Page 1
Service Manual
SE-3 Patroller
Page 2
Headlight (page 34)
Front Cowl (page 17)
Windshield (page 32)
Fender (page 22)
Light Cluster (page 36)
Front Tire/Wheel (page 28)
Rear Tire/Wheel
(page 30)
Side Panel (page 20)
Front Fender (page 24)
SE-3 Patrollerii
Page 3
Front Brake
Master Cylinder (page 59)
Control Cluster (page 72)
Handlebar Grip
(page 76)
Rear Brake
Master Cylinder (page 59)
Throttle (page 74)
UI Module (page 70)
Accessory Power Outlet (page 50)
Front Cowl (page 17)
Light Cluster (page 36)
Side Panel (page 20)
Battery Module (page 8)
KeyLock (page 49)
Bib Panel (page 14)
Glove Box Door (page 48)
Storage Tray (page 13)
Fender (page 22)
Rear Tire/Wheel (page 30)
Service Manual iii
Rear Strobe Light (page 42)
Rider Detect Mat (page 82)
Brake Light (page 40)
Rear Directional Light (page 41)
Page 4
Copyright, Trademarks, Patent, and Contact Information
Document number & revision: 24538-00001 ad
Copyright © 2015 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 SE-3 Patroller 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
SE-3 Patrolleriv
Page 5
Contents
Copyright, Trademarks, Patent, and Contact Information ..........................................................................iv
General Safety Precautions .................................................................................................. 1
Safety Conventions ........................................................................................................................................ 1
Important Safety Notices ..............................................................................................................................1
Introduction .......................................................................................................................... 5
Purpose ..........................................................................................................................................................5
Audience .........................................................................................................................................................5
Certification ...................................................................................................................................................5
General Service Procedure ............................................................................................................................6
Related User Materials ...................................................................................................................................6
Battery Module ......................................................................................................................7
Battery Module...............................................................................................................................................8
Body Panels..........................................................................................................................11
Exploded View ..............................................................................................................................................12
Storage Tray ................................................................................................................................................. 13
Bib Panel .......................................................................................................................................................14
Glove Box ...................................................................................................................................................... 16
Front Cowl ..................................................................................................................................................... 17
Light Cluster ................................................................................................................................................. 18
Side Panel .................................................................................................................................................... 20
Fender .......................................................................................................................................................... 22
Front Fender (Boot) .................................................................................................................................... 24
Front Splash Guard ..................................................................................................................................... 25
Main Splash Guard ...................................................................................................................................... 26
Tire/Wheel Assemblies ...................................................................................................... 27
Front Tire/Wheel ......................................................................................................................................... 28
Rear Tire/Wheel .......................................................................................................................................... 30
Windshield ...........................................................................................................................31
Windshield ................................................................................................................................................... 32
v
Page 6
Contents
Lights ................................................................................................................................... 33
Headlight ..................................................................................................................................................... 34
Headlight Alignment ................................................................................................................................... 35
Accessing the Light Cluster ........................................................................................................................ 36
Front Strobe Light ........................................................................................................................................37
Side Strobe Light ........................................................................................................................................ 38
Front Directional Light ................................................................................................................................ 39
Brake Light .................................................................................................................................................. 40
Rear Directional Light ..................................................................................................................................41
Rear Strobe Light ........................................................................................................................................ 42
Battery Compartment ........................................................................................................43
Battery Slides .............................................................................................................................................. 44
Battery Bumpers ......................................................................................................................................... 45
Bib Panel Components ....................................................................................................... 47
Glove Box Door ............................................................................................................................................ 48
KeyLock ....................................................................................................................................................... 49
Accessory Power Outlet .............................................................................................................................. 50
Brakes ...................................................................................................................................51
Brake Fluid ................................................................................................................................................... 52
Draining Brake Lines ................................................................................................................................... 53
Bleeding Brake Lines .................................................................................................................................. 54
Front Caliper ................................................................................................................................................ 56
Front Rotor .................................................................................................................................................. 58
Master Cylinder ........................................................................................................................................... 59
Brake Lever ..................................................................................................................................................60
Rear Caliper & Rotor ................................................................................................................................... 62
Front Brake Line .......................................................................................................................................... 64
Rear Brake Line ........................................................................................................................................... 66
Controls ............................................................................................................................... 69
UI Module .................................................................................................................................................... 70
UI Housing .................................................................................................................................................... 71
Control Cluster .............................................................................................................................................72
Throttle .........................................................................................................................................................74
Handlebar Grip .............................................................................................................................................76
SE-3 Patrollervi
Page 7
Contents
Siren .....................................................................................................................................77
Siren..............................................................................................................................................................78
Rider Detect Mat .................................................................................................................81
Rider Detect Mat ......................................................................................................................................... 82
Drive Train ........................................................................................................................... 85
Gearbox ....................................................................................................................................................... 86
Elastomer Bushing & Drive Hub ................................................................................................................. 88
Accessing the Motor Cavity ........................................................................................................................ 89
Motor ........................................................................................................................................................... 90
Motor Controller.......................................................................................................................................... 92
Steering Column ................................................................................................................. 93
Handlebar .................................................................................................................................................... 94
Front Fork .................................................................................................................................................... 96
Front Fender Bracket .................................................................................................................................. 98
Power Interface ..................................................................................................................99
Electronics Shield ..................................................................................................................................... 100
Charger ....................................................................................................................................................... 101
PI Board ......................................................................................................................................................102
Fuses ...........................................................................................................................................................104
Maximum Speed ........................................................................................................................................105
Harnesses ...........................................................................................................................107
Left/Right Motor Power Harness ..............................................................................................................108
Left/Right Drive Harness ........................................................................................................................... 110
Handlebar Controls Harness ..................................................................................................................... 112
User Interface Harness .............................................................................................................................. 114
Light Cluster Harness ................................................................................................................................ 116
Tail Light Harness ....................................................................................................................................... 118
Rear Strobe Light Harness ........................................................................................................................120
Accessory Power Harness .........................................................................................................................122
KeyLock Harness ........................................................................................................................................ 123
Siren Harness .............................................................................................................................................124
Service Interface Harness .........................................................................................................................125
Service Manual vii
Page 8
Contents
Post-Service Tests .............................................................................................................127
Drive Disable and Rider Detect Mat ..........................................................................................................127
Lights, Horn, and Siren ..............................................................................................................................127
Brake Check ...............................................................................................................................................127
Ride Test .....................................................................................................................................................128
Charge Test ................................................................................................................................................. 128
Fasteners ........................................................................................................................... 129
Tools and Equipment ........................................................................................................ 135
Glossary..............................................................................................................................137
SE-3 Patrollerviii
Page 9
General Safety Precautions
Safety Conventions
The following safety messaging conventions are used throughout this document:
WARNING!
CAUTION!
NOTICE
Warns you about actions that could result in death or serious injury.
Warns you about actions that could result in minor or moderate injury.
Indicates information considered important, but not related to personal injury. Examples
include messages regarding possible damage to the SE-3 Patroller 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 SE-3 Patroller, you must read and follow all instructions and warnings in this manual.
• Always power off the SE-3 Patroller 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.
• Remove the Battery Module before performing any service on the SE-3 Patroller.
• Wait two minutes after removing the Battery Module before removing the Electronics Shield or touching any electrical
components. This is how long it takes for the capacitors on the PI Board to self-discharge. Touching the PI Board before
the capacitors have fully discharged could result in electric shock.
CAUTION!
• Always wear gloves when handling chemicals (such as lubricants, corrosion inhibitors, greases, or oils) to reduce the
potential for skin damage or irritation.
Battery Module
WARNING!
• Do not use the Battery Module if the casing is broken or if the Battery Module emits an unusual odor, smoke, or excessive
heat, or leaks any substance. Avoid contact with any substance seeping from the Battery Module. Batteries contain toxic
and corrosive materials that could cause serious injury.
• Keep out of reach of children and pets. Exposure to battery voltage could result in death or serious injury.
• Unplug or disconnect the SE-3 Patroller from AC power before removing or attaching the Battery Module or performing
any service. Never work on any part of the SE-3 Patroller when it is plugged into AC power. You risk serious bodily injury
from electric shock as well as damage to the SE-3 Patroller.
• The cells within the Battery Module contain toxic substances. Do not attempt to open the Battery Module. Do not insert
any object into the Battery Module or use any device to pry at the Battery Module casing. If you insert an object into any
of the Battery Module ports or openings you could suffer electric shock, injury, burns, or cause a fire. Attempting to open
the Battery Module casing will damage the casing and could release toxic and harmful substances, and will render the
Battery Module unusable.
• Observe and follow all safety information on the warning label found on the Battery Module.
1
Page 10
General Safety Precautions
• Use only charging devices approved by Segway and never attempt to bypass or override their charging protection
circuits.
• Do not wash the SE-3 Patroller with a power washer or high pressure hose. Avoid getting water into the Charge Port.
Avoid exposure to heavy downpours or extended periods of heavy rain (including during riding, storage, or while being
transported). Clean with soap and water and a soft cloth. Make sure that the Charge Port is dry before you plug in the
Power Cord. Failure to follow these instructions could expose you to electric shock, injury, burns, or cause a fire.
• Do not submerge the SE-3 Patroller or Battery Module in water. If you suspect the Battery Module has 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 SE-3 Patroller outdoors and away from flammable objects. Failure to do so could
expose you to electric shock, injury, burns, or cause a fire.
• As with all rechargeable batteries, do not charge near flammable materials. When charging, the batteries heat up and
could ignite a fire.
• Failure to adhere to these warnings could lead to serious injury, death, fire, or damage to property.
NOTICE
• Failure to charge the Battery Module could result in permanent damage to the Battery Module. Left unplugged, the
Battery Module could fully discharge over time, causing permanent damage.
• Comply with all local and federal or individual country laws when disposing of and transporting Battery Modules.
Fasteners
WARNING!
• Use only Segway-approved fasteners. Other fasteners may not perform as expected and may come loose.
• Do not tighten or reuse any lock nut. Instead, when any lock nut is loose or removed, replace the lock nut with a new
Segway-approved lock nut.
• Before using a fastener, make certain the fastener is the correct size and type with any necessary washer and thread lock
in place.
• 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.
• Failure to adhere to these warnings could lead to serious injury or death or damage to property.
Cable Ties
CAUTION!
• When removing cable ties, be careful not to cut or nick harnesses. Damaged harnesses must be replaced.
• You must replace all cable ties that you remove. Loose wires can rub against sharp edges, which can cause them to break
over time.
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 any electronic components or harnesses, best-practice electrostatic discharge (ESD) control
procedures must be followed. Failure to follow ESD procedures could result in personal injury or damage to property.
SE-3 Patroller2
Page 11
General Safety Precautions
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.
Service Manual 3
Page 12
General Safety Precautions
SE-3 Patroller4
Page 13
Introduction
Purpose
The purpose of this manual is to provide instructions for servicing the Segway SE-3
Patroller.
Audience
This manual is written for Segway Certified Service Technicians working under
agreement with Segway Inc.
Certification
Becoming a Segway Certified Service Technician, SE-3 Patroller, involves a two-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 SE-3 Patroller parts and assemblies according to the
following scheme:
Table 1: Certication Levels
Level Parts and Assemblies Instructions
1 • Body Panels
• Tire/Wheel Assemblies
• Windshield
• Lights
• Battery Compartment
• Bib Components
2 • All Level 1 (see above)
• Brakes
• Controls
• Siren
• Rider Detect Mat
• Drive Train
• Steering Column
• Power Interface
• Harnesses
page 11
page 27
page 31
page 33
page 43
page 47
See above
page 51
page 69
page 77
page 81
page 85
page 93
page 99
page 107
5
Page 14
Introduction
General Service Procedure
Before performing any service on the SE-3 Patroller, you must first determine which
components may be damaged or malfunctioning. In some cases this requires a
simple visual inspection — as in the case of a cracked or damaged body panel. In
other cases diagnostic equipment must be used to troubleshoot the problem —
as when the vehicle turns on but won’t drive. No matter what the problem is, the
general service procedure is the same:
1. Identify — identify the symptoms.
2. Diagnose — determine which components may be malfunctioning.
3. Replace — replace the malfunctioning component(s).
4. Verify — operate the vehicle to verify the problem has been solved.
It may be the case that there are multiple problems affecting an SE-3 Patroller. Try
to isolate the problems and solve them one at a time.
Related User Materials
The following additional materials may be needed for reference during service:
• Segway SE-3 Patroller User Manual
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.
SE-3 Patroller6
Page 15
Battery Module
Overview
This component is not serviceable; if there is a problem with the Battery Module it
must be replaced.
When to Replace
Replace when troubleshooting determines that the Battery Module is
malfunctioning.
Safety
WARNING!
