SEGA Enduro Racer Upright Type Owner's Manual

Introduction to the Owner's Manual

SEGA Enterprises, Ltd. has been supplying innovative and popular game machines to the world market for over 30 years, supported by high electronic technology including LSIs and microprocessors. This owner's manual provides detailed information covering the general operation of electronic assemblies, electromechanicals, servicing control, and spare parts for the ENDURO RACER, a new SEGA product. It is intended for individuals with knowledge of electricity and technical expertise, especially concerning ICs, CRTs, and microprocessors. Users should carefully read this manual to acquire sufficient knowledge before working on the machine. Non-technical personnel should not touch the interior system in case of a malfunction.

1. Handling Precautions

When installing or inspecting the machine, observe the following points to ensure safe game enjoyment:

• Always turn off the power before working on the machine.
• Avoid quickly inserting or pulling out plugs, as this is dangerous.
• Ensure that the power cord or grounding wire is not exposed in a dangerous manner. Grounding connections must be made safely at specified positions.
• Do not use any fuse that does not meet the specified rating.
• Ensure complete connections for the IC board and other connectors. Insufficient insertion is very dangerous.
• For IC board circuit inspections, only logic tone is permitted. The use of a tester is not allowed. After confirming no irregularities, turn the power ON.

2. Prevention of Counterfeiting and Conversion

Labelling

To prevent counterfeits and conversions, SEGA products are affixed with specific labels. When handling these goods, confirm the presence of these labels. They are used to prevent illegal acts such as unauthorized copying of products and printed circuit boards, or conducting business by manufacturing similar merchandise, converting, selling, or using such products or printed circuit boards.

Original Seal

This seal is affixed to machines manufactured by SEGA. It typically states: "SEGA Original Seal. This product is designed and manufactured by SEGA Enterprises Ltd. Original Enduro Racer No. [Serial Number]. SEGA Enterprises, Ltd. Japan."

License Seal

This seal is affixed to kits, such as printed circuit boards, of SEGA products. It typically states: "SEGA License Seal. This product is manufactured under the license of SEGA Enterprises Ltd. License Enduro Racer No. [Serial Number]. SEGA Enterprises, Ltd. Japan."

Copyright Notice

This SEGA product includes the copyright notice: Ⓒ SEGA 1986. This signifies that the work was disclosed in 1986 and is the property of SEGA Enterprises, Ltd.

3. Precautions Concerning the Place of Installation

The ENDURO RACER is an indoor game machine and must not be installed outdoors. Even indoors, avoid installing it in the following locations to ensure proper usage:

• Places subject to rain, water leakage, or condensation due to humidity.
• Proximity to an indoor swimming pool and/or shower.
• Places subject to direct sunlight.
• Places subject to heat sources from heating units or hot air.
• Vicinity of highly inflammable/volatile chemicals or hazardous matter.
• Sloped surfaces.
• Vicinity of anti-disaster facilities such as fire exits and fire extinguishers.
• Places subject to any type of violent impact.
• Dusty places.

4. Name of Parts

The Enduro Racer upright type cabinet includes the following main components:

• 20" Monitor (Part No. 200-5072)
• Billboard (Part No. MX-1101-01)
• Window Mask (Part No. MX-1013, RH-1015)
• Front Panel
• Assy Handle (Part No. MX-20002)
• Start Button
• Coin Entry
• Bracket Step (Part No. 105-5033)

The cabinet is a tall, upright structure with a monitor screen at the top, a handlebar assembly in the middle, and a base with a step for the player.

5. Removing the Handle Unit

To adjust the accelerator, brake, and centering, the handle unit must be removed. This procedure involves:

1. Taking off 6 tamperproof screws (M5×12, M8×30) using a tamperproof wrench.
2. Removing the handle unit as shown in the diagram, which depicts the handle assembly with various screws and components like the handle unit itself, tamperproof screws (M5×12 and M8×30), and an 'X' axis indicator.

Refer to the separate section on "Adjusting the Accelerator, Brake and Centering" for further details. Tools required include tamperproof wrenches for M4, M5, M6, and M8 screws (Part Nos. 540-0006-01, 540-0007-01, 540-0015-01, 540-0009-01, 540-0018, 540-0017).

6. Servicing the Handle Unit and Window Mask

To service these components:

1. The handle unit can be opened by removing 4 tamperproof screws (M4×25).
2. To remove the window mask from the cabinet, first remove the mask holder front panel, then the tamperproof screws (M4×8) located inside the window mask.
3. Next, open the assembly towards the user.

