Segway C80 E-Moped - Right Brake Assembly Repair Video
How to replace the right brake assembly
Tool preparation: 2.7mm pentagonal bit, 3.95mm pentagonal bit, 5.45mm mm pentagonal bit, 10mm socket wrench, PH2 bit, H5 bit, Cable tie, Scissors/ Oblique pliers, Electric screwdriver Part 1: disassembly Pull out the panel along the edge with force. Remove 4 pentagonal screws ST4.212 with 3.95mm pentagonal bit, then pull out the cowl panel with force. Remove the screws ST4.212 on both sides of the front inner fender and take out the fender. Disconnect the head light wiring harness, remove the screws of the headlight with PH2 bit, and then remove the headlight. Remove the cowl panel connector upwards and cut off the cable tie. Remove the winding tape and take down the wire harnesses, then disconnect the right status lamp harness, right combination switch harness, throttle harness and right brake handle harness respectively. Remove the 4screws with ST4.212 with 3.95mm pentagonal bit, remove 2 screws M612 with 5.45 mm pentagonal bit, then take out the back hidden line shell. Remove 2 screws ST4.29.5 with PH2 bit, then take out the front hidden line shell. Remove the screw M410 with 2.7mm pentagonal bit, then take out the right combination switch. Remove two screws M612 with H5 bit and remove the splint, then remove the brake assembly and status light from the handlebar. Cut off the cable tie of the oil pipe and remove it from the clamp. Remove the bolts M830 of the disc brake pump with 10mm socket wrench and remove it from the disc brake plate. Remove 1 screw M310 with PH2 bit and the take out the throttle from the brake assembly. Remove 1 screw M48 with PH2 bit and take out the right status lamp from the brake assembly. Part 2: assembly Take the new disc brake assembly, and install the status lamp, fasten 1 screw M48 with PH2 bit, Torque: 2.7-4N·m. Install the throttle and fasten 1 screw M310 with PH2 bit, Torque: 0.8-1.2N·m. Install the disc brake pump, clip the disc brake shoes into the plate, and fasten 2 bolts M830 with 10mm socket wrench, Torque: 28-33N·m. Then put the brake assembly to the handlebar, and clip the oil pipe into the clamp. Arrange the throttle harness and press it into the cable slot. The install the clamp plate, pay attention to the clamp plate positioning hook into the handlebar positioning hole, tighten two M612 screws with H5 bit, Torque: 7-11N·m Install the right combination switch, buckle it in place, and the gap is less than 1mm. Pay attention to wiring from the slot of combination switch and brake handle assembly to avoid extrusion. Then fasten one screw M410 with PH2 bit, Torque: 2.7-4N·m. Connect throttle finger harness, brake handle harness, status lamp harness and combination switch harness respectively, Be careful not to connect the brake handle harness in reverse: red to yellow, black to black. Arrange the wiring harness and install the cable tie and install the cowl panel connector. Install the front hidden wire shell. Pay attention to place the harness into the hidden wire shell, and fasten two screws ST4.29.5 with PH2 bit, Torque: 1.9-2.7 N·m. Install the back hidden wire shell, the hidden wire shell should be buckled in place, fasten two pentagonal screws M614 with 5.45mm pentagonal bit, Torque: 7-11N·m. Then fasten 4 pentagonal screws st4.212 with 3.95mm pentagonal bit, Torque: 1.9-2.7N·m Put the oil pipe into the clamp, Arrange the wiring harness and install the winding tape, then fix the wire harness with the harness clamp. Fix the oil pipe with a cable tie. Install the headlight, pre tighten the upper screw M612, then fasten screws ST4.212 on both sides of the light with PH2 bit, Torque: 1.9-2.7N·M. then fasten the screw M612 with PH2 bit, Torque: 7-11N·m, and connect the wire harness of the light, Pay attention to the front lamp wiring harness around the tap lock. Install the front inner fender, align the clips on both sides with the slots, and press in. fasten the screws on both sides with PH2 bit, Torque: 1.9-2.7N·m. Attach the edge panel to the frame, Pay attention to the alignment of the clip slot. Then fasten 4 pentagonal screws ST4.212 with 3.95mm pentagonal bit, and Torque: 1.9-2.7N·m. Install the front plate, and align to the clamping slot and make it fully engaged