Specifications

Safety first!
Professional motor mechanics are trained in safe working
procedures. However enthusiastic you may be about getting on
with the job in hand, do take the time to ensure that your safety
is not put at risk. A moments lack of attention can result in an
accident, as can failure to observe certain elementary
precautions.
There will always be new ways of having accidents, and the
following points do not pretend to be a comprehensive list of all
dangers; they are intended rather to make you aware of the
risks and to encourage a safety-conscious approach to all work
you carry out on your vehicle.
Essential DOs and DON'Ts
DON'T start the engine without first ascertaining that the
transmission is in neutral.
DON'T suddenly remove the filler cap from a hot cooling
system - cover it with a cloth and release the pressure gradually
first, or you may get scalded by escaping coolant.
DON'T attempt to drain oil until you are sure it has cooled
sufficiently to avoid scalding you.
DON'T grasp any part of the engine, exhaust or silencer without
first ascertaining that it is sufficiently cool to avoid burning you.
DON'T allow brake fluid or antifreeze to contact the machine's
paintwork or plastic components.
DON'T syphon toxic liquids such as fuel, brake fluid or
antifreeze by mouth, or allow them to remain on your skin.
DON'T inhale dust - it may be injurious to health (see Asbestos
heading).
DON'T allow any spilt oil or grease to remain on the floor —
wipe it up straight away, before someone slips on it.
DON'T use ill-fitting spanners or other tools which may slip and
cause injury.
DON'T attempt to lift a heavy component which may be
beyond your capability - get assistance.
DON'T rush to finish a job, or take unverified short cuts.
DON'T allow children or animals in or around an unattended
vehicle.
DON'T inflate a tyre to a pressure above the recommended
maximum. Apart from overstressing the carcase and wheel rim,
in extreme cases the tyre may blow off forcibly.
DO ensure that the machine is supported securely at all times.
This is especially important when the machine is blocked up to
aid wheel or fork removal.
DO take care when attempting to slacken a stubborn nut or
bolt. It is generally better to pull on a spanner, rather than push,
so that if slippage occurs you fall away from the machine rather
than on to it.
DO wear eye protection when using power tools such as drill,
sander, bench grinder etc.
DO use a barrier cream on your hands prior to undertaking dirty
jobs — it will protect your skin from infection as well as making
the dirt easier to remove afterwards; but make sure your hands
aren't left slippery. Note that long-term contact with used
engine oil can be a health hazard.
DO keep loose clothing (cuffs, tie etc) and long hair well out of
the way of moving mechanical parts.
DO remove rings, wristwatch etc, before working on the vehicle
- especially the electrical system.
DO keep your work area tidy - it is only too easy to fall over
articles left lying around.
DO exercise caution when compressing springs for removal or
installation. Ensure that the tension is applied and released in a
controlled manner, using suitable tools which preclude the
possibility of the spring escaping violently.
DO ensure that any lifting tackle used has a safe working load
rating adequate for the job.
DO get someone to check periodically that all is well, when
working alone on the vehicle.
DO carry out work in a logical sequence and check that
everything is correctly assembled and tightened afterwards.
DO remember that your vehicle's safety affects that of yourself
and others. If in doubt on any point, get specialist advice.
IF, in spite of following these precautions, you are unfortunate
enough to injure yourself, seek medical attention as soon as
possible.
Asbestos
Certain friction, insulating, sealing, and other products -
such as brake linings, clutch linings, gaskets, etc - contain
asbestos. Extreme care must be taken to avoid inhalation of
dust from such products since it is hazardous to health. If in
doubt, assume that they do contain asbestos.
Fire
Remember at all times that petrol (gasoline) is highly
flammable. Never smoke, or have any kind of naked flame
around, when working on the vehicle. But the risk does not end
there - a spark caused by an electrical short-circuit, by two
metal surfaces contacting each other, by careless use of tools,
or even by static electricity built up in your body under certain
conditions, can ignite petrol vapour, which in a confined space
is highly explosive.
Always disconnect the battery earth (ground) terminal
before working on any part of the fuel or electrical system, and
never risk spilling fuel on to a hot engine or exhaust.
It is recommended that a fire extinguisher of a type suitable
for fuel and electrical fires is kept handy in the garage or
workplace at all times. Never try to extinguish a fuel or electrical
fire with water.
Note: Any reference to a 'torch' appearing in this manual
should always be taken to mean a hand-held battery-operated
electric lamp or flashlight. It does not mean a welding/gas torch
or blowlamp.
Fumes
Certain fumes are highly toxic and can quickly cause
unconsciousness and even death if inhaled to any extent. Petrol
(gasoline) vapour comes into this category, as do the vapours
from certain solvents such as trichloroethylene. Any draining or
pouring of such volatile fluids should be done in a well
ventilated area.
When using cleaning fluids and solvents, read the instruc-
tions carefully. Never use materials from unmarked containers -
they may give off poisonous vapours.
Never run the engine of a motor vehicle in an enclosed
space such as a garage. Exhaust fumes contain carbon mon-
oxide which is extremely poisonous; if you need to run the
engine, always do so in the open air or at least have the rear of
the vehicle outside the workplace.
The battery
Never cause a spark, or allow a naked light, near the
vehicle's battery. It will normally be giving off a certain amount
of hydrogen gas, which is highly explosive.
Always disconnect the battery earth (ground) terminal
before working on the fuel or electrical systems.
If possible, loosen the filler plugs or cover when charging
the battery from an external source. Do not charge at an
excessive rate or the battery may burst.
Take care when topping up and when carrying the battery.
The acid electrolyte, even when diluted, is very corrosive and
should not be allowed to contact the eyes or skin.
If you ever need to prepare electrolyte yourself, always add
the acid slowly to the water, and never the other way round.
Protect against splashes by wearing rubber gloves and goggles.
Mains electricity and electrical equipment
When using an electric power tool, inspection light etc,
always ensure that the appliance is correctly connected to its
plug and that, where necessary, it is properly earthed
(grounded). Do not use such appliances in damp conditions
and, again, beware of creating a spark or applying excessive
heat in the vicinity of fuel or fuel vapour. Also ensure that the
appliances meet the relevant national safety standards.
Ignition HT voltage
A severe electric shock can result from touching certain
parts of the ignition system, such as Ihe HT leads, when the
engine is running or being cranked, particularly if components
are damp or the insulation is defective. Where an electronic
ignition system is fitted, the HT voltage is much higher and
could prove fatal.