This process allows for cleaning of the monitor screen (CRT surfaces) and replacement of the billboard. The diagram illustrates the cabinet with components such as the billboard (MX-1011-01), front glass, tamperproof screws (M4×25, M4×8, M8×30), mask holder (RH-1022), window mask (MX-1013, RH-1015), handle unit (MX-20002), and the main cabinet structure.

7. Adjustment of the Service Switch

The service switch layout is accessible by opening the coin chute door. The main components visible are:

• ① Demagnetizing Switch
• ② Service Switch
• ③ Test Switch
• ④ Volume Knob (Left)
• ⑤ Volume Knob (Right)
• Cash Box
• Coin Meter

Operating Instructions

• ① Demagnetizing Switch: Used for removing on-screen color unevenness.
• ② Service Switch: Used for servicing and increasing credits without registering on the meter (allows game checking).
• ③ Test Switch: For operating this switch, refer to section 16, "Self-Testing."
• ④⑤ Volume Adjustment: The volume of the right/left speakers is adjusted separately. Pay attention to the right/left volume balance.

8. Handle's Centering Adjustment

When the handle is stationary, the screen display in SELF-TEST MODE should show a variable of 80H for normal operation.

Diagnostic Input Test Values:

• Handle Right Left: 80H
• Brake: (See page 8-11)
• Accelerator: (See page 8-11)
• Bank Up Down: (See page 8-11)

Allowable Range: 7CH, 7DH, 7EH, 7FH, 80H, 81H, 82H, 83H, 84H

• Maximum Value: Over B8H
• Minimum Value: Under 48H

The diagram shows the handle assembly with an adjust plate (MX-2055), spur gear, pinion gear, volume bracket (MX-2044), and screws A and B. An 'X' axis is indicated for adjustment direction.

Adjusting Method

1. To move the volume bracket in the X direction, release the 2 screws A (M4 × 10) that fasten the volume bracket.
2. When the volume bracket is moved in the X direction, the pinion and spur gears will disengage. At this time, turn the volume shaft and make adjustments so that the variable is within the allowable range.
3. Where necessary, make fine adjustments by loosening screws B (M4 × 10) and moving the adjust plate in the Y direction.
4. Make backlash adjustments by moving the volume bracket in the X direction.

9. Handle's Bank Up Down Adjustment

When the handle is stationary, the screen display in SELF-TEST MODE should show a variable of 30H for normal operation.

Diagnostic Input Test Values:

• Handle Right Left: (See page 8-11)
• Brake: (See page 8-11)
• Accelerator: (See page 8-11)
• Bank Up Down: 30H

Allowable Range: 2CH, 2DH, 2EH, 2FH, 30H, 31H, 32H, 33H, 34H

• Maximum Value: Over 78H
• Minimum Value: Under 2CH

The diagram shows the handle assembly with a volume bracket (MX-2045), pinion gear, spur gear, adjust plate (MX-2016), and screws A and B. 'X' and 'Y' axes are indicated for adjustment directions.

Adjusting Method

1. To move the volume bracket in the X direction, release the 2 screws A (M4 × 10) that fasten the volume bracket.
2. When the volume bracket is moved in the X direction, the pinion and spur gears will disengage. At this time, turn the volume shaft and make adjustments so that the variable is within the allowable range.
3. Where necessary, make fine adjustments by loosening screws B (M4 × 10) and moving the adjust plate in the Y direction.
4. Make backlash adjustments by moving the volume bracket in the X direction.

10. Replacing the Parts Related to the Accelerator and the Brake

Replacing the Accelerator Wire

1. Remove the 2 tamperproof screws A (M5 × 20) to disassemble the upper case and lower case from the accelerator case.
2. By turning the lower case counterclockwise, remove the firmly attached accelerator wire from the lower case.
3. To remove the accelerator wire, first remove the accelerator spring and then nut C.

The diagram illustrates the accelerator and brake assembly, showing the accelerator wire (MX-2115), nut B, brake wire (MX-2116), nut A, handle (MX-2035), lower case, accelerator case, grip (107-0009X), brake lever (601-5419X), spacer (HN-5045), upper case, and tamperproof screw A (M5×20).

Replacing the Brake Wire

1. Loosen the brake lever nut first and then remove the brake wire.
2. To completely remove the brake wire, take off the brake spring first and then nut D.

