (3.7 ft-lbf)

20536-00001
SHCS, M8 x 1.25 x 65 Gearbox 6 T-45 40 N-m (30 ft-lbf)
20537-00002
BHCS, M4 x 0.7 x 10 Fender (i2) 8 T-20 1.5 N-m (13 in-lbf)

20538-00001
SHCS, M6 x 1.0 x 30 LeanSteer Stem 4 T-30 11 N-m (8.1 ft-lbf)

20539-00001
BHCS, M6 x 1.0 x 14 Chassis Cover 10 T-27 6.0 N-m (4.5 ft-lbf)

20540-00001
C–2 Segway Personal Transporter SE Service Manual

Fasteners
Table C–1: Fasteners (cont.)

BHCS, M6 x 1.0 x 20 Console, Front and Rear 3 T-27 11 N-m (8.1 ft-lbf)
20540-00005
BHCS, M6 x 1.0 x 25 Console, Center 1 T-27 11 N-m (8.1 ft-lbf)

20540-00006
SHCS, M4 x 0.7 x 30, SEMS Battery 8 3 mm 1.6 N-m (14 in-lbf)

20541-00002
BHCS, M6 x 1.0 x 25 Gearbox Cover 6 4 mm 6.0 N-m (4.5 ft-lbf)

20553-00001
BHCS, M6 x 1.0 x 28 Fender Frame 6 4 mm 6.0 N-m (4.5 ft-lbf)

20553-00002
Front Console Cover* 2 4 mm 1.5 N-m (13 in-lbf)

SHCS, M5 x 0.8 x 10
Fascia (Front and Rear) 4 4 mm 1.5 N-m (13 in-lbf)
20554-00001
*For use without a Parking Stand.
SHCS, M5 x 0.8 x 20 Front Console Cover* 2 4 mm 1.5 N-m (13 in-lbf)

20554-00004
*For use with a Parking Stand.
Balance Sensor Assembly (OEM) 4 T-10 1.6 N-m (14 in-lbf)

PHCS, M3 x 0.5 x 12, SEMS
Front Light Pipe (OEM) 2 T-10 1.6 N-m (14 in-lbf)
20566-00001
Self-tapping. For use only when installing a BSA into a new Powerbase Chassis,
or when installing a Front Light Pipe into a new Console.
CU Board (OEM) 28 T-10 1.6 N-m (14 in-lbf)

Radio Board (OEM) 6 T-10 1.6 N-m (14 in-lbf)
BHCS, M3 x 0.5 x 8
Power Board (OEM) 8 T-10 1.6 N-m (14 in-lbf)
20567-00001 AC Input Filter (OEM) 5 T-10 1.6 N-m (14 in-lbf)
Self-tapping. For use only when installing a CU Board into a new Powerbase Chassis,
or when installing a Radio Board, Power Board, or AC Input Filter into a new Console.
BHCS, M6 x 1.0 x 18 Fender (x2) 8 4 mm See note.

20871-00001
Tighten one-half to one full turn after fastener is seated.
Segway Personal Transporter SE Service Manual C–3

Fasteners
Table C–1: Fasteners (cont.)

Balance Sensor Assembly 4 T-10 1.6 N-m (14 in-lbf)
PHCS, M3 x 0.5 x 12, SEMS
Front Light Pipe 2 T-10 1.6 N-m (14 in-lbf)
20972-00001
For use when reinstalling a BSA into the original Powerbase Chassis,
. or when reinstalling a Front Light Pipe into the original Console.
CU Board 28 T-10 1.6 N-m (14 in-lbf)

Radio Board 6 T-10 1.6 N-m (14 in-lbf)
PHCS, M3 x 0.5 x 8
Power Board 8 T-10 1.6 N-m (14 in-lbf)
20973-00001 AC Input Filter 5 T-10 1.6 N-m (14 in-lbf)
For use when reinstalling a CU Board into the original Powerbase Chassis,
. or when reinstalling a Radio Board, Power Board, or AC Input Filter into the original Console.
SHCS, M10 x 1.5 x 40 x2 Turf Hub Adapter 8 8 mm 35 N-m (26 ft-lbf)
20991-00002
SHCS, M8 x 1.25 x 16 LeanSteer Frame 2 5 mm 11 N-m (8.1 ft-lbf)
23517-00001
BHCS, M4 x 0.7 x 12, SEMS AC Input Filter, Plug 2 T-20 1.0 N-m (9 in-lbf)
23559-00001
SHCS, M5 x 0.8 x 8 AC Input Filter, Ground 1 4 mm 3.0 N-m (27 in-lbf)