Always remove the Battery Module before servicing the SE-3 Patroller. Failure to
remove the Battery Module could result in serious injury or death due to electric
shock.
Contents
• Battery Module
7
Page 16
Battery Module
Battery Module
Tools Required: None
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Flip out and twist the latches as shown in Figure 1.
3. Use the handle to slide the Battery Module part way
out.
4. Grasp both the front handle and the top handle of the
Battery Module (Figure 2). Slide the Battery Module
completely out.
Flip latches out
Figure 1: Flip Out and Twist the Battery Module Latches
Twist latches inward
Figure 2: Slide the Battery Module out of the SE-3 Patroller
SE-3 Patroller8
Page 17
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Make sure the latches are configured as in Figure 3.
3. Holding the Battery Module by both front and top
handles, slide it into the opening.
4. Twist the latches and fold them back (Figure 4) to
lock the Battery Module.
Battery Module
Figure 3: Slide the Battery Module into the SE-3 Patroller
Twist latches outward
Figure 4: Twist and Close the Battery Module Latches
Close latches to lock
Service Manual 9
Page 18
Battery Module
SE-3 Patroller10
Page 19
Body Panels
Overview
Body Panels attach to the frame to create the shape and style of the SE-3 Patroller.
Body panels serve a number of functions. Among other things, they provide a
mounting location for lights, they protect the internal components from the
elements, and they protect the rider from touching the wheels.
When to Replace
Replace a Body Panel when it is cracked, bent, or otherwise broken.
Safety
WARNING!
Do not operate the SE-3 Patroller without all body panels installed.
CAUTION!
When removing body panels, place them on a soft, clean surface to prevent
scratching or marring of the body panel.
Contents
• Exploded View
• Storage Tray
• Bib Panel
• Glove Box
• Front Cowl
• Light Cluster
• Side Panel
• Fender
• Front Fender (Boot)
• Front Splash Guard
• Main Splash Guard
11
Page 20
Body Panels
Exploded View
The exploded view (below) identifies all of the body panels on the SE-3 Patroller.
Front Cowl
(23750-00001)
Right Side Panel
(24130-00001)
Light Cluster
(23776-00001)
Right Storage Tray
(23759-00001)
Left Storage Tray
(23758-00001)
Bib Panel
(24117-00001)
Right Fender
(23757-00001)
Left Fender
(23756-00001)
Front Fender
(23761-00001)
Front Splash Guard
(24077-00001)
Figure 5: Body Panels, Expoded View
Main Splash Guard
(24076-00001)
Left Side Panel
(24129-00001)
SE-3 Patroller12
Page 21
Storage Tray
The Storage Tray is the first component to remove when
removing body panels. Both Storage Trays must be removed
before removing the Bib Panel.
Tools Required: 4 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Using a 4 mm hex wrench, remove the fastener at the
bottom of the Storage Tray.
3. Remove the Storage Tray.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Insert the Storage Tray and line up the hole in the
bottom of the Storage Tray with the threaded hole in
the vehicle’s frame.
3. Using a 4 mm hex wrench, install the fastener.
Torque to 1.0 N-m (0.74 ft-lbf). Do not over-tighten.
Body Panels
24270-00006
1.0 N-m (0.74 ft-lbf)
Storage Tray
Left 23758-00001
Right 23759-00001
Figure 6: Storage Tray
Service Manual 13
Page 22
Body Panels
Bib Panel
The Bib Panel is also known as the Front Tower Panel.
Tools Required: 4 mm hex wrench
2.5 mm hex wrench
Torque wrench
Wire cutters
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
3. Using a 4 mm hex wrench, remove the eight fasteners
as shown in Figure 7.
4. Gently pull the Bib Panel off the frame to access the
cable harnesses connected to it.
5. Disconnect the two quick connect terminals from the
back of the Accessory Power Outlet (Figure 10).
6. Using wire cutters, remove the cable tie on the
KeyLock. See Figure 9.
7. Slide the rubber protector off the KeyLock.
8. Press the tab on the side of the Connector Block and
pull it off the KeyLock (Figure 11).
9. Using a 2.5 mm hex wrench, remove the two
fasteners on the Charge Port (IEC Socket).
See Figure 8.
10. Pull the Bib Panel completely off the frame.
24270-00006
4.0 N-m (3.0 ft-lbf)
Bib Panel
(24117-00001)
24270-00006
5.5 N-m (4.0 ft-lbf)
Figure 7: Bib Panel
IEC Socket
20307-00005
1.6 N-m (1.2 ft-lbf)
Figure 8: Charge Port
Figure 9: Rubber Protector Covering the KeyLock
SE-3 Patroller14
Page 23
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Using a 2.5 mm hex wrench and two fasteners, install
the Charge Port (IEC Socket) onto the Bib Panel.
Torque to 1.6 N-m (1.2 ft-lbf).
NOTICE
Make sure the IEC socket is aligned correctly.
3. Slide the connector block onto the back of the
KeyLock. Pull on it to verify that it is locked in place.
4. If necessary, connect the two quick connect
terminals to the KeyLock (Figure 11).
Pin 1 Black
Pin 2 Red
Pin 3 Empty
5. Slide the rubber protector over the connector block
and secure with a cable tie. See Figure 9.
6. Connect the two quick connect terminals to the
Accessory Power Outlet (Figure 10).
+ Red
– Black
7. Slide the Bib Panel onto the frame.
8. Using a 4 mm hex wrench, install the eight fasteners
as shown in Figure 7.
Torque the upper two fasteners to 4.0 N-m
(3.0 ft-lbf).
Torque the lower six fasteners to 5.5 N-m (4.0 ft-lbf).
9. Check the Glove Box Lock Plate alignment (see
Figure 13). When the Glove Box lock is turned, there
should be some friction between the pawl and the
Lock Plate. The weather stripping around the Glove
Box Door should compress slightly.
Torqe the Lock Plate fastener to 1.6 N-m (1.2 ft-lbf).
10. Install the following components:
a. Storage Trays (page 13)
b. Battery Module (page 8)
11. Perform post-service tests (page 127).
Body Panels
Figure 10: Accessory Power Outlet
Tab
Figure 11: KeyLock Connector Block
Service Manual 15
Figure 12: KeyLock Terminals
Page 24
Body Panels
Glove Box
The Gove Box fastens to the frame at the opening and rests on
studs on the frame at its other end.
Tools Required: 3 mm hex wrench
4 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
3. Using a 4 mm hex wrench, remove the three
fasteners and Lock Plate as shown in Figure 13.
4. Gently lift the Glove Box off of the Frame.
5. Using a 3 mm hex wrench, remove the two fasteners
connecting the Service Port to the back of the Glove
Box (Figure 14).
6. Remove the Splash Shield (Figure 15).
20553-00001
1.6 N-m (1.2 ft-lbf)
Figure 13: Glove Box Fasteners
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Install the Splash Shield (Figure 15).
3. Using a 3 mm hex wrench, attach the Service Port
harness to the back of the Glove Box (Figure 14).
Orient the connector with the narrow side down.
Torque to 1.6 N-m (1.2 ft-lbf).
4. Align the Glove Box on the frame. The back of the
Glove Box has holes which slide over studs in the
frame. The Glove Box opening has holes that line up
with the holes in the frame.
5. Using a 4 mm hex wrench, install the three fasteners
and Lock Plate as shown in Figure 13.
Torque to 1.6 N-m (1.2 ft-lbf).
6. Install the following components:
a. Bib Panel (page 14)
b. Storage Trays (page 13)
c. Battery Module (page 8)
7. Perform post-service tests (page 127).
24315-00001
1.6 N-m (1.2 ft-lbf)
24400-00001
1.6 N-m (1.2 ft-lbf)
Figure 14: Service Port
Splash Shield
(24419-00001)
Figure 15: Splash Shield
SE-3 Patroller16
Page 25
Front Cowl
The Front Cowl fastens to the left and right Side Panels.
Tools Required: 4 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
3. Using a 4 mm hex wrench, remove the six fasteners
as shown in Figure 16.
4. Lift the Front Cowl off of the frame.
Body Panels
Front Cowl
(23750-00001)
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Place the Front Cowl onto the SE-3 so that it rests on
the Light Cluster and the Side Panels.
3. Using a 4 mm hex wrench, install the six fasteners as
shown in Figure 16.
Torque to 4.0 N-m (3.0 ft-lbf).
4. Install the following components:
a. Glove Box (page 16)
b. Bib Panel (page 14)
c. Storage Trays (page 13)
d. Battery Module (page 8)
5. Perform post-service tests (page 127).
24270-00004
4.0 N-m (3.0 ft-lbf)
Figure 16: Fasten the Front Cowl
Service Manual 17
Page 26
Body Panels
Light Cluster
These instructions describe how to remove and install the
Light Cluster body panel. For instructions on replacing
individual lights, see page 33.
Tools Required: 4 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
e. Front Cowl (page 17)
3. Using a 4 mm hex wrench, remove the two fasteners
as shown in Figure 17.
4. Remove the two cable ties around the light cluster
harnesses.
5. Detach the wire harnesses (Figure 18).
6. Slide the Light Cluster forward and lift it off the
frame.
24270-00006
4.0 N-m (3.0 ft-lbf)
Unpopulated
Light Cluster
(23776-00001)
Figure 17: Light Cluster
Figure 18: Light Harnesses with Cable Ties
SE-3 Patroller18
Page 27
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Slide the Light Cluster onto the frame.
NOTICE
You may need to loosen the fasteners holding the
Side Panels to the floating bracket. See Figure 20, p.
20. Be sure to torque the fasteners after installing
the Light Cluster.
3. Using a 4 mm hex wrench, install the two fasteners as
shown in Figure 17.
Torque to 4.0 N-m (3.0 ft-lbf).
4. Connect the wire harnesses. Connect the left and
right directionals to the labeled harnesses. The
strobe lights can be connected to any of the strobe
light harnesses. See Figure 19.
Right Directional Yellow + Green
Left Directional Black/White + Brown/White
5. Install two cable ties around the light harnesses to
keep them neat and safe from sharp corners.
See Figure 18.
6. Install the following components:
a. Front Cowl (page 17)
b. Glove Box (page 16)
c. Bib Panel (page 14)
d. Storage Trays (page 13)
e. Battery Module (page 8)
7. Perform post-service tests (page 127).
Right
Directional Light
Strobe Lights
(Order Not Important)
Figure 19: Light Harness Connectors
Body Panels
Left
Directional Light
Service Manual 19
Page 28
Body Panels
Side Panel
The Side Panels attach to a floating bracket at the front of the
steering column.
Tools Required: 4 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
e. Front Cowl (page 17)
f. Light Cluster (page 18)
3. Using a 4 mm hex wrench, remove the four front
fasteners (two each side) as shown in Figure 20.
4. Using a 4 mm hex wrench, remove the three side
fasteners as shown in Figure 21.
5. Using a 4 mm hex wrench, remove the bracket
fastener as shown in Figure 22.
6. Lift the Side Panel off of the frame. Pull the bottom
out then lift up.
Side Panel
24270-00004
4.0 N-m (3.0 in-lbf)
Figure 20: Front Fasteners
Side Panel
Left 24129-00001
Right 24130-00001
24270-00004
5.5 N-m (4.0 ft-lbf)
Figure 21: Side Fasteners
SE-3 Patroller20
Page 29
Body Panels
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. If the Side Panel Bracket is not already installed,
install it now. Using a 4 mm hex wrench, install the
four fasteners as shown in Figure 23.
Torque to 4.0 N-m (3.0 in-lbf).
3. Place the Side Panel onto the frame so that the
bracket rests on the frame. Align the holes in the Side
Panel with the holes in the frame.
4. Using a 4 mm hex wrench, install the three side
fasteners as shown in Figure 21.
Torque to 5.5 N-m (4.0 ft-lbf).
5. Using a 4 mm hex wrench, install the four front
fasteners (two each side) as shown in Figure 20.
Loosely install theses fasteners on both Side Panels
before tightening.
Torque to 4.0 N-m (3.0 ft-lbf).
6. Using a 4 mm hex wrench, install the bracket fastener
as shown in Figure 22.
Torque to 5.5 N-m (4.0 ft-lbf).
7. Install the following components:
a. Light Cluster (page 18)
b. Front Cowl (page 17)
c. Glove Box (page 16)
d. Bib Panel (page 14)
e. Storage Trays (page 13)
f. Battery Module (page 8)
8. Perform post-service tests(page 127).
24270-00004
5.5 N-m (4.0 ft-lbf)
Figure 22: Bracket Fastener
24270-00004
4.0 N-m (3.0 ft-lbf)
Bracket
24031-00001
Figure 23: Side Panel Bracket
Service Manual 21
Page 30
Body Panels
Fender
The Fender attaches to the frame and gearbox bracket.
