WARNING
Read all safety instructions before beginning any service procedure. Failure to follow these instructions may result in personal injury, damage to the product, or voiding the warranty.
General safety
- Service must be performed by trained personnel only.
- Remove metal accessories from hands and wrists (rings, watches, bracelets) before starting work — they can cause short circuits or get caught in rotating parts.
- Work on a stable, clean, well-lit surface.
- Remove the kill switch before starting any service procedure to prevent accidental motor start.
- Keep the motor shaft free of rotation during service — never activate the motor with the housing open or partially assembled.
- Disconnect the battery before working on any electrical components.
- Allow the motor to cool completely before disassembly if it has been in use.
Electrical safety
DANGER
The battery pack contains high-energy lithium cells. Incorrect handling can cause fire, explosion or severe burns.
- Never short-circuit the battery terminals.
- Do not puncture, crush or deform the battery pack.
- Do not expose the battery to temperatures above 50 °C.
- Disconnect the motor cable from the battery before removing or installing the battery.
- Inspect power cables for damage before reassembly. