Segway Max Pro (2.2) Electric Scooter - Front Fork Assembly Repair Video

How to replace the front fork assembly?Tool preparation Torque screwdriver, H3, T15, T25, T30, PH2, 8# wrench, 10#wrench, 26# wrench, needle nose pliers, Tweezers, 2 new reflection stickers and front fork assembly. Remove the stem Remove 1 M510 screw on the front side of the front tube with T25. Remove 2 M616 screws on the back side of the front tube with T30. Pull out the stem, disconnect the connection of control bus, Remove the black plate cover of the brake box, Take the brake cable plastic connector from the groove of the brake box, Brake cable pass through the open slot of front tube, Remove the brake cable connector from the brake cable box, then take off the stem. Remove the front tube Remove 1 M620 screw on the front tube with the T30 and take out the Sheath. Then remove 3 M620 screws on the back side of the front tube with the T30; Take away the tube upward. Take off the box of the brake cable Remove the front fork covers and the fender Remove the four rubber plugs and two reflection stickers with tweezers, then remove 6 M48 screws with H3 on each side of the front fork cover . Separate the front fork covers on both sides by hand and remove the front fork covers. Remove the ST3.59.5 cross recessed pan head tapping screw with the PH2, remove the front fender. Remove the brake cable Remove the nylon locknut M5 with 8# ratchet wrench, remove the adjusting nut, the perforated cylindrical and the dust cover in turns Remove the M6 hex nut with10# wrench, Remove the brake cable from the hole of front fork fixing block. Then pull the brake cable out from the bottom of the front fork. Remove the Y wire Remove the label with tweezers; Remove 4 screws M48 on the controller with T15, Disconnect the controller cable from the Y-wire. Straighten the wheel and pull out the Y wire. Remove the front fork assembly Take out the front fork headset bolt and flat washer with 26mm wrench, then take out the tube adapter, the dust cover and the opening holding ring in turns. Take away the front fork assembly Install the front fork assembly Install the opening holding ring: the small end is downward, the opening towards right. install the dust cover assembly and tube adapter: pay attention to the direction of installation on adapter, the end with bar is upward, and install the headset bolt and washer with 26# wrench, Torque: 31-33N·m. Install Y line Bend the end of Y- wire connecting controller slightly, insert it from the controller end into the hole of front fork, connect to the controller, install the controller in place, and tighten four M 4 * 8 screws on the controller with T15 Torque: 2 ± 0.2N · M Install the brake cable The brake cable passes through the bottom of the front fork and pull it out from the middle hole of the headset bolt. The brake cable then goes from the hole of the front fork fixing block, Install the brake junction box on the upper end of the brake cable .Tighten the M6 hex nut with10# wrench, Torque: 4-6N·m. Install the dust cover, perforated cylindrical, and the adjusting nut. Tighten the nylon locknut M5 with 8# ratchet wrench, Torque: 5.5±0.5 N·m. Install the front fender and the fork covers Install the front fender, tighten 4 screws with the PH2, Torque: 1.6±0.1N·m. Install the new fork covers on the scooter and ensure that the front fork covers are fixed to each other, tighten 6 M48 screws on both sides with the H3, Torque: 1.0-1.6N·m, install the four rubber plugs and two reflection stickers on each side of the front fork. Install the front tube Install the front tube and sheath on the front fork assembly, confirm that the tube hole is aligned with the tube adapter hole, tighten 3 M620 screws on the back side of the front tube with the T30 bit, Torque: 9-12N·m, place the Sheath in place, and then tighten the front side screw M620 with the T30 bit, Torque:5-7N·m. Install the stem Insert the brake cable from the open slot of front tube, insert the other end of the cable into the brake box, The brake cable plastic connector is installed in the groove of the brake wire box, Install plate cover of the brake box. Connect the control bus and insert the stem into the front tube. Tighten 2 M616 screws with T30, Torque: 9-12N·m. Tighten 1 M510 screw with T25, Torque: 5-6N·m Function detection Power on the scooter, and confirm that it functions properly