SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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Repair and Service Manual
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SAFETY
NOTICES, CAUTIONS, WARNINGS
AND DANGERS
Throughout this manual, the following
NOTICES, CAU-
TIONS
,
WARNINGS
and
DANGERS
are used. For the
protection of all personnel and the vehicle, be aware of
and observe the following:
NOTICE: A NOTICE indicates a condition that
should be observed.
A CAUTION indicates a condition
that may result in damage to the
vehicle or surrounding facilities.
A WARNING indicates a hazardous
condition which could result in
serious injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
IMPORTANT SAFETY WARNING
In any product, components will eventually fail to perform
properly as the result of normal use, age, wear or abuse.
It is virtually impossible to anticipate all possible compo-
nent failures or the manner in which each component
may fail.
Be aware that a vehicle requiring repair indicates that the
vehicle is no longer functioning as designed and there-
fore should be considered potentially hazardous. Use
extreme care when working on any vehicle. When diag-
nosing, removing or replacing any components that are
not operating correctly, take the time to consider the
safety of yourself and others around you if the compo-
nent should move unexpectedly.
Some components are heavy, spring loaded, highly cor-
rosive, explosive, or may produce high amperage or
reach high temperatures. Battery acid and hydrogen gas
could result in serious bodily injury to the technician/
mechanic and bystanders if not treated with the highest
degree of caution. Be careful not to place hands, face,
feet or body in a location that could expose them to injury
should an unforeseen situation occur.
Always use the appropriate tools listed in the tool list and
wear approved safety equipment.
MODIFICATIONS TO VEHICLE
To prevent personal injury or death
to the operator or passenger(s), do
not make changes to the weight
distribution or the center of gravity which could
make the vehicle unstable or prone to roll over.
Do not modify the vehicle in any manner that will change
the weight distribution of the vehicle.
GENERAL MAINTENANCE
To prevent severe injury or death
resulting from improper servicing
techniques, observe the following
Warnings:
Do not attempt any type of service before reading
and understanding all notes, cautions and warnings
in this manual.
When any maintenance procedure or inspection is per-
formed, it is important to exercise caution to insure the
safety of the technician/mechanic or bystanders and to
prevent damage to the vehicle.
Always read and understand the
entire
relevant manual
section (chapter) before attempting any inspection or
service.
BEFORE SERVICING THE VEHICLE
Before attempting to inspect or service a vehicle, be sure
to read and understand the following warnings:
To prevent personal injury or death,
observe the following:
Before working on the vehicle, remove all
jewelry (watches, rings, etc.).
Be sure that no loose clothing or hair can
become caught in the moving parts of the
powertrain.
Use caution not to contact hot objects.
Any servicing requiring adjustments to be
made to the powertrain while the motor is
running must be made with both rear wheels
raised.
To prevent the possibility of motor
disintegration, never operate the vehicle at
full throttle for more than 4 - 5 seconds
while the vehicle is in a “no load” condition.
Wear OSHA approved clothing and eye
protection when working on anything that
could expose the body or eyes to potential
injury. In particular, use care when working
with or around batteries, compressed air, or
solvents.
Always turn the key switch to ‘OFF’ and
remove the key before disconnecting a live
circuit.
When connecting battery cables, pay
particular attention to the polarity of the
battery terminals. Never confuse the
positive and negative cables.
The parking ‘PARK’ brake should always be
set, except for cases where the powertrain
must be allowed to rotate or service is being
performed on the brake system.
If repairs are to be made that will require
welding or cutting, the batteries must be
removed.
PRELIMINARY