The diagram shows the accelerator and brake wire assembly with accelerator spring (HN-5109), brake spring (HN-5110), pinion gear (601-5415), nut C, nut D, brake wire (MX-2116), accelerator wire (MX-2115), and pinion gear (601-5415).

Caution

When replacing the accelerator wire and the brake wire, ensure to first remove the PLAY INSTRUCTIONS PLATE (see page 12). After wire replacement, ensure necessary adjustments are made.

11. Adjusting the Accelerator/Brake

After replacing the wires for the accelerator and the brake, perform the following test. Display the screen in the SELF-TEST MODE (see page 20).

Accelerator Adjustment

Set the allowable range so that when the accelerator is released, the variable is 00H.

• Allowable Range: 00H-04H
• Maximum Value (with the accelerator fully open): Over 80H

Make adjustments by adjusting the wire length using NUT B.

Brake Adjustment

Set the allowable range so that when the brake is released, the variable is 00H.

• Allowable Range: 00H-04H
• Maximum Value (maximum braking): Over 80H

Make adjustments by adjusting the wire length using NUT A.

When activating the accelerator/brake, the pinion gear revolves approximately 216°.

The diagram shows the accelerator wire with nut B and the brake wire with nut A, illustrating how the wires connect to the handle mechanism.

Removing the Play Instructions Plate

Remove the 4 nuts and then the 4 tamperproof screws (M4×8).

The diagram shows the holder plate (MX-2053-01) secured by tamperproof screws (M4×8), with the accelerator wire (MX-2115) and brake wire (MX-2116) running underneath, secured by nuts A, B, and C.

12. Replacing the Volume Control for the Accelerator/Brake

To remove the cover (MX-2050), take off the 2 screws (M4×8) and 2 tamperproof screws (M4×8).

The diagram shows the handle unit assembly with the cover (MX-2050), tamperproof screw (M4×8), handle unit, bracket, accelerator volume (220-5130), screw (M4×8), and brake volume (220-5130).

Disassembling Procedure

1. To remove the bracket from the handle unit, take off the 4 screws (M4×8) from each bracket.
2. To remove the pinion gear, release the 2 set screws of the pinion gear attached to the volume control shaft.
3. To remove the volume control from the volume bracket, take off the volume control shaft nut.
4. After replacement, assemble in the reverse manner.
5. Make adjustments by moving the volume bracket in the X direction around the screw used for backlash adjustments.

13. DIP Switch Setting

Game Price Setting (DIP SW A)

The DIP switches on Game Board A (834-6000-01) control game pricing. The table below shows various credit options based on DIP switch positions (OFF/ON).

The diagram shows the internal view of the coin chute door, indicating Coin SW #1 and Coin SW #2, and the location of Game Board A (834-6000-01) with its DIP switches.

Option Switch Setting (DIP SW B)

The DIP switches on Game Board B (834-6003-01) control various game options.

The diagram shows the location of Game Board B (834-6003-01) with its DIP switches labeled A and B.

14. Game Difficulty Setting

In this game, the 4 difficulty levels can be set using DIP SWITCH B on GAME BOARD B for the following aspects: ① Other bikes appearance frequency, ② Play time adjustments, and ③ Time adjustment in relation to real time. The default difficulty level when shipped is MEDIUM. In actual play, the difficulty can be adjusted based on the player's skill level.

1. Other Cars' Appearance Frequency (Switch 2, 3)

※ When shipping, the default is MEDIUM.

2. Play Adjustment (Switch 4, 5)

※ When shipping, the default is MEDIUM (WHEELIE TYPE) or MEDIUM (UPRIGHT TYPE and SIT-DOWN TYPE).

3. Time Adjustment in Relation to Real Time (SW 6, 7)

※ When shipping, the default is MEDIUM.

Specific Setting Illustration (Detailed Examples)

This table provides examples of DIP switch combinations for various difficulty levels.

15. EPROM/ROM Location

The game's EPROMs and ROMs are located on specific game boards.

Assy Game Board B (834-6003-01) and Assy Game Board A (834-6000-01)

The diagram shows two stacked circuit boards, labeled 'Assy Game Board B' and 'Assy Game Board A', with a 'Shield Base' (RH-1515) underneath. Various points on the boards are indicated with letters A, B, C, D, representing connections or components.