Tools Required: 4 mm hex wrench
10 mm socket wrench
Wire cutters
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
3. Using a 4 mm hex wrench, remove the six outside
fasteners and P-clip (Figure 24).
4. Using a 10 mm socket wrench, remove the lock nut
and P-clip on the back of the upper inside fastener.
5. Using a 4 mm hex wrench, remove the three inside
fasteners (Figure 25).
6. Reach inside the wheel well and disconnect the
Tail Light Harness from the Brake Light and Rear
Directional Light.
7. Lift the Fender off the frame.
Reach between the Fender and the Bracket; push the
center of the Fender away from the Bracket.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Place the Fender on the frame.
3. Connect the Tail Light Harness to the Brake Light and
Rear Directional Light.
4. Using a 4 mm hex wrench, install the three inside
fasteners (Figure 25). Place the longer fastener
through the upper hole.
Torque to 5.5 N-m (4.0 ft-lbf).
5. Install a P-clip around the Tail Light Harness and slide
it onto the back of the long fastener just installed.
6. Using a 10 mm socket wrench, install a lock nut to
hold the P-clip in place.
Torque to 5.5 N-m (4.0 ft-lbf).
7. Install a P-clip around the Tail Light Harness and
orient it as shown in Figure 24.
8. Using a 4 mm hex wrench, install the six outside
fasteners and the P-clip (see Figure 24).
Torque to 5.5 N-m (4.0 ft-lbf).
P-Clip
(24509-00001)
23202-00004
5.5 N-m (4.0 ft-lbf)
P-Clip
(24509-00001)
Fender
Push to
Remove
24270-00004
5.5 N-m (4.0 ft-lbf)
Some components not shown.
Figure 24: Outside Fasteners
Fender
Left 23756-00001
Right 23757-00001
24270-00006
5.5 N-m (4.0 ft-lbf)
24270-00004
5.5 N-m (4.0 ft-lbf)
Figure 25: Inside Fasteners
SE-3 Patroller22
Page 31
Installation (cont.)
9. Install the following components:
a. Bib Panel (page 14)
b. Storage Trays (page 13)
c. Battery Module (page 8)
10. Perform post-service tests (page 127).
Body Panels
P-Clip
(24509-00001)
Outside Fasteners
(24270-00004)
Inside Fasteners
2x (24270-00004)
1x (24270-00006)
Fender
Bracket
Left 24297-00001
Right 24298-00001
P-Clip
(24509-00001)
23202-00004
5.5 N-m (4.0 ft-lbf)
Bracket Fasteners
(24270-00006)
4.0 N-m (3.0 ft-lbf)
Service Manual 23
Gearbox Assembly
Figure 26: Exploded View of Fender
Page 32
Body Panels
Front Fender (Boot)
The Front Fender must be removed any time Front Fork
components need to be accessed.
Tools Required: 4 mm hex wrench
6 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Using a 6 mm hex wrench, remove the two large
fasteners (one per side). See Figure 27.
3. Using a 4 mm hex wrench, remove the four small
fasteners.(two per side).
4. Remove the Front Fender.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Place the Front Fender over the front wheel so that it
rests on the bracket.
3. Using a 6 mm hex wrench, install the two large
fasteners (one per side). See Figure 27.
Torque to 5.5 N-m (4.0 ft-lbf).
4. Using a 4 mm hex wrench, install the four small
fasteners (two per side).
Torque to 5.5 N-m (4.0 ft-lbf).
24270-00006
5.5 N-m (4.0 ft-lbf)
24437-00003
5.5 N-m (4.0 ft-lbf)
Figure 27: Front Fender Fasteners
SE-3 Patroller24
Page 33
Front Splash Guard
The Front Splash Guard is flexible and bends around the
bracket on the Front Fork.
Tools Required: 4 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the Front Fender (page 24).
3. Using a 4 mm hex wrench, remove the eight fasteners
as shown in Figure 28.
4. Remove the Front Splash Guard.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Align the Front Splash Guard against the bracket on.
Orient the part number toward the wheel.
3. Using a 4 mm hex wrench, install the eight fasteners
as shown in Figure 28.
Torque to 5.5 N-m (4.0 ft-lbf).
4. Install the Front Fender (page 24).
Body Panels
24270-00004
5.5 N-m (4.0 ft-lbf)
Front Splash Guard
24077-00001
Figure 28: Front Splash Guard
Service Manual 25
Page 34
Body Panels
Main Splash Guard
The Main Splash Guard is flexible and attaches to the frame
and to the floating bracket that holds the Front Panels
together.
Tools Required: 4 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Front Fender (page 24)
b. Front Splash Guard (page 25)
c. Front Fender Bracket (page 98)
3. Using a 4 mm hex wrench, remove the eight fasteners
as shown in Figure 29.
4. Starting at the top, bend one side of the Main Splash
Guard out from behind the Side Panel. Work from top
to bottom until the entire side is released.
5. Slide the Main Splash Guard off the vehicle.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Slide the Main Splash Guard on the frame.
3. Starting at the top, bend the Main Splash Guard to fit
behind the Side Panels. Work from top to bottom.
4. Using a 4 mm hex wrench, install the eight fasteners
as shown in Figure 29.
Torque to 5.5 N-m (4.0 ft-lbf).
5. Install the following components:
a. Front Fender Bracket (page 98)
b. Front Splash Guard (page 25)
c. Front Fender (page 24)
24270-00004
5.5 N-m (4.0 ft-lbf)
Main Splash Guard
24076-00001
Some components not shown.
Figure 29: Main Splash Guard
SE-3 Patroller26
Page 35
Tire/Wheel Assemblies
Overview
The SE-3 Patroller has three wheels: one front wheel and two rear wheels. For
general tire care information, refer to the
Segway SE-3 Patroller User Manual
.
When to Replace
Replace a Tire/Wheel Assembly under any of the following conditions, including, but
not limited to:
• Persistent leak in tire after reinflation.
• Wheel is cracked or bent.
• Tire is flat, cracked, or excessively worn.
Excess wear is determined as follows:
– Front tire tread depth is less than 2 mm.
– Rear tire tread depth is less than 3.8 mm
or tread is worn down flush with the tread wear indicators.
Tire inflation pressure can dramatically affect range, traction, and tread wear.
Ensure tires are properly inflated as follows:
• Front: 22 psi (1.52 Bar; 152 kPa)
• Rear: 25 psi (1.72 Bar; 172 kPa)
Contents
• Front Tire/Wheel
• Rear Tire/Wheel
Safety
WARNING!
When jacking up the SE-3 Patroller, make sure the SE-3 Patroller is stable or use
a jack stand to stabilize it while the wheel is off the ground. Failure to stabilize the
SE-3 Patroller could result in death or serious injury from the vehicle falling over.
27
Page 36
Tire/Wheel Assemblies
Front Tire/Wheel
Replacing the Front Tire/Wheel involves removing the Front
Fender (Boot), removing the caliper and rotor, and removing
the Front Spindle off of the Front Fork.
Tools Required: Vehicle jack
4-inch bar clamp
6 mm hex wrench
30 mm socket wrench (2)
Wheel nut key
19 mm or 21 mm socket wrench
Torque wrench
Setup
When removing or installing the front Tire/Wheel, prepare the
SE-3 Patroller by following these steps:
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Place a vehicle jack under the center front of the skid
plate. Raise the SE-3 Patroller until the front wheel is
off the ground (Figure 30).
Place jack here
Figure 30: Front Lifting Point
WARNING!
Make sure the SE-3 Patroller is stable or use a jack
stand to stabilize it while the wheel is off the ground.
Failure to stabilize the SE-3 Patroller could result in
death or serious injury from the vehicle falling over.
Removal
1. Prepare the SE-3 Patroller by following the Setup
instructions (above).
2. Remove the Front Fender (page 24).
3. Using a bar clamp and socket, compress the caliper
as shown in Figure 31, then remove the bar clamp.
NOTICE
If you don’t have a bar clamp, you will need to remove
the rotor fasteners. See page 58.
4. Using a 6 mm hex wrench, remove the two fasteners
holding the caliper in place. See Figure 32.
Slide the caliper off the rotor.
NOTICE
Secure the caliper so that it doesn’t fall or otherwise
stress the brake line.
Socket
Bar Clamp
Figure 31: Compress the Caliper
23868-00001
28.5 N-m (21.0 ft-lbf)
Figure 32: Front Caliper Bolts
5. Using a 30 mm socket wrench, remove the axle and
slide it out. See Figure 33.
6. Slide the wheel assembly out of the front fork.
7. Using the wheel nut key, remove the four fasteners
holding the wheel onto the Spindle. See Figure 34.
8. Slide the wheel off the Spindle.
SE-3 Patroller28
Page 37
Installation
1. Prepare the SE-3 Patroller by following the Setup
instructions (page 28).
2. Slide the wheel onto the spindle. Orient the wheel so
the valve stem is away from the rotor.
See Figure 34.
3. Using the wheel nut key, install the four fasteners
attaching the wheel to the spindle.
Torque to 67 N-m (49 ft-lbf).
4. Slide the wheel assembly onto the front fork. Orient
the Wheel assembly so the rotor is toward the left
side of the SE-3.
5. Slide the axle through the forks and wheel assembly.
See Figure 33.
6. Using a pair of 30 mm socket wrenches, fasten the
nut onto the axle.
Torque to 85 N-m (63 ft-lbf).
7. Using a bar clamp and socket, compress the caliper
as shown in Figure 31, then remove the bar clamp.
8. Slide Caliper onto the Rotor so that the Rotor rests
between the two brake pads.
9. Using a 6 mm hex wrench, install the two fasteners
holding the Caliper in place. See Figure 32.
Torque to 28.5 N-m (21 ft-lbf).
10. Install the Front Fender (page 24).
11. Perform post-service tests (page 127).
24404-00001
85 N-m (63 ft-lbf)
23789-00001
67 N-m (49 ft-lbf)
Tire/Wheel Assemblies
Axle
(23773-00001)
Figure 33: Front Axle Removal
Spindle
23768-00001
Front Tire/Wheel
23765-00001
Figure 34: Front Wheel on Spindle
Service Manual 29
Page 38
Tire/Wheel Assemblies
Rear Tire/Wheel
Tools Required: Vehicle jack
Wheel nut key
19 mm or 21 mm socket wrench
torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Using the wheel nut key, loosen but do not remove
the four Wheel Nuts.
3. Place the vehicle jack under the back of the SE-3
Patroller skid plate, close to the wheel being changed
(Figure 35). Raise the SE-3 Patroller until the wheel
is just off the ground.
WARNING!
Do not lift both rear wheels off the ground. Two
wheels must always remain in contact with the
ground to reduce the possibility of the SE-3 Patroller
tipping over while it is on the jack.
4. Using the wheel nut key, remove all four Wheel nuts.
5. Pull the wheel off the studs.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Jack up the SE-3 Patroller (Figure 35).
3. Make sure all mounting surfaces are clean and free of
debris.
4. Slide the wheel onto the studs.
5. Using the wheel nut key, install the four Wheel Nuts.
Ensure the wheel nuts are fully seated and are a little
more than hand tight.
6. Lower the SE-3 Patroller and remove the jack.
7. Using the wheel nut key, torque the four Wheel Nuts
to 67 N-m (49 ft-lbf). Torque nuts in a cross pattern:
top, bottom, left, right (Figure 36).
8. Perform post-service tests (page 127).
Place jack here
Figure 35: Rear Lifting Points
Torque the four Wheel Nuts
in a cross pattern.
Figure 36: Installing a Rear Wheel
SE-3 Patroller30
Page 39
Windshield
Overview
The Windshield protects the UI Module.
When to Replace
Replace the Windshield when it is cracked or otherwise broken.
Contents
• Windshield
31
Page 40
Windshield
Windshield
Tools Required: 4 mm hex wrench
10 mm socket wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Using both a 4 mm hex wrench and a 10 mm socket
wrench, remove the four hex nuts on the underside of
the Windshield. See Figure 37.
3. Remove the fasteners and lift the Windshield off the
handlebar frame.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Install four grommets into the holes in the handlebar
frame. These grommets protect the Windshield from
vibration.
3. Orient the Windshield on the SE-3 Patroller so that
the holes in the Windshield align with the holes in the
handlebar frame.
4. Insert fasteners from above. Hand tighten hex nuts
from underneath.
5. Using both a 4 mm hex wrench and a 10 mm socket
wrench, tighten the fasteners.
Torque to 1.5 N-m (1.1 ft-lbf).
24270-00006
Windshield
(23802-00001)
Grommet
(23805-00001)
23202-00004
1.5 N-m (1.1 ft-lbf)
Figure 37: Windshield
NOTICE
Do not over tighten. Over tightening could damage
the Windshield.