23591-00001
C–4 Segway Personal Transporter SE Service Manual

D Tools and Equipment
This appendix lists the tools and equipment recommended for servicing
and diagnosing a Segway PT. Segway recommends that Certified Service
Technicians purchase the Segway Tool Kit (p/n 22177-00001).
Table D–1: Tools and Equipment
Tool Description
Air compressor (if complete 2 gallon capacity minimum; 1 per service technician. The following or similar is recommended:
service area compressed air Powermate 2 Gallon Side Stack Mini Air Compressor (VSP0000201).
system not installed)
Cleaning supplies Ammonia or ammonia-based window cleaner; isopropyl alcohol (90%); cotton swabs; shop
rags.
ESD equipment Field electrostatic discharge (ESD) kit including anti-static mat, wrist strap, line with gator clip,
and ground lead. Correct grounding of mat and wrist strap is essential.
Flathead screwdriver, small
Hex adapter 1/4 inch square to 1/4 inch hex
Hex bits 2.5 mm, 3 mm, 4 mm, 5 mm, 8 mm
Hex wrenches 2.5 mm, 3 mm, 4 mm, 5 mm, 8 mm
Low pressure inflation gauge
Mallet Plastic or rubber, 24 oz.
Multi-meter Capable of measuring both voltage and resistance as called out in the Segway Gen2 PT
General Information and Diagnostics Guide.
Pen light
Ratchet 3/8 inch drive
Safety glasses
Shop vacuum (wet/dry vac) The following or similar is recommended: Ridgid 12 Gallon (WD1250)
Six-lobe bits T-10, T-20, T-27, T-30, T-45
Socket 13 mm hex, 6-point preferred
Socket extension 3 inch long, 3/8 inch drive
Tire iron 14 inch long, motorcycle type (qty 3)
Tire pump Air pump with Schrader valve attachment
Torque wrenches Adapters to fit the following hex and 6-lobe bits:
3/8 inch drive torque limiting ratchet (40 – 50 N-m range)
1/4 inch drive torque limiting ratchet (5 – 13.5 N-m range)
1/4 inch drive torque limiting screwdriver (0.3 – 1.6 N-m range)
Trigger-style bar clamp 12 inch bar clamp
Vise Grip Needle nose, small
Segway Personal Transporter SE Service Manual D–1

Tools and Equipment
D–2 Segway Personal Transporter SE Service Manual

E Glossary
Balance Sensor Assembly (BSA)
A component that senses the PT’s orientation and communicates with the CU Boards and motors to balance the PT.
Button Head Cap Screw (BHCS)
A type of screw with a rounded head and an indentation (hex or 6-lobe) used for tightening.
Chassis
The chassis is the aluminum base that all the other components of the PT are mounted to.
Console
The part of the PT that rests between the rider’s legs. It contains electronics and the pivot assembly.
CU Board
There are two Control Unit (CU) boards in the PT. These boards communicate with the BSA and the motors to control
the performance of the PT.
Electrostatic Discharge (ESD)
The rapid discharge of accumulated electrical charge. To prevent damage to the Segway PT, a Certified Service
Technician should always stand on a static mat, wear a grounding heel, or wear a grounding wrist strap while working
on electrical elements of the PT.
Harness
A group of cables bound together to form one assembly, typically with connectors that plug or snap into place.
InfoKey Controller
The InfoKey Controller is a wireless device used to turn the PT on/off, change settings, and more. Each InfoKey
Controller is paired with a particular PT.
LeanSteer
The handlebar and related components used to turn the PT left and right.
Light Pipe
A light pipe is a clear plastic component whose purpose is to deliver light from an LED to another location on the PT.
Lithium-ion (Li-ion) Battery
A type of rechargeable battery in which lithium ions move between electrodes when charging and discharging.
Pan Head Cap Screw (PHCS)
A type of screw with a wide flat head and an indentation (hex or 6-lobe) used for tightening.
Personal Transporter (PT)
A self-balancing mobility device for one person.
Powerbase
The fully-populated chassis with BSA, CU Boards, and motors.
SEMS
A screw and washer assembly.
Serviceable Powerbase (SPB)
A stripped-down PT consisting of the powerbase, gearboxes, and console.
Socket Head Cap Screw (SHCS)
A type of screw with a cylindrical head and an indentation (hex or 6-lobe) used for tightening.
Segway Personal Transporter SE Service Manual E–1