Assy CPU BD (837-6001-01)

This board contains various ICs with specific functions:

The diagram shows a layout of the CPU board with labeled IC positions (IC 2, IC 54, IC 55, IC 56, IC 67, IC 68, IC 69, IC 84, IC 85, IC 86, IC 87, IC 97, IC 98, IC 99, IC 100).

Assy Control BD (837-6002-01)

This board contains ICs related to fixed scroll characters and zoom data:

The diagram shows the control board with ICs labeled IC123, IC60, IC46, and IC31.

Assy ROM BD (837-6004-01)

This board contains numerous ICs primarily for scenery figures:

The diagram shows the ROM board with a grid of IC positions (1-8, 11-18, 21-36).

Assy Sound BD (837-6005-01)

This board contains ICs for sound data and programs:

The diagram shows the sound board with ICs labeled IC5, IC6, IC72, and IC73.

16. Self-Testing

The main purpose of these tests is to check the operations of the game boards, identify defects, adjust monitor colors, ensure satisfactory sound production, indicate DIP switch assignments, and check bookkeeping functions.

Kind of Tests

1. Memory Test: Checks EPROM programs and RAM map area.
2. Input Test: Tests handle operation, START buttons, and coin switches.
3. Output Test: Tests start lamp operation.
4. Sound Test: Checks sound quality from the PCB and adjusts speaker balance.
5. CRT Test: Checks monitor color display and linearity.
6. Dip Switch Assignment: Indicates each DIP switch assignment.
7. Bookkeeping: Displays information data on average score and average play time.

1. Test Operation

1. Push the test switch to display the diagnostic menu on the screen.
2. Select "CONTINUE" or "INDIVIDUAL" using the START button.
3. Move the accelerator to position the arrow to the desired test item.

Select by Accelerator Push Test Switch

Select the desired test item using the accelerator and push the test switch button.

[CONTINUE]

Bring the arrow sign (by operating the accelerator) to "CONTINUE" first, then move it to one of the tests to start. Push the TEST button, and the tests will be performed sequentially, starting from the test where the arrow was originally set to "EXIT." If the START button is pushed when the arrow is at "CONTINUE," it will change to "INDIVIDUAL." Pushing it again returns it to "CONTINUE."

[INDIVIDUAL]

If the arrow is at "INDIVIDUAL" first and brought to a certain test you wish to conduct, only that test is performed by pushing the TEST button.

When each test is finished in "CONTINUE" mode, push the TEST button, and it will automatically proceed to the next test. If the TEST button is pushed in "INDIVIDUAL" mode, the diagnostic menu (Fig. 1) is shown. To end the test mode at this time, bring the arrow to "EXIT" and push the TEST button, and it will return to the ADVERTISEMENT mode.

2. Test Items

(1) Memory Test

The diagnostic screen for Memory Test shows "ROMS TEST" and "RAMS TEST" sections, listing various ICs (e.g., IC 84, IC 85, IC 97, IC 98, IC 86, IC 99, IC 67, IC 54 for ROMs; IC 83, IC 113, IC 127, IC 96, IC 112, IC 126, IC 110, IC 136, IC 79, IC 103, IC 135, IC 78, IC 63 for RAMs). An indication of "GOOD" following an IC No. means the IC is functioning correctly. Push the TEST button to proceed to the next test item.

(2) Input Test

The diagnostic screen for Input Test shows the status of various inputs:

• COIN#1: (Value)
• COIN#2: (Value)
• START: (Status)
• SERVICE: (Status)
• HANDLE RIGHT LEFT: 80H
• BRAKE: 00H
• ACCELERATOR: 00H
• BANK UP DOWN: 30H

These values correspond to the normal states as described in sections 8-11. Operate the DIP switches. When "ON" is indicated on the right side of the corresponding item on the screen, it is OK. If the data value increases when the HANDLE is inclined to the left or decreases when it is inclined to the right, it tests satisfactorily. If the data value increases when the HANDLE is pulled downward and decreases when it is released, the testing is OK. When the tests are ended, push the TEST button.

(3) Output Test

The diagnostic screen for Output Test shows "START LAMP." If the start lamp lights up, it is functioning properly. Push the TEST button when the testing has been completed.

(4) Sound Test

The diagnostic screen for Sound Test lists various sound effects and music tracks:

• 1. COIN IN
• 2. START
• 3. REBOUND
• 4. EXPLOSION
• 5. EXTEND
• 6. EFFECT SOUND 1
• 7. " " 2
• 8. " " 3
• 9. " " 4
• 10. MUSIC 1
• 11. " 2
• 12. " 3
• 13. " 4
• 14. " 5
• 15. VOICE 1
• 16. " 2
• 17. " 3
• 18. " 4

Select by HANDLE, then PUSH START BUTTON. When the test has been completed, push the TEST button.