SE-3 Patroller32
Page 41
Lights
Overview
The SE-3 Patroller has a headlight, brake lights, directional lights, and strobe lights.
There are two colors of strobe lights: red/blue for police, and amber for security.
When to Replace
Replace a light when diagnostic testing indicates that a light is malfunctioning.
NOTICE
When connecting light harnesses, make sure the connectors snap firmly into place.
Contents
• Headlight
• Headlight Alignment
• Accessing the Light Cluster
• Front Strobe Light
• Side Strobe Light
• Front Directional Light
• Brake Light
• Rear Directional Light
• Rear Strobe Light
33
Page 42
Lights
Headlight
The Headlight rests on an adjustable bracket behind the
Windshield.
Tools Required: 3 mm hex wrench
Wire cutters
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
e. Front Cowl (page 17)
f. Windshield (page 32)
3. Disconnect the harness. See Figure 39.
4. Remove the two cable ties.
5. Using a 3 mm hex wrench, remove the two fasteners
as shown in Figure 38.
6. Remove the Headlight.
24315-00006
1.6 N-m (1.2 ft-lbf)
Figure 38: Headlight
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Slide the Headlight harness through the hole in the
bracket.
3. Using a 3 mm hex wrench, attach the headlight to the
bracket as shown in Figure 38.
Torque to 1.6 N-m (1.2 ft-lbf).
4. Connect the Harness. See Figure 39.
5. Install two cable ties.
6. Align the Headlight (page 35).
7. Install the following components:
a. Windshield (page 32).
b. Front Cowl (page 17)
c. Glove Box (page 16)
d. Bib Panel (page 14)
e. Storage Trays (page 13)
f. Battery Module (page 8)
8. Perform post-service tests (page 127).
Headlight
Connector
Figure 39: Headlight Harness
SE-3 Patroller34
Page 43
Headlight Alignment
Always align the Headlight after performing any service that
affects the Headlight.
Lights
Tools Required: 4 mm hex wrench
10 mm socket wrench
Digital level
Torque wrench
Procedure
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Using a 4 mm hex wrench and a 10 mm socket
wrench, loosen the Headlight Bracket fasteners as
shown in Figure 40. Loosen just enough to adjust the
headlight angle.
3. Place a digital level on top of the bracket. Adjust the
bracket until it is at 12°.
4. Tighten the Headlight Bracket fasteners and torque
to 6.0 N-m (4.4 ft-lbf).
23202-00004
6.0 N-m (4.4 ft-lbf)
24270-00004
Figure 40: Headlight Bracket
Service Manual 35
Page 44
Lights
Accessing the Light Cluster
To acess the Light Cluster, remove the body panels listed
below.
Remove Body Panels
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
e. Front Cowl (page 17)
Side Strobe Light
Front Strobe Light
NOTICE
Some of the lights require plastic sleeves to be
installed on the fasteners. See Figure 43.
Install Body Panels
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Install the following components:
a. Front Cowl (page 17)
b. Glove Box (page 16)
c. Bib Panel (page 14)
d. Storage Trays (page 13)
e. Battery Module (page 8)
Directional Light
Figure 41: Light Cluster Components
Right
Directional Light
Figure 42: Light Cluster Harness
Figure 43: Fastener with Plastic Sleeve
Stobe Lights
(Order Not Important)
Left
Directional Light
SE-3 Patroller36
Page 45
Front Strobe Light
Tools Required: 3 mm hex wrench
7 mm socket wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Access the Light Cluster by following the instructions
to Remove Body Panels on page 36.
3. Disconnect the wire harness.
4. Using a 3 mm hex wrench and a 7 mm socket wrench,
remove the two fasteners securing the light.
See Figure 44.
5. Remove the light.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Feed the wire harness through the hole in the Light
Cluster and connect it to the Front Light Harness.
See Figure 45.
3. Orient the light.
Police: Red toward center
Blue toward outside
Security: Locate the heat vent (Figure 46)
Right light = heat vent down
Left light = heat vent up.
4. Slide the plastic sleeves onto the fasteners, then
install the fasteners and lock nuts (Figure 44).
5. Using a 3 mm hex wrench and a 7 mm socket wrench,
tighten the fasteners.
Torque to 1.6 N-m (1.2 ft-lbf).
Front Strobe Light
Police 24252-00001
Security 24252-00002
24315-00006
Lights
23202-00001
1.6 N-m (1.2 ft-lbf)
Figure 44: Front Stobe Lights
Figure 45: Light Harnesses
Heat Vent
CAUTION!
Do not overtighten. Overtightening may damage the
rubber seal around the light.
6. Reassemble the SE-3 Patroller by following the
instructions to Install Body Panels on page 36.
7. Perform post-service tests (page 127).
Service Manual 37
Cap
Figure 46: Heat Vent Location
Page 46
Lights
Side Strobe Light
Tools Required: 3 mm hex wrench
7 mm socket wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Access the Light Cluster by following the instructions
to Remove Body Panels on page 36.
3. Disconnect the wire harness.
4. Using a 3 mm hex wrench and a 7 mm socket wrench,
remove the two fasteners securing the light.
See Figure 47.
5. Remove the light.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Feed the wire harness through the hole in the Light
Cluster and connect it to the Front Light Harness.
3. Orient the light. The pigtail is offset where it connects
with the light. Orient the lights so the pigtail is toward
the top on one light and toward the bottom on the
other light. See Figure 48.
4. Slide the plastic sleeves onto the fasteners, then
install the fasteners and lock nuts (Figure 47).
5. Using a 3 mm hex wrench and a 7 mm socket wrench,
tighten the fasteners.
Torque to 1.6 N-m (1.2 ft-lbf).
Side Strobe Light
Police 24253-00002
Security 24253-00003
23202-00001
1.6 N-m (1.2 ft-lbf)
24315-00007
Figure 47: Side Strobe Lights
CAUTION!
Do not overtighten. Overtightening may damage the
rubber seal around the light.
6. Reassemble the SE-3 Patroller by following the
instructions to Install Body Panels on page 36.
7. Perform post-service tests (page 127).
Pigtail is offset
toward the top
Figure 48: Harness Offset
SE-3 Patroller38
Page 47
Front Directional Light
Tools Required: 3 mm hex wrench
7 mm socket wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Access the Light Cluster by following the instructions
to Remove Body Panels on page 36.
3. Disconnect the wire harness.
4. Using a 3 mm hex wrench and a 7 mm socket wrench,
remove the two fasteners securing the light.
See Figure 49.
5. Remove the light.
Lights
23202-00001
1.6 N-m (1.2 ft-lbf)
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Feed the wire harness through the hole in the Light
Cluster and connect it to the Front Light Harness.
NOTICE
Connect the left-hand light to the connector labeled
“Left” and the right-hand light to the connector
labeled “Right.”
3. Slide the plastic sleeves onto the fasteners, then
install the fasteners and lock nuts (Figure 49).
4. Using a 3 mm hex wrench and a 7 mm socket wrench,
tighten the fasteners.
Torque to 1.6 N-m (1.2 ft-lbf).
CAUTION!
Do not overtighten. Overtightening may damage the
rubber seal around the light.
5. Reassemble the SE-3 Patroller by following the
instructions to Install Body Panels on page 36.
6. Perform post-service tests (page 127).
24315-00002
Right
Directional
Light
Front Directional Light
(24251-00001)
Figure 49: Front Directional Lights
Left
Directional
Light
Service Manual 39
Figure 50: Directional Light Connectors
Page 48
Lights
Brake Light
Tools Required: 3 mm hex wrench
7 mm socket wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Reach into the wheel well and disconnect the Brake
Light harness. See Figure 54.
3. Use a 7 mm socket wrench, remove the lock nut and
P-clip on the back of the Brake Light. See Figure 52.
4. Using a 3 mm hex wrench, remove the two Brake
Light fasteners. See Figure 51.
5. Remove the Brake Light.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Feed the Brake Light harness through the hole in the
Fender.
3. Reach into the wheel well and connect the harness.
4. Slide the plastic sleeves onto the fasteners, then
install the fasteners and (Figure 51).
5. Using a 3 mm hex wrench, tighten the fasteners.
Torque to 1.0 N-m (0.74 ft-lbf).
Brake Light
(24254-00001)
24315-00008
1.0 N-m (0.74 ft-lbf)
Figure 51: Brake Light
CAUTION!
Do not overtighten. Overtightening may damage the
rubber seal around the light.
6. Install a P-clip around the pigtails from both the
Brake Light and Directional Light (see Figure 52).
Slide the P-clip onto the upper Brake Light fastener.
7. Using a 7 mm socket wrench, install a lock nut to hold
the P-clip in place.
Torque to 1.6 N-m (1.2 ft-lbf).
8. Perform post-service tests (page 127).
23202-00001
1.6 N-m (1.2 ft-lbf)
P-Clip
(24346-00001)
Figure 52: Tail Light Harnesses
SE-3 Patroller40
Page 49
Rear Directional Light
Tools Required: 3 mm hex wrench
7 mm socket wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Reach into the wheel well and disconnect the Rear
Directional Light harness. See Figure 54.
3. Use a 7 mm socket wrench, remove the lock nut and
P-clip on the back of the Brake Light. See Figure 52.
4. Using a 3 mm hex wrench, remove the two fasteners.
See Figure 53.
5. Remove the Rear Directional Light.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Feed the Rear Directional Light harness through the
hole in the Fender.
3. Reach into the wheel well and connect the harness.
4. Slide the plastic sleeves onto the fasteners, then
install the fasteners (Figure 53).
5. Using a 3 mm hex wrench, tighten the fasteners.
Torque to 1.0 N-m (0.74 ft-lbf).
Lights
Rear Directional Light
(24251-00001)
24315-00004
1.0 N-m (0.74 ft-lbf)
Figure 53: Rear Directional Light
CAUTION!
Do not overtighten. Overtightening may damage the
rubber seal around the light.
6. Install a P-clip around the pigtails from both the
Brake Light and Directional Light (see Figure 52).
Slide the P-clip onto the upper Brake Light fastener.
7. Using a 7 mm socket wrench, install a lock nut to hold
the P-clip in place.
Torque to 1.6 N-m (1.2 ft-lbf).
8. Perform post-service tests (page 127).
Figure 54: Wire Harnesses
Service Manual 41
Page 50
Lights
Rear Strobe Light
Tools Required: 3 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Rider Detect Mat (page 82)
c. Motor Cavity Lid (page 89)
3. Disconnect the Rear Strobe Light harness.
See Figure 55.
4. Using a 3 mm hex wrench, remove the two fasteners.
See Figure 56.
5. Remove the Rear Strobe Light.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Feed the Rear Strobe Light harness through the hole
in the Skid Plate.
3. Connect the Rear Strobe Light harness.
See Figure 55.
4. Orient the light.
Police: Red toward center
Blue toward outside
Security: Locate the heat vent (Figure 57)
Right light = heat vent down
Left light = heat vent up.
5. Using a 3 mm hex wrench, install the two fasteners.
See Figure 56. Torque to 1.6 N-m (1.2 ft-lbf).
6. Install the following components:
a. Motor Cavity Lid (page 89)
b. Rider Detect Mat (page 82)
c. Battery Module (page 8)
7. Perform post-service tests (page 127).
Figure 55: Rear Strobe Light Harnesses
Rear Strobe Light
Police 24252-00001
Security 24252-00002
24315-00006
1.6 N-m (1.2 ft-lbf)
Figure 56: Rear Strobe Lights
Heat Vent
Cap
Figure 57: Heat Vent Location
SE-3 Patroller42
Page 51
Battery Compartment
Overview
Inside the Battery Compartment are the Battery Slides and Battery Bumpers, which
together position the Battery Module correctly against the PI Board.
When to Replace
Replace the Battery Slides or Battery Bumpers when they are cracked, excessively
worn, or otherwise broken.
Contents
• Battery Slides
• Battery Bumpers
43
Page 52
Battery Compartment
Battery Slides
The Battery Slides orient the Battery Module in the frame.
They also allow the Battery Module to slide smoothly when
being installed or removed.
Tools Required: 2.5 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the Battery Module (page 8).
3. Using a 2.5 mm hex wrench, remove the fasteners
from the Battery Slides. See Figure 58.
4. Remove the Battery Slides.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Align the Battery Slides in the battery compartment.
3. Using a 2.5 mm hex wrench, install the fasteners.
Torque to 1.0 N-m (0.74 ft-lbf).
4. Install the Battery Module (page 8).
20709-00001
1.0 N-m (0.74 ft-lbf)
Figure 58: Battery Slides
SE-3 Patroller44
Page 53
Battery Bumpers
The Battery Bumpers position the Battery Module at the
correct distance from the frame so that there is a good
connection between the Battery Module and the PI Board.
Tools Required: 4 mm hex wrench
8 mm socket wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Front Fender (page 24)
c. Front Splash Guard (page 25)
d. Front Fender Bracket (page 98)
e. Main Splash Guard (page 26)
3. Using an 8 mm socket wrench, remove the lock nuts
holding the three brake line P-Clips to the front of the
frame. See Figure 59.
4. Slide the P-Clips off the threaded studs.
5. Using a 4 mm hex wrench, remove the Battery
Bumpers. See Figure 60.
NOTICE
Keep track of how many washers go with each
bumper. Bumper alignment is critical for maintaining
a solid battery connection. Because of variations
in the frame, different SE-3 Patrollers may have
different quantities of washers installed with the
bumpers.
Battery Compartment
23202-00003
1.4 N-m (1.0 ft-lbf)
Figure 59: Brake Line P-Clips
Battery Bumpers
(23948-00001)
Figure 60: Battery Bumpers
Service Manual 45
Page 54
Battery Compartment
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Assemble the Battery Bumper. Slide the fastener
through the bumper, then slide washers onto the
fastener. See Figure 61.
NOTICE
Use the same number of washers as were removed
when the Battery Bumper was disassembled.
24409-00008
2.0 N-m (1.5 ft-lbf)
3. Using a 4 mm hex wrench, attach the Battery
Bumpers to the frame.
Torque to 2.0 N-m (1.5 ft-lbf).
4. Slide the three brake line P-Clips onto the threaded
studs on the front of the frame. See Figure 59.
5. Using an 8 mm socket wrench, install the lock nuts on
the threaded studs.
Torque to 1.4 N-m (1.0 ft-lbf).
6. Install the following components:
a. Main Splash Guard (page 26)
b. Front Fender Bracket (page 98)
c. Front Splash Guard (page 25)
d. Front Fender (page 24)
e. Battery Module (page 8)
7. Perform post-service tests (page 127).
Washers
Figure 61: Assembled Battery Bumper
SE-3 Patroller46
Page 55
Bib Panel Components
Overview
These are replaceable components that attach to the Bib Panel.
When to Replace
Replace the Glove Box Door when it is cracked, excessively worn, or otherwise
broken. Replace the KeyLock or Accessory Power Outlet when troubleshooting
determines that the component is malfunctioning.
Bib Panel Components
• Glove Box Door
• KeyLock
• Accessory Power Outlet
47
Page 56
Bib Panel Components
Glove Box Door
Tools Required: 2.5 mm hex wrench
7 mm socket wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Pop off the top hinge caps (Figure 62).
3. Open the Glove Box Door and locate the fasteners on
the inside top of the Glove Box.
4. Using a 2.5 mm hex wrench and a 7 mm socket
wrench, remove the four fasteners.
5. Remove the Glove Box Door.
NOTICE
Do not operate the SE-3 Patroller without the Glove Box Door
installed. The warning label on the Glove Box Door must be
visible.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Align the Glove Box Door on the Bib Panel.
3. Insert the four fasteners from above: through the
hinges and into the holes in the Bib Panel.
4. Slide an O-ring onto the fasteners from underneath,
then slide a washer and a nut onto the fasteners.
5. Using a 2.5 mm hex wrench and a 7 mm socket
wrench, install the fasteners.
Torque to 1.6 N-m (1.2 ft-lbf).
6. Close the Glove Box Door and verify that the latch
works properly.
Hinge Cap
20307-00005
1.6 N-m (1.2 ft-lbf)
Glove Box Door
(24120-00001)
O-ring
(24423-00001)
Washer
(20450-00001)
Lock Nut
(23202-00001)
1.6 N-m (1.2 ft-lbf)
Figure 62: Glove Box Door
SE-3 Patroller48
Page 57
KeyLock
Tools Required: None
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
3. Press the tab on the side of the connector block
and pull it off the back side of the KeyLock. See
Figure 64.
4. Unscrew the plastic nut on the back of the KeyLock.
See Figure 63.
5. Remove the KeyLock.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Insert the KeyLock through the hole on the right hand
side of the Bib Panel. See Figure 63.
3. Thread the plastic nut onto the back of the KeyLock.
Tighten finger tight, then turn an additional 1/8 turn.
4. Slide the connector block onto the back of the
KeyLock until it snaps in place.
5. Install the following components:
a. Bib Panel (page 14)
b. Storage Trays (page 13)
c. Battery Module (page 8)
6. Perform any post-service tests (page 127).
Bib Panel Components
Nut
KeyLock
(23969-00001)
Figure 63: KeyLock
Tab
Figure 64: KeyLock Closeup
Service Manual 49
Page 58
Bib Panel Components
Accessory Power Outlet
Tools Required: None
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
3. Unscrew the plastic nut on the back of the Accessory
Power Outlet. See Figure 65.
4. Remove the Accessory Power Outlet.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Insert the Accessory Power Outlet through the hole
on the left hand side of the Bib Panel.
3. Thread the plastic nut onto the back of the Accessory
Power Outlet.
Tighten finger tight, then turn an additional 1/8 turn.
4. Install the following components:
a. Bib Panel (page 14)
b. Storage Trays (page 13)
c. Battery Module (page 8)
5. Perform any post-service tests (page 127).
Nut
Accessory Power Outlet
(23979-00001)
Figure 65: Accessory Power Outlet
SE-3 Patroller50
Page 59
Brakes
Overview
There are two brake systems: front and rear. Each brake system includes a master
cylinder (with brake lever), brake line, caliper(s), and rotor(s).
When to Replace
Replace rotors at or before they reach the wear limit (3.2 mm).
Replace caliper when less than 1 mm of brake pad material remains.
Replace a master cylinder when diagnostic testing indicates it is malfunctioning.
Replace the brake lines when they are punctured, leaking, or otherwise
malfunctioning.
NOTICE
Avoid spilling brake fluid on plastic, rubber, or painted parts. Protect these parts
with a shop towel when servicing the brake system.
Contents
• Brake Fluid
• Draining Brake Lines
• Bleeding Brake Lines
• Front Caliper
• Front Rotor
• Master Cylinder
• Brake Lever
• Rear Caliper & Rotor
• Front Brake Line
• Rear Brake Line
51
Page 60
Brakes
Brake Fluid
Check the Brake Fluid level as part of your regular
maintenance routine. Be sure to check both the left and right
master cylinders.
Checking the Fluid Level
WARNING
Do not operate the SE-3 Patroller if the brake fluid level is low.
The brakes may not activate properly and the vehicle may not
stop as intended.
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Make sure the brake fluid reservoir is level.
3. Inspect the sight glass and determine if fluid is below
the “low” mark (Figure 66). If fluid is below the “low”
mark, brake fluid needs to be added.
Adding Brake Fluid
Tools Required: Phillips screwdriver
Torque wrench
1. Use a Phillips screwdriver to remove the two screws
on top of the brake fluid reservoir.
2. Remove the reservoir cap and gasket.
3. Add DOT 4 brake fluid; do not overfill the reservoir.
Screws
1.5 N-m (1.1 ft-lbf)
LOWER
Low mark
Figure 66: Checking the Brake Fluid Level
NOTICE
Use only fresh DOT 4 brake fluid from a new
container. Avoid getting any brake fluid on hands,
clothing, or painted parts. Immediately wipe up any
spilled fluid.
4. Replace the gasket and the reservoir cap.
5. Use a Phillips screwdriver to install the two screws on
top of the brake fluid reservoir.
Torque to 1.5 N-m (1.1 ft-lbf).
SE-3 Patroller52
Page 61
Draining Brake Lines
Drain the brake line before replacing a master cylinder, brake
line, or caliper.
Tools Required: Gloves
Shop Towels
¼ in. tubing
Empty container
Phillips screwdriver
¼ in. wrench
Procedure
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the wheels are chocked.
2. Access the Caliper
Front: remove the Front Fender (page 24)
Rear: remove a Rear Wheel (page 30)
3. Using a Phillips screwdriver, remove the cover of the
Master Cylinder.
4. Fit one end of the tubing over the bleed valve on the
Caliper. Place the other end in an empty container.
See Figure 67.
5. Using a ¼ in. wrench, open the bleed valve. Brake
fluid will flow out of the bleed valve. See Figure 68.
6. Pump the brake lever to drain the Master Cylinder.
7. After all the fluid has drained, use the ¼ in. wrench to
close the bleed valve.
Brakes
Figure 67: Draining the Front Brake Line
NOTICE
Some fluid will remain in the brake line and Master
Cylinder. When disconnecting components of the
brake system, use shop towels to absorb any brake
fluid that leaks out.
8. Dispose of used brake fluid in accordance with your
local environmental regulations.
WARNING!
Do not operate the SE-3 Patroller with the brake line
drained. You may not be able to come to a stop.
Figure 68: Draining the Rear Brake Line
Service Manual 53
Page 62
Brakes
Bleeding Brake Lines
Bleed the brake line after replacing a master cylinder, brake
line, or caliper. Also bleed the brake line if air is in the brake line
or if there is insufficient pressure in the brake lever.
WARNING!
• Use only DOT 4 brake fluid from a sealed container.
• Use a clean funnel when filling the brake fluid reservoir.
• Do not use brake fluid taken from old or already opened
containers.
• Do not mix different fluids.
• Failure to follow these warnings could result in damage to
the brake system, which could cause serious bodily injury
or death if the brake system fails to engage.
Tools Required: Gloves
¼ in. tubing
Empty container
Phillips screwdriver
¼ in. wrench
5 mm hex wrench
Torque wrench
Digital level
Figure 69: Bleeding the Front Brake Line
Procedure
NOTICE
Assistance is required to perform this procedure.
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the wheels are chocked.
CAUTION!
You can’t bleed the rear brake line with the parking
brake on. Chock the wheels and ensure the SE-3
doesn’t move.
2. Access the Caliper
Front: remove the Front Fender (page 24)
Rear: remove a Rear Wheel (page 30)
3. Using a 5 mm hex wrench, loosen the fasteners
holding the Master Cylinder to the handlebar.
4. Rotate the Master Cylinder until it is level, then
tighten the fasteners again.
5. Using a Phillips screwdriver, remove the cover of the
Master Cylinder.
6. Pour brake fluid (DOT 4 only) into the Master Cylinder
until it reaches the FILL line.
Figure 70: Bleeding the Rear Brake Line
NOTICE
Be careful not to drip brake fluid on the SE-3 Patroller.
7. Fit one end of the tubing over the bleeder valve on the
Caliper. Place the other end in an empty container.
See Figure 69.
SE-3 Patroller54
Page 63
8. Squeeze the brake lever.
9. While the brake lever is being squeezed, open the
bleeder valve. See Figure 70. As brake fluid drains out
of the bleeder valve, the brake lever will move toward
the handlebar.
10. Before the brake lever touches the handlebar, close
the bleeder valve.
11. Release the brake lever.
12. Repeat steps 8–11 until the brake lever is firm.
CAUTION!
Do not let the Master Cylinder run dry. This could
introduce air into the brake line. Keep adding brake
fluid to the Master Cylinder to keep the fluid level at
the FILL line.
13. Using a ¼ in. wrench, tighten the bleeder valve.
Torque to 4.5 N-m (3.3 ft-lbf).
14. Place the cap on the Master Cylinder. Using a Phillips
screwdriver, install the two fasteners.
Torque to 1.5 N-m (1.1 ft-lbf).
15. Using a 5 mm hex wrench, loosen the fasteners
holding the Master Cylinder to the handlebar.
16. Rotate the Master Cylinder so that it is 11.5° from
horizontal, then tighten the fasteners again.
See Figure 71. Torque to 10 N-m (7.4 ft-lbf).
17. Install the following components:
Front: install the Front Fender (page 24)
Rear: install a Rear Wheel (page 30)
18. Perform post-service tests (page 127).
Brakes
Figure 71: Aligning the Master Cylinder
Service Manual 55
Page 64
Brakes
Front Caliper
Tools Required: 4-inch bar clamp
6 mm hex wrench
14 mm socket wrench
Torque wrench
Vehicle jack
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Place a vehicle jack under the center front of the skid
plate. Raise the SE-3 Patroller until the front wheel is
off the ground (Figure 72).
WARNING!
Make sure the SE-3 Patroller is stable or use a jack
stand to stabilize it while the wheel is off the ground.
Failure to stabilize the SE-3 Patroller could result in
death or serious injury from the vehicle falling over.
3. Remove the Front Fender (page 24).
4. Using a bar clamp and socket, compress the caliper
as shown in Figure 73, then remove the bar clamp.
Place jack here
Figure 72: Front Lifting Point
NOTICE
If you don’t have a bar clamp, you will need to remove
the rotor fasteners. See page 58.
