Gen 1 Handlebar Replacement

From SegwaySocial

by Crash

If you have ever changed a goose neck on a bicycle or adjusted one this will be easy.

Tools:

• 5mm hex end wrench.
• Small Flathead Screw Driver.
• Rubber malet or small hammer.
• One six pack of beer (optional)
• Milk Crate, to use as a segway stand, (It makes it easier)

Detailed Steps

Step 1: Loosen the height adjustment collar and set the Control Shaft (CS) to the lowest possible height.

Step 2: Take your flathead screw driver and pry up the 'KEY PORT' side of the grey plastic cover.

• DO NOT remove whole cover*

Step 3: You should now have the 5mm head of the Handle Bar (HB) exposed, loosen the bolt 6~7 turns left.

Step 4: At this point place the handle end of the screw driver on the 5mm bolt head and tap it with the mallet or just smack it once or twice until the HB becomes loose. Do not remove the HB at this time there are just a few more steps.

Step 5: Loosen the Control Shaft Base (CSB) 5mm bolt and tap it in to break the bind, twist the HB left to right and while holding the CS remove the entire HB and disconect the Hypertronic conections.

Step 6: Before you remove the old HB plug the new HB into the conecters and boot the vehicle up, Do not put it balance mode without the shaft, the HT will buck like you have never seen before, If you have the HT on a Milk Crate put it into balance mode and if the problem persists without the grips attached, the HB is not your problem. If good goto Step 7.

Step 7: At this point return to the HB and CS. Gently 'wiggle' the HB left to right while pulling upwards the HB will come two thirds of the way out and stop, dont panic its not stuck, its slotted to match a track for the rivet you see on the left hand side, twist to the left when you hit the stop and the shaft will come free. Take a look at the Left side of the new one to get orrientated.

Step 8: Now you will be able to set the CS to the loosest setting, leave about 2 inches hanging out for the rebuild, reasembally is oppisite and some people want to know the tourqe setting and this is what I tell them... "There are only three important tourqe setting the 4 on the batteries, the 5 on the fenders, and the what I call the dead turn on the wheels, otherwise tighten them good.".

Step 9: After you have snuggly tighten the HB 5mm bolt, pull the Hyper connectors and reatach them. Loosen the CS addjustment collar so as not to pinch the coonection wires, seat the CS and tighten the 5mm bolt on the CSB, it doesnt matter if it is on straight at this point. Return you focus to the HB and tighten the bolt while seating the HB with slight wiggles lefts and right. Snap the keyport cover on and tap with the handle of your screw driver or rubber mallet.

Step 10: Remove your HT from the stand and loosen the CSB 5mm and lay the Segway face down on a towel or cardboard and adjust until centered tighten the CSB bolt, boot and glide.