Segway B200 E-Bike - Right Brake Handle Assembly Repair Video

Tool preparation: Electric screwdriver, bit:T30, T25, T10, T20, H2, ratchet wrench: 8mm, 11mm, 14mm, long-nose pliers, L-type 2.5mm hex key, Corner maker Operating steps: Remove the battery, and refer to B200-C004 SOP of replacing the battery

Loosen the adjusting nut M5 and the locking nut M5 of the rear brake cable with a 14mm and 8mm ratchet wrench(P1), and insert the L-type 2.5mm hex key into the end of the brake cable to fix the brake cable, then use the 8mm ratchet wrench to remove the locking nut M5(P2, P3)

Remove the adjusting nut M5, spring dust shield and lock pillar in turn(P4, P5)

Use T30 bit and corner maker to remove the two screws M6×16 on the back of the IOT(P6), and take out the IOT(P7), then disconnect the wiring harness(P8)

Loosen female connector of rear brake cable(P9), and disconnect the rear brake cable connection(P10)

Use T20 bit to remove the three screws M4×12 on the dashboard assembly(P11, P12), then lift the dashboard assembly up and disconnect the wiring harness from the right brake handle assembly to the dashboard assembly(P13)

Use T25bit to remove the screw covering the end of the handlebar grip(P14), and remove the handlebar grip end cover, then pull out the handlebar grip(P15)

Use T10 bit to remove the screw M3×8 from the retaining ring(P16), then remove the retaining ring (P17)

Use T30 bit to loosen the set screw on right brake handle(P18), and pull out the brake handle(P19)

Grip the brake handle firmly, use long nose pliers to remove the brake cable head from the clamp(P20), and use H2 bit to loosen the brake cable set screw(P21), then pull out the brake cable(P22)

Pull out the wiring harness between the brake handle assembly and the dashboard assembly, and remove the right brake handle assembly(P23)

Get a new right brake handle assembly, thread the wiring harness between the brake handle assembly and the dashboard assembly along the brake handle slot and through the right inner hole of the vertical tube from the direction (P24, P25), then put the right brake handle assembly into the right handle

Pull the cylinder end of the brake cable out of the casing, and plug the casing into the corresponding slot, and use H2 bit to lock the brake cable set screw(Torque: 0.7±0.1 N·m)(P26), then grip the brake handle firmly, use long nose pliers to insert the brake cable head into the clamp(P27)

Put the right brake handle assembly into the brake handle slot(P28), and use T30 bit to lock the set screw on the brake handle(Torque: 5-6 N·m)(P29)

Insert the retaining ring(P30), use T10 bit to lock the screw M3×8 of the retaining ring(Torque: 0.5-0.6N·m) and the screw must not protrude from the surface of the retaining ring(P31)

Get the handlebar grip, and the handlebar grip will be placed in the groove(P32, P33) corresponding to the limit ring (P34)

Place the handlebar grip end cover in the slot of the handlebar grip card, and use a leather mallet to tap the end cover in place without gaps(P35), then use T25 bit to lock the screw of the end cover(Torque: 4-4.5N·m)(P36)

Connect the wiring harness between the right brake handle assembly and the dashboard assembly(P37), and use T20 bit to lock the three screws M4×12on the dashboard assembly(Torque: 1.2±0.1N·m)(P38, P39)

Connect the rear brake cable(P40), and tighten female connector of rear brake cable, and use 11mm ratchet wrench to set the torsion (Torque: 1.0-1.3 N·m)(P41)

Connect the wiring harness(P42), and install IOT(P43), Use T30 bit and corner maker to lock the two screws M6×16 on the back of the IOT(Torque: 3.5-4.0 N·m)(P44)

Install spring dust shield, lock pillar successively and adjusting nut M5 (P45, P46), and use 8mm ratchet wrenches and L-type 2.5mm hex key to preload the rear brake adjusting nut M5 and lock nut M5(P47) Fine-tune the braking steps:①Clamp right brake handle with Max 41mm fixture, and flat push vehicle can push(the rear wheel can roll continuously for at least half a turn)②Replace the Min 38mm fixture to clamp right brake handle, and flat push vehicle rear wheel can not move③Fine-tune the braking is ok, then fastening the lock nut M5 next to the adjusting nut M5, then fixed torsion:5.5±0.5 N·m④Then debugging is ok, mark with white paint pen to confirm the loosening condition later

Install the battery(P48), and refer to B200-C004 SOP of replacing the battery