Glossary
E–2 Segway Personal Transporter SE Service Manual

24019-00001 aa

Werkstatthandbuch Segway I2 SE - EnG - Level 1 & 2

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Werkstatthandbuch Segway I2 SE - EnG - Level 1 & 2

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Segway® Personal Transporter

ii Segway Personal Transporter SE Service Manual

Segway Patent Information

Segway Customer Care: 866-4SEGWAY (866-473-4929)

Segway Personal Transporter SE Service Manual iii

General Safety Precautions..................................................................................................ix

4 Tire/Wheel Assembly.................................................................................................. 4–1

Segway Personal Transporter SE Service Manual v

6 Powerbase Trim............................................................................................................ 6–1

8 Serviceable Powerbase................................................................................................ 8–1

10 Chassis Cover............................................................................................................. 10–1

12 Balance Sensor Assembly..........................................................................................12–1

vi Segway Personal Transporter SE Service Manual

A Post-Service Tests........................................................................................................ A–1

B Parts List....................................................................................................................... B–1

Segway Personal Transporter SE Service Manual vii

viii Segway Personal Transporter SE Service Manual

Important Safety Notices

Segway Personal Transporter SE Service Manual ix

x Segway Personal Transporter SE Service Manual

Segway Personal Transporter SE Service Manual 0–1

Table 0–1: Certification Levels (cont.)

0–2 Segway Personal Transporter SE Service Manual

Customer Replaceable Kits and Technician Replaceable Parts

Related User Materials

Segway Personal Transporter SE Service Manual 0–3

Handlebar Handlebar Clamp

Gearbox Cover Console Trim

Front Console Trim

0–4 Segway Personal Transporter SE Service Manual

Segway Personal Transporter SE Service Manual 1–1

Standard LeanSteer Frame

Upper LeanSteer Tube

Height Adjust Knob

Washer Plate End Cap

Figure 1–1: Standard LeanSteer Frame Components

1–2 Segway Personal Transporter SE Service Manual

Patroller LeanSteer Frame

Upper LeanSteer Tube

Lower LeanSteer Tube Wedge

Washer Plate End Cap

Figure 1–2: Patroller LeanSteer Frame Components

Segway Personal Transporter SE Service Manual 1–3

1. Make sure the Segway PT is powered off and

1–4 Segway Personal Transporter SE Service Manual

Figure 1–6: Check LeanSteer Frame

Segway Personal Transporter SE Service Manual 1–5

3. Using a T-30 6-lobe wrench, install the four

Figure 1–8: LeanSteer Stem Comparison

1–6 Segway Personal Transporter SE Service Manual

Figure 1–9: Remove InfoKey Controller

Segway Personal Transporter SE Service Manual 1–7

InfoKey Controller Battery

Figure 1–12: InfoKey Controller Battery

1–8 Segway Personal Transporter SE Service Manual

Segway Personal Transporter SE Service Manual 2–1

2–2 Segway Personal Transporter SE Service Manual

Segway Personal Transporter SE Service Manual 3–1

3–2 Segway Personal Transporter SE Service Manual

1. Make sure the PT is powered off and unplugged.

9. Repeat Steps 1–8 for the second Battery.

Segway Personal Transporter SE Service Manual 3–3

3–4 Segway Personal Transporter SE Service Manual