(5) C.R.T. Test

The diagnostic screen for CRT Test shows "RGB COLOR BAR" with color bars (RED, GREEN, BLUE, YELLOW, BLACK, PINK, LIGHT BLUE, WHITE) and "C.R.T. POSITION CHECK." When the test has been completed, push the TEST button.

(6) DIP Switch Assignments

The diagnostic screen for DIP Switch Assignments shows the current settings for DIP SW. A and DIP SW. B, along with their corresponding functions and values (e.g., COIN SW#1 1 COIN, COIN SW#2 1 COIN, TYPE UPRIGHT, GAME DIFFICULTY MEDIUM/HARD, TIME ADJUST MEDIUM, TIME CONTROL MEDIUM, ADVERTISE SOUND OFF).

(7) Bookkeeping

The diagnostic screen for Bookkeeping displays usage and operational data:

• COIN CHUTE #1: (Usage frequency)
• COIN CHUTE #2: (Usage frequency)
• COIN CREDIT: (Number of coin credits)
• SERVICE CREDIT: (Usage frequency of service switch)
• TOTAL CREDIT: (Number of credits)
• TOTAL TIME: (Operating time in hour-minute-second format)

Only data within the range of up to 999H 59M 59S can be memorized. This screen is for testing. When the tests are finished, push the START button, and the following will be shown:

• NUMBER OF GAME: (Value)
• AVE. SCORE: (Value)
• TOP SCORE: (Value)
• LOW SCORE: (Value)
• GAME TIME: TOTAL (H M S), AVERAGE (H M S), LONGEST (H M S)

Every time the start button is pressed, the bookkeeping test display is repeated. When the test is finished, push the TEST button to end the test (in the case of "INDIVIDUAL"), however, the test mode returns to Fig. 1 first.

Note: Once the power source is turned OFF, all the bookkeeping data will be completely cleared. If any data exceeds the bookkeeping function's capacity, "OVERFLOW" will be indicated on the screen, and the function will stop. At this time, turn the power OFF and then ON again for reuse.

(8) EXIT

In the state shown in Fig. 1, operate the handle to bring the arrow to "EXIT" and push the TEST button. The self-testing will then end and return to the ADVERTISING mode.

17. Parts List

This section provides a detailed list of parts for the SEGA Enduro Racer U/R (Upright/Racer) model.

① Top Assy SEGA Enduro Racer U/R

The diagram shows an exploded view of the Enduro Racer cabinet and its main components, including the handle assembly and various internal parts, with numbered callouts corresponding to the parts list.

② Assy Cabinet U/R (D-1/3)

This diagram provides a side and front view of the cabinet assembly with numerous numbered callouts for various components.

② Assy Cabinet U/R (RH-10002) (D-2/3)

② Assy Cabinet U/R (RH-10002) (D-3/3)

③ Assy Subcabinet U/R (RH-1600) (D-1/2)

This diagram provides a side and front view of the subcabinet assembly with numerous numbered callouts for various components.

③ Assy Subcabinet U/R (RH-1600) (D-2/2)

④ Assy Sub Handle (MX-2500) (D-1/3)

This diagram provides an exploded view of the sub handle assembly with numerous numbered callouts for various components.

④ Assy Sub Handle (MX-2500) (D-2/3)

④ Assy Sub Handle (MX-2500) (D-3/3)

⑤ Assy Control (MX-2111)

This diagram provides an exploded view of the control assembly with numerous numbered callouts for various components.

⑥ Assy Power Supply U/R (RH-40002) (D-1/2)

This diagram provides an exploded view of the power supply assembly with numerous numbered callouts for various components.

⑥ Assy Power Supply U/R (RH-40002) (D-2/2)

18. Schematic Diagram

A detailed schematic diagram is provided, illustrating the electrical connections and circuitry of the SEGA Enduro Racer arcade machine. This includes power supply connections, control board wiring, sound board connections, CPU board interfaces, and various input/output signals for components like the coin switches, start button, handle, accelerator, brake, and monitor. The diagram also shows power transformer wiring for different voltage inputs (90V, 100V, 110V, 120V, 200V, 220V, 230V, 240V).