5. Using a 6 mm hex wrench, remove the two fasteners
holding the caliper in place. See Figure 74.
Slide the caliper off the rotor.
NOTICE
Secure the caliper so that it doesn’t fall or otherwise
stress the brake line.
6. Disconnect the brake line:
a. Drain the brake line (page 53).
b. Using a 14 mm socket wrench, remove the
Banjo Bolt.
Socket
Bar Clamp
Figure 73: Compress the Caliper
23783-00001
28.5 N-m (21.0 ft-lbf)
Figure 74: Front Caliper Bolts
SE-3 Patroller56
Page 65
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Using a 14 mm socket wrench, attach the Banjo Bolt
(on the end of the brake line) to the Caliper.
Torque to 28.5 N-m (21.0 ft-lbf).
See Figure 75.
CAUTION!
Always use new crush washers when attaching a
Banjo Bolt to any component. Used crush washers
may leak, causing a reduction in braking force.
Brakes
Hollow Screw
28.5 N-m (21.0 ft-lbf)
3. Carefully slide the Caliper onto the Rotor so the Rotor
rests between the two brake pads.
4. Using a 6 mm hex wrench, install the two fasteners
holding the Caliper in place. See Figure 74.
Torque to 28.5 N-m (21 ft-lbf).
5. Bleed the Brake Line (page 54).
6. Install the Front Fender (page 24).
7. Perform post-service tests (page 127).
Crush Washer
(23958-00001)
Banjo Bolt
Crush Washer
(23958-00001)
Figure 75: Brake Line Fasteners
Service Manual 57
Page 66
Brakes
Front Rotor
Tools Required: 5 mm hex wrench
30 mm socket wrench (2)
Torque wrench
Vehicle jack
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Place a vehicle jack under the center front of the skid
plate. Raise the SE-3 Patroller until the front wheel is
off the ground (Figure 72).
3. Remove the following components:
a. Front Fender (page 24)
b. Front Caliper (page 56)
NOTICE
Do not disconnect the caliper from the
brake line.
4. Using a 30 mm socket wrench, remove the axle and
slide it out. See Figure 76.
5. Slide the wheel assembly out of the front fork.
6. Using a 5 mm hex wrench, remove the five fasteners
holding the rotor in place. See Figure 77.
7. Remove the Rotor.
Axle
(23773-00001)
24404-00001
85 N-m (63 ft-lbf)
Figure 76: Front Axle Removal
Front Rotor
23762-00001
Installation
8. Align the Rotor with the flange on the spindle.
9. Using a 5 mm hex wrench, install the five fasteners
holding the Rotor in place. See Figure 77.
Torque to 7 N-m (5 ft-lbf).
10. Slide the wheel assembly onto the front fork. Orient
the wheel assembly so the rotor flange is toward the
left side of the SE-3.
11. Slide the axle through the forks and wheel assembly.
See Figure 76.
12. Using a pair of 30 mm socket wrenches, fasten the
nut onto the axle.
Torque to 85 N-m (63 ft-lbf).
13. Install the following components:
a. Front Caliper (page 56)
b. Front Fender (page 24)
14. Perform post-service tests (page 127).
23786-00001
7.0 N-m (5.0 ft-lbf)
Figure 77: Front Rotor Explode
SE-3 Patroller58
Page 67
Master Cylinder
These instructions apply to both the Front (left) and Rear
(right) Master Cylinders.
Tools Required: 5 mm hex wrench
14 mm socket wrench
Digital level
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Drain the brake fluid out of the brake line.
See page 53.
3. Using a 14 mm socket wrench, remove the Banjo Bolt
on the Master Cylinder. See Figure 78.
4. Using a 5 mm hex wrench, remove the two fasteners
on the Master Cylinder. See Figure 79.
5. Pull the Master Cylinder off of the handlebar.
Brakes
Banjo Bolt
28.5 N-m (21.0 ft-lbf)
Figure 78: Master Cylinder
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Orient the Master Cylinder on the handlebar.
3. Using a 5 mm hex wrench, install the clamp holding
the Master Cylinder to the handlebar.
4. Using a digital level, orient the Master Cylinder so
that it is 11.5° off of horizontal, with the handlebar
tipped downward. See Figure 80.
Torque to 10 N-m (7.4 ft-lbf).
5. Using a 14 mm socket wrench, install the Banjo Bolt
onto the Master Cylinder. See Figure 75.
Torque to 28.5 N-m (21.0 ft-lbf).
CAUTION!
Always use new crush washers when attaching a
Banjo Bolt to any component. Used crush washers
may leak, causing a reduction in braking force.
6. Install brake fluid and bleed the brake line
(see page 54).
7. Peform post-service tests (page 127).
LOWER
Fasteners
10 N-m (7.4 ft-lbf)
Figure 79: Master Cylinder Fasteners
Service Manual 59
Figure 80: Aligning the Master Cylinder
Page 68
Brakes
Brake Lever
Tools Required: Flathead screwdriver
10 mm socket wrench
Phillips head screwdriver
Torque wrench
UltraLube marine & trailer bearing grease
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the wheels are chocked.
CAUTION!
You can’t remove the right-hand brake lever with the
parking brake on. Chock the wheels and ensure the
SE-3 Patroller doesn’t move.
2. If removing the left-hand brake lever, proceed to
step 3 below.
If removing the right-hand brake lever, first remove
the parking brake cap:
a. Using a flathead screwdriver, remove the
retaining ring (Figure 81).
NOTICE
Be careful not to lose the retaining ring.
Since it is under spring tension, it can travel
a long distance through the air. Use your
hand to catch or deflect it so it doesn’t get
lost.
b. Slide the pin out and remove the parking
brake cap.
c. Using a phillips head screwdriver, remove
the two screws. Keep track of the spring and
lock washers.
3. Using a 10 mm socket wrench, remove the nut
underneath the brake lever (Figure 82).
4. Using a 10 mm socket wrench, unscrew and remove
the shoulder bolt (Figure 83).
5. Remove the brake lever and the parking brake
bracket, if applicable.
Parking
Brake Cap
Retaining Ring
Figure 81: Retaining Ring
Pin
Nut
10 N-m (7.4 ft-lbf)
Figure 82: Nut Location
Parking Brake
Bracket
Shoulder Bolt
10 N-m (7.4 ft-lbf)
Figure 83: Parking Brake Cap Removed
SE-3 Patroller60
Page 69
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the wheels are chocked.
CAUTION!
You can’t service the right-hand brake lever with the
parking brake on. Chock the wheels and ensure the
SE-3 Patroller doesn’t move.
2. Put a thin film of lubrication on the shoulder of the
shoulder bolt (Figure 86) and on the end of the
piston (Figure 84). Use UltraLube marine and trailer
grade bearing grease (P/N 24431-00001).
3. Orient the brake lever with the end ball facing toward
the front of the SE-3 Patroller (see Figure 85).
4. Slide the brake lever in place, making sure the spring
is seated correctly. One end of the spring fits into a
hole in the brake housing and the other end fits into a
hole in the brake lever.
5. If installing the right-hand brake lever, position the
parking brake bracket on top of the brake housing.
6. Using a 10 mm socket wrench, install the shoulder
bolt (Figure 83). Torque to 10 N-m (7.4 ft-lbf).
7. Using a 10 mm socket wrench, install the nut
underneath the brake lever (Figure 82).
Torque to 10 N-m (7.4 ft-lbf).
8. If installing the right-hand brake lever, install the
parking brake as follows:
a. Using a phillips head screwdriver, install
the spring and front screw, as shown in
Figure 87.
b. Using a phillips head screwdriver, install the
second screw.
c. Torque both screws to 1.5 N-m (1.1 ft-lbf).
d. Place the parking brake cap over the spring
and slide the pin through the holes.
e. Install a retaining ring on the end of the pin.
9. Perform post-service tests (page 127) to verify the
brakes are functioning properly.
Brakes
Piston
Spring
Figure 84: Spring Location
Front
Figure 85: Brake Lever
Lubricate Shoulder Only
Figure 86: Shoulder Bolt
Service Manual 61
Parking
Brake Bracket
Spring attaches
to front screw
1.5 N-m (1.1 ft-lbf)
Figure 87: Parking Brake Spring
Page 70
Brakes
Rear Caliper & Rotor
Tools Required: 6 mm hex wrench
14 mm socket wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Fender (page 22)
e. Rear Tire/Wheel (page 30)
NOTICE
Leave the SE-3 jacked up.
23868-00001
28.5 N-m (21.0 ft-lbf)
Rear Caliper
Right 23812-00001
Left 23810-00001
3. Chock the wheels.
4. Release the rear brake.
5. Using a 6 mm hex wrench, remove the two caliper
fasteners. See Figure 88.
6. Remove the Caliper and secure it so it doesn’t strain
the brake line.
7. Remove the Rotor and Spacer. See Figure 89.
Place the rotor on a clean surface.
NOTICE
Scratching the Rotor or introducing debris could
shorten the life of the Rotor.
8. To remove the Caliper:
a. Drain the brake line (page 53).
b. Using a 14 mm socket wrench, disconnect
the Banjo Bolt.
Figure 88: Rear Caliper
Rear Rotor
23732-00001
Figure 89: Rear Rotor
Spacer
24318-00001
SE-3 Patroller62
Page 71
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Ensure the Rotor, Spacer, and all mounting surfaces
are clean and free of debris.
3. Install the Rotor and Spacer. See Figure 89.
4. Using a 14 mm socket wrench, attach the Banjo Bolt
(on the end of the brake line) to the Caliper.
See Figure 91.
Torque to 28.5 N-m (21.0 ft-lbf).
CAUTION!
Always use new crush washers when attaching a
Banjo Bolt to any component. Used crush washers
may leak, causing a reduction in braking force.
5. Carefully slide the Caliper onto the Rotor so the Rotor
is between the two brake pads.
6. Using a 6 mm hex wrench, install the two caliper
fasteners. See Figure 88.
Torque to 28.5 N-m (21.0 ft-lbf).
7. Install the following components:
a. Rear Tire/Wheel (page 30)
b. Fender (page 22)
c. Bib Panel (page 14)
d. Storage Trays (page 13)
e. Battery Module (page 8)
8. Perform post-service tests (page 127).
Brakes
23868-00001
28.5 N-m (21.0 ft-lbf)
Caliper Bracket
23861-00001
Figure 90: Rear Caliper Bracket
Hollow Screw
28.5 N-m (21.0 ft-lbf)
Crush Washer
(23958-00001)
Service Manual 63
Banjo Bolt
Crush Washer
(23958-00001)
Figure 91: Brake Line Fasteners
Page 72
Brakes
Front Brake Line
Replacing the Front Brake Line can be a messy job. Be careful
not to let any brake fluid get on the harnesses, electronics, or
rotor. Immediately wipe up any spilled brake fluid with a shop
towel.
Tools Required: 2.5 mm hex wrench
14 mm socket wrench
Wire cutters
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
e. Front Cowl (page 17)
f. Light Cluster (page 18)
g. Front Fender (page 24)
3. Drain the brake fluid out of the front brake line
(see page 53).
4. Using a 14 mm socket wrench, disconnect the Banjo
Bolt from the Caliper. See Figure 93.
NOTICE
Place the Banjo Bolt in a container to catch any brake
fluid that drains out.
Cable tie
Front Brake Line
23955-00001
P-Clips
2.5 N-m (1.8 ft-lbf)
5. Using a 2.5 mm hex wrench, remove the three
P-Clips. See Figure 92.
6. Using wire cutters, remove the cable tie on the
steering column. See Figure 92.
7. Using a 14 mm socket wrench, disconnect the Banjo
Bolt from the Master Cylinder. See Figure 78.
8. Remove the brake line.
P-Clip
Figure 92: Front Brake Line
SE-3 Patroller64
Page 73
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Using a 14 mm socket wrench, connect a Banjo Bolt
to the Master Cylinder. See Figure 78.
Torque to 28.5 N-m (21.0 ft-lbf).
3. Thread the Brake Line between the Main Splash
Guard and the frame.
4. Run the Brake Line down the steering column and
through both cable clamps.
5. Install a cable tie around both brake lines on the
steering column.
NOTICE
Make sure there is enough slack in the brake lines to
turn the handlebar full left and right.
6. Using a 14 mm socket wrench, connect the Banjo Bolt
to the Caliper. See Figure 94.
Brakes
Banjo Bolt
28.5 N-m (21.0 ft-lbf)
Figure 93: Front Caliper Banjo Bolt
CAUTION!
Always use new crush washers when attaching a
Banjo Bolt to any component. Used crush washers
may leak, causing a reduction in braking force.
7. Using a 2.5 mm hex wrench, install three P-Clips: two
on the frame and one on the Front Fender Bracket.
See Figure 92.
Torque to 2.5 N-m (1.8 ft-lbf).
NOTICE
Make sure there is enough slack in the brake line to
turn the wheel full left and right.
8. Install brake fluid and bleed the brake line
(see page 54).
9. Install the following components:
a. Front Fender (page 24)
b. Light Cluster (page 18)
c. Front Cowl (page 17)
d. Glove Box (page 16)
e. Bib Panel (page 14)
f. Storage Trays (page 13)
g. Battery Module (page 8)
10. Perform post-service tests (page 127).
Hollow Screw
28.5 N-m (21.0 ft-lbf)
Crush Washer
(23958-00001)
Banjo Bolt
Crush Washer
(23958-00001)
Figure 94: Brake Line Fasteners
Service Manual 65
Page 74
Brakes
Rear Brake Line
Tools Required: 2.5 mm hex wrench
8 mm socket wrench
14 mm socket wrench
Wire cutters
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
e. Front Cowl (page 17)
f. Light Cluster (page 18)
g. Side Panels (page 20)
h. Fenders (page 22)
i. Main Splash Guard (page 26)
3. Drain the brake fluid out of the rear brake line
(see page 53).
4. Using a 14 mm socket wrench, disconnect one of the
Banjo Bolts from its Caliper.
Rear Brake Line
23956-00001
NOTICE
Place the Banjo Bolt in a container to catch any brake
fluid that drains out.
5. Repeat step 4 for the Banjo Bolt on the other side.
6. Using a 2.5 mm hex wrench, remove the P-Clips on
the sides of the frame (one each side). See Figure 96.
7. Using an 8 mm socket wrench, remove the lock nuts
holding the three P-Clips to the front of the frame.
Then slide the P-Clips off the threaded studs.
See Figure 97.
8. Using wire cutters, remove the cable tie holding the
brake lines to the steering column.
9. Using a 14 mm socket wrench, disconnect the Banjo
Bolt from the Master Cylinder.
10. Remove the Brake Line.
Figure 95: Rear Brake Line
P-Clip
2.5 N-m (1.8 ft-lbf)
Figure 96: Rear Brake Line
SE-3 Patroller66
Page 75
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Using a 14 mm socket wrench, connect the upper
Banjo Bolt to the Master Cylinder. See Figure 98.
Torque to 28.5 N-m (21.0 ft-lbf).
3. Route the brake line down the steering column and
around the right side of the front fork. See Figure 95.
4. Install a cable tie around both brake lines on the
steering column.
NOTICE
Make sure there is enough slack to turn the handlbar
full left and right.
5. Install three P-Clips onto the brake line, then slide the
P-Clips onto the threaded studs on the frame.
See Figure 97.
6. Using an 8 mm socket wrench, install a lock nut over
the P-Clip on each threaded stud.
Torque to 1.4 N-m (1.0 ft-lbf).
7. Route one end of the brake line along the right side
of the frame. Thread the brake line between the
harnesses and the frame. See Figure 96.
8. Using a 14 mm socket wrench, attach the Banjo Bolt
to the Caliper. See Figure 98.
Torque to 28.5 N-m (21.0 ft-lbf).
9. Using a 2.5 mm hex wrench, install a P-Clip holding
the brake line to the side of the frame.
NOTICE
Make sure the brake line has plenty of slack around
corners to avoid pinching or rubbing.
10. Repeat steps 7–9 on the left side of the frame.
11. Install brake fluid and bleed the brake line (page
54).
12. Install the following components:
a. Main Splash Guard (page 26)
b. Fenders (page 22)
c. Side Panels (page 20)
d. Light Cluster (page 18)
e. Front Cowl (page 17)
f. Glove Box (page 16)
g. Bib Panel (page 14)
h. Storage Trays (page 13)
i. Battery Module (page 8)
13. Perform post-service tests (page 127).
Brakes
23202-00003
1.4 N-m (1.0 ft-lbf)
Figure 97: Brake Line P-Clips
Hollow Screw
28.5 N-m (21.0 ft-lbf)
Crush Washer
(23958-00001)
Banjo Bolt
Crush Washer
(23958-00001)
Figure 98: Brake Line Fasteners
Service Manual 67
Page 76
Brakes
SE-3 Patroller68
Page 77
Controls
Overview
This chapter covers the UI, Control Cluster, Throttle, and Handlebar Grip.
When to Replace
Replace the Control Cluster or Throttle when troubleshooting determines that it is
malfunctioning.
Replace the Handlebar Grip when it is cracked, loose, or otherwise broken.
NOTICE
To service Brake Levers, see the Brakes chapter (page 51).
Contents
• UI Module
• UI Housing
• Control Cluster
• Throttle
• Handlebar Grip
69
Page 78
Controls
UI Module
The UI Module is how the user interacts with the SE-3 Patroller.
NOTICE
The fault history is stored in the UI Module. Replacing the UI
Module will essentially “reset” the fault history.
Tools Required: 4 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the Battery Module (page 8).
3. Using a 4 mm hex wrench, remove the four fasteners
as shown in Figure 99.
4. Disconnect the harness as shown in Figure 100.
5. Remove the UI Module.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Connect the harness as shown in Figure 100.
3. Using a 4 mm hex wrench, install the four fasteners
as shown in Figure 99.
Torque to 1.8 N-m (1.3 ft-lbf).
4. Install the Battery Module (page 8).
5. Perform post-service tests (page 127).
UI Module
(24088-00001)
Figure 99: UI Module
Figure 100: UI Harness
24409-00003
1.8 N-m (1.3 ft-lbf)
SE-3 Patroller70
Page 79
UI Housing
Tools Required: 4 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. UI Module (page 70)
3. Using a 4 mm hex wrench, remove the four fasteners
as shown in Figure 101.
4. Carefully push the rubber grommet out of the hole in
the back of the UI Housing. See Figure 102.
NOTICE
Do not use any sharp or pointed tools. You could
puncture the grommet, thereby allowing water to
enter the UI Housing.
Controls
UI Housing
(23811-00001)
24270-00001
2.8 N-m (2.1 ft-lbf)
5. Remove the UI Housing.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Orient the UI Housing on the frame.
3. Insert the UI Harness into the UI Housing and
carefully press the grommet into place.
See Figure 102.
NOTICE
Do not use any sharp or pointed tools. You could
puncture the grommet, thereby allowing water to
enter the UI Housing.
4. Using a 4 mm hex wrench, install the four fasteners
as shown in Figure 101.
Torque to 2.8 N-m (2.1 ft-lbf).
5. Install the following components:
a. UI Module (page 70)
b. Battery Module (page 8)
6. Perform post-service tests (page 127).
Figure 101: UI Housing
Figure 102: UI Harness Grommet
Service Manual 71
Page 80
Controls
Control Cluster
Tools Required: T15 Torx wrench
Wire cutters
Torque wrench
Digital level
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
e. Front Cowl (page 17)
3. Disconnect the wire harness. See Figure 103.
4. Using a pair of wire cutters, remove the two cable ties
on the steering column.
5. Using a T15 Torx wrench, loosen the three fasteners
on the under side of the Control Cluster.
See Figure 104.
6. Pull the two halves apart, and lift the Control Cluster
off the Handlebar.
Figure 103: Control Cluster Harness
SE-3 Patroller72
Page 81
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Slide the Control Cluster onto the handlebar.
3. Leave a small gap (5 mm) between the Control
Cluster and the Handlebar Grip.
4. Orient the Control Cluster so the bottom is parallel to
the ground (0°).
5. Using a T15 Torx wrench, install the three fasteners.
Torque to 2.8 N-m (2.0 ft-lbf).
NOTICE
Tighten the fasteners carefully to make sure the two
halves align correctly with each other.
Controls
6. Connect the wire harness. See Figure 103.
7. Install two cable ties around the harnesses on the
steering column.
8. Install the following components:
a. Front Cowl (page 17)
b. Glove Box (page 16)
c. Bib Panel (page 14)
d. Storage Trays (page 13)
e. Battery Module (page 8)
9. Perform post-service tests (page 127).
2.8 N-m (2.0 ft-lbf)
Figure 104: Control Cluster Fasteners
Service Manual 73
Page 82
Controls
Throttle
The throttle needs to be calibrated for the particular SE-3
Patroller it is installed on. For instructions on calibrating the
throttle contact Segway Technical Support.
Tools Required: Phillips screwdriver
Wire cutters
Torque wrench
LPS heavy duty silicone lubricant
Digital level
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
e. Front Cowl (page 17)
3. Disconnect the wire harness. See Figure 106.
4. Using a pair of wire cutters, remove the two cable ties
on the steering column.
5. Using a Phillips screwdriver, loosen the two fasteners
on the underside of the Throttle. See Figure 105.
6. Slide the Throttle off the handlebar.
4.0 N-m (3.0 ft-lbf)
Figure 105: Throttle
SE-3 Patroller74
Page 83
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Spray some LPS Heavy Duty Silicone Lubricant
(P/N 24430-00001) on the first 100 mm of the
handlebar. This will help the Throttle to rotate
smoothly and evenly.
NOTICE
Do not apply lubricant where the Throttle clamps to
the Handlebar. This could reduce the holding power
of the Throttle clamp, allowing it to rotate.
3. Slide the Throttle onto the handlebar. Slide it until it
bottoms out, then pull it back 3–5 mm.
4. Using a digital level, align the Throttle so that the rear
face (rider side) is at 82°.
5. Using a Phillips screwdriver, tighten the two fasteners
on the underside of the Throttle.
Torque to 4.0 N-m (3.0 ft-lbf).
Controls
NOTICE
Tighten the fasteners carefully to make sure there is
an even and consistent gap between the two halves.
6. Connect the wire harness. See Figure 106.
grey & red/black
black & orange/black
7. Install two cable ties around the harnesses on the
steering column.
8. Install the following components:
a. Front Cowl (page 17)
b. Glove Box (page 16)
c. Bib Panel (page 14)
d. Storage Trays (page 13)
e. Battery Module (page 8)
9. Perform post-service tests (page 127).
Figure 106: Throttle Harness
Service Manual 75
Page 84
Controls
Handlebar Grip
The Handlebar Grip does not slide off easily. To remove it, you
will have to cut it off the handlebar.
Tools Required: Cutting tool (box cutter or utility knife)
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Score the Handlebar Grip with a cutting tool.
CAUTION!
Be careful not to cut yourself with the sharp blade.
3. Grab the Handlebar Grip near the flange and tear it at
the score line you created.
4. Tear the Handlebar Grip and pull it off the handlebar.
Handlebar Grip
(23807-00001)
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Slide the end of the Handlebar Grip onto the left
handlebar. See Figure 107.
3. Press the palm of your hand onto the end of the
Handlebar Grip. Push the Handlebar Grip onto the
handlebar until it is fully seated.
NOTICE
Do not twist the Handlebar Grip when installing it.
Figure 107: Handlebar Grip
SE-3 Patroller76
Page 85
Siren
Siren
The Siren produces both the horn and siren sounds.
When to Replace
Replace when troubleshooting determines that the Siren is malfunctioning.
Contents
• Siren
77
Page 86
Siren
Siren
Tools Required: 4 mm hex wrench
10 mm socket wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
e. Main Splash Guard (page 26)
3. Locate the Siren on the front of the frame.
See Figure 108.
4. Reach behind the Right Side Panel and disconnect
the siren harness. See Figure 109.
5. Using a 10 mm socket wrench, loosen the nut on each
side of the Siren. See Figure 111.
6. Pull the Siren off the bracket.
7. Using a 4 mm hex wrench, remove the two fasteners
holding the bracket to the frame. See Figure 110.
8. Remove the bracket.
Figure 108: Siren
Figure 109: Siren Harness Connector
SE-3 Patroller78
Page 87
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Orient the bracket on the frame.
3. Using a 4 mm hex wrench, install the two bracket
fasteners. See Figure 110.
Torque to 7.5 N-m (5.5 ft-lbf).
4. Verify that the bolts are loosely installed on the
bracket.
5. Slide the Siren onto the bracket so the bolt heads go
through the slots on the sides of the siren.
6. Using a 10 mm socket wrench, tighten the nuts on
the bracket. See Figure 111.
Torque to 2.5 N-m (1.8 ft-lbf).
7. Thread the siren lead behind the Right Side Panel and
connect it to the Siren Harness. See Figure 108.
8. Install the following components:
a. Main Splash Guard (page 26)
b. Glove Box (page 16)
c. Bib Panel (page 14)
d. Storage Trays (page 13)
e. Battery Module (page 8)
9. Perform post-service tests (page 127).
Siren
24270-00001
7.5 N-m (5.5 ft-lbf)
Figure 110: Siren Bracket
Siren Bracket
Siren
23839-00001
Figure 111: Siren Fasteners
Service Manual 79
2.5 N-m (1.8 ft-lbf)
Page 88
Siren
SE-3 Patroller80
Page 89
Rider Detect Mat
Overview
The Rider Detect Mat acts as an operator presence control device by only allowing
the SE-3 Patroller to drive while the rider is standing on the Rider Detect Mat.
When to Replace
Replace the Rider Detect Mat when it is excessively worn or when troubleshooting
determines that it is malfunctioning.
Contents
• Rider Detect Mat
81
Page 90
Rider Detect Mat
Rider Detect Mat
Tools Required: 3 mm hex wrench
Torque wrench
CAUTION!
Do not bend the Rider Detect Mat harness where it connects
to the Rider Detect Mat. The cable can become damaged,
rendering the Rider Detect Mat unusable.
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8).
b. Storage Trays (page 13).
c. Bib Panel (page 14).
d. Glove Box (page 16).
e. Front Cowl (page 17).
f. Light Cluster (page 18).
g. Left Side Panel (page 20).
3. Using a 3 mm hex wrench, remove the four fasteners
as shown in Figure 112.
4. Disconnect the harness from the PI Board.
See Figure 113.
5. Lift the Rider Detect Mat and slide it off of the SE-3
Patroller.
24367-00002
4.0 N-m (3.0 ft-lbf)
Rider Detect Mat
(23714-00001)
Figure 112: Rider Detect Mat
Figure 113: Rider Detect Harness
SE-3 Patroller82
Page 91
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Orient the Rider Detect Mat on the SE-3 Patroller with
the wire harness toward the front.
3. Feed the wire harness through the hole in the frame.
4. Connect the wire harness to the left side of the PI
Board. See Figure 113.
5. Slide the Rider Detect Mat in place. The front should
rest under the tab and the rear should line up with the
threaded studs.
6. Using a 3 mm hex wrench, install the four fasteners
as shown in Figure 112.
Torque to 4.0 N-m (3.0 ft-lbf).
7. Install the following components:
a. Left Side Panel (page 20).
b. Light Cluster (page 18).
c. Front Cowl (page 17).
d. Glove Box (page 16).
e. Bib Panel (page 14)
f. Storage Trays (page 13).
g. Battery Module (page 8).
8. Perform post-service tests (page 127).
Rider Detect Mat
Figure 114: Rider Detect Mat Harness
Service Manual 83
Page 92
Rider Detect Mat
SE-3 Patroller84
Page 93
Drive Train
Overview
The Drive Train consists of the Gearbox, Motor, Motor Controller, and the couplings
that join them together.
When to Replace
Replace when troubleshooting determines that a component is malfuctioning.
Contents
• Gearbox
• Elastomer Bushing & Drive Hub
• Accessing the Motor Cavity
• Motor
• Motor Controller
85
Page 94
Drive Train
Gearbox
Tools Required: 8 mm hex wrench
6 mm hex wrench
4 mm hex wrench
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Fender (page 22)
e. Rear Tire/Wheel (page 30)
f. Rear Caliper & Rotor (page 62)
NOTICE
Leave the SE-3 Patroller jacked up and chock the
wheels.
20991-00002
67 N-m (49 ft-lbf)
Flat Washer
24434-00005
Figure 115: Gearbox
WARNING!
Make sure the SE-3 Patroller is stable or use a jack
stand to stabilize it while the wheel is off the ground.
Failure to stabilize the SE-3 Patroller could result in
death or serious injury from the vehicle falling over.
3. Using a 8 mm hex wrench, remove the three
fasteners as shown in Figure 115.
4. Pull the Gearbox off of the chassis.
5. Make note of the O-ring and keep track of it.
See Figure 116.
6. If replacing the gearbox, remove the following
components as well:
a. Using a 6 mm hex wrench, remove the two
fasteners on the Caliper Bracket. Set the
Caliper Bracket aside. See Figure 117.
b. Using a 4 mm hex wrench, remove the three
fasteners on the Fender Bracket. Set the
Fender Bracket aside. See Figure 118.
O-Ring
23851-00001
Figure 116: Gearbox O-Ring
SE-3 Patroller86
Page 95
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Install the O-ring on the input side of the Gearbox.
See Figure 116.
3. Orient the Gearbox on the Frame so that the Gearbox
is tipped toward the rear of the SE-3 Patroller.
4. Slide the Gearbox into place, making sure the plastic
coupling fits over the Elastomer Bushing.
5. Using an 8 mm hex wrench, install the three Gearbox
fasteners. See Figure 115.
Torque to 67 N-m (49 ft-lbf).
6. Using a 6 mm hex wrench, install the Caliper Bracket.
See Figure 117. Torque to 28.5 N-m (21.0 ft-lbf).
7. Using a 4 mm hex wrench, install the Fender Bracket.
See Figure 118. Torque to 4.0 N-m (3.0 ft-lbf).
NOTICE
Orient the Fender Bracket with the indent away
toward the rider platform.
Drive Train
23868-00001
28.5 N-m (21.0 ft-lbf)
Caliper Bracket
(23861-00001)
Figure 117: Caliper Bracket
8. Install the following components:
a. Rear Caliper & Rotor (page 62)
b. Rear Tire/Wheel (page 30)
c. Fender (page 22)
d. Bib Panel (page 14)
e. Storage Trays (page 13)
f. Battery Module (page 8)
9. Perform post-service tests (page 127).
Fender Bracket
Left 24297-00001
Right 24298-00001
24270-00006
4.0 N-m (3.0 ft-lbf)
Figure 118: Fender Bracket
Service Manual 87
Page 96
Drive Train
Elastomer Bushing & Drive Hub
Check to see if the Elastomer Bushing is worn or damaged.
Presence of excessive particles of elastomer material indicates
that replacement is necessary.
Tools Required: Cotton swab
Molykote G-n paste
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Fender (page 22)
e. Rear Tire/Wheel (page 30)
f. Rear Caliper & Rotor (page 62)
g. Gearbox (page 86)
3. Pull the Drive Hub off the Motor.
4. Pull the Elastomer Bushing off of the Drive Hub
(Figure 119).
Elastomer Bushing
(21091-00001)
Drive Hub
(24008-00001)
Figure 119: Elastomer Bushing
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Orient the Elastomer Bushing with the tabs toward
the Drive Hub.
3. Slide the Elastomer Bushing onto the Drive Hub.
4. Use a cotton swab to spread some Molykote G-n
paste (P/N 24505-00001) on the splines inside the
Drive Hub. This paste helps reduce wear between the
Drive Hub and the Motor.
5. Slide the Drive Hub onto the Motor.
6. Install the following components:
a. Gearbox (page 86)
b. Rear Caliper & Rotor (page 62)
c. Rear Tire/Wheel (page 30)
d. Fender (page 22)
e. Bib Panel (page 14)
f. Storage Trays (page 13)
g. Battery Module (page 8)
7. Perform post-service tests (page 127).
SE-3 Patroller88
Page 97
Accessing the Motor Cavity
Tools Required: 3 mm hex wrench
Torque wrench
Accessing
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Remove the following components:
a. Battery Module (page 8)
b. Storage Trays (page 13)
c. Bib Panel (page 14)
d. Glove Box (page 16)
e. Front Cowl (page 17)
f. Light Cluster (page 18)
g. Left Side Panel (page 20)
h. Rider Detect Mat (page 82)
3. Lift off the Rider Detect Spacer.
4. Using a 3 mm hex wrench, remove the eight fasteners
as shown in Figure 120.
5. Remove the Motor Cavity Lid.
Drive Train
Rider Detect Spacer
(23944-00001)
24367-00002
4.0 N-m (3.0 ft-lbf)
Figure 120: Motor Cavity Lid
Securing
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Align the Motor Cavity Lid on the chassis/frame.
3. Using a 3 mm hex wrench, install the eight fasteners
as shown in Figure 120.
Torque to 4.0 N-m (3.0 ft-lbf).
4. Place the Rider Detect Spacer on top of the Motor
Cavity Lid.
5. Install the following components:
a. Rider Detect Mat (page 82)
b. Left Side Panel (page 20)
c. Light Cluster (page 18)
d. Font Cowl (page 17)
e. Glove Box (page 16)
f. Bib Panel (page 14)
g. Storage Trays (page 13)
h. Battery Module (page 8)
6. Perform post-service tests (page 127).
Service Manual 89
Page 98
Drive Train
Motor
Tools Required: 5 mm hex wrench
10 mm socket wrench
Torque wrench
Cotton swab
Molykote G-n paste
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Access the motor cavity (page 89). This involves
disassembling the SE-3 Patroller until the motor
cavity is exposed.
3. Disconnect the Hall Sensor Feedback harness.
4. Using a 10 mm socket wrench, disconnect the motor
phase leads. See Figure 121.
5. Using a 5 mm hex wrench, remove the four fasteners
as shown in Figure 122. Lift the Motor Assembly out
of the motor cavity.
6. Make note of the O-ring and keep track of it.
7. Using a 5 mm hex wrench, remove the four fasteners
as shown in Figure 123.
8. Remove the motor mount plate and keep track of the
O-ring.
9. Remove the Drive Hub.
Hall
Sensor
Feedback
Harness
Motor Phase
Leads
Figure 121: Motor Harnesses
Motor Mount Plate
(23860-00001)
23869-00001
12 N-m (8.9 ft-lbf)
O-Ring
(23863-00001)
Notch
Figure 122: Motor Assembly
SE-3 Patroller90
Page 99
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Use a cotton swab to spread some Molykote G-n
paste (P/N 24505-00001) on the splines inside the
Drive Hub. This paste helps reduce wear between the
Drive Hub and the Motor.
3. Slide the Drive Hub onto the Motor.
4. Place an O-ring on the motor.
5. Orient the Bracket on the Motor so the notch on the
Bracket is centered between the harnesses on the
motor. See Figure 123.
6. Using a 5 mm hex wrench, install the four fasteners
as shown in Figure 123.
Torque to 12 N-m (8.9 ft-lbf).
7. Place an O-ring on the motor mount plate.
8. Orient the Motor Assembly so the notch on the motor
mount plate is toward the rear of the SE-3 Patroller.
Slide the Motor Assembly into place (Figure 122).
9. Using a 5 mm hex wrench, install the four fasteners
as shown in Figure 122.
Torque to 12 N-m (8.9 ft-lbf).
10. Using a 10 mm socket wrench, connect the motor
phase leads.
W White
V Red
U Brown
Arrange the hardware stack as shown in Figure 126.
Torque to 7.5 N-m (5.5 ft-lbf).
11. Connect the Hall Sensor Feedback harness.
See Figure 121.
12. Secure the motor cavity (page 89).
13. Perform post-service tests (page 127).
Drive Train
O-Ring
(23864-00001)
23869-00001
12 N-m (8.9 ft-lbf)
Notch
Drive Hub
(24008-00001)
Figure 123: Motor Bracket
Service Manual 91
Page 100
Drive Train
Motor Controller
When replacing the left motor controller, the throttle needs
to be recalibrated. For instructions on calibrating the throttle
contact Segway Technical Support.
Tools Required: 5 mm hex wrench
10 mm socket wrench
Flathead screwdriver
Torque wrench
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Access the motor cavity (page 89). This involves
disassembling the SE-3 Patroller until the motor
cavity is exposed.
3. Using a 10 mm socket wrench, disconnect the power
and motor current harnesses.
4. Using a flathead screwdriver, lift the tab on the Drive
Harness while pulling the connector off.
See Figure 125.
5. Using a 5 mm hex wrench, remove the four fasteners
holding the motor plate onto the bottom of the motor
cavity. See Figure 124.
NOTICE
Do not remove the four star drive fasteners holding
the Motor Controller cover.
23869-00003
7.5 N-m (5.5 ft-lbf)
Motor Controller
(23722-00001)
Figure 124: Motor Controller
6. Remove the Motor Controller.
Installation
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
2. Place the Motor Controller in the Motor Cavity. Orient
it so the large connector is toward the rear.
3. Using a 5 mm hex wrench, install the four fasteners.
Torque to 7.5 N-m (5.5 ft-lbf).
4. Connect the Drive Harness.
Using a 10 mm socket wrench, install the remaining
harnesses:
Power
B+ Red
B– Black
Motor
W White
V Red
U Brown
Arrange the hardware stack as shown in Figure 126.
Torque to 7.5 N-m (5.5 ft-lbf).
5. Secure the motor cavity (page 89).
6. Perform post-service tests (page 127).
Figure 125: Removing the Harness
24436-00004
7.5 N-m (5.5 ft-lbf)
Figure 126: Hardware Stack
Lock Washer
(24435-00003)
Flat Washer
(24434-00003)
Ring Terminal
SE-3 Patroller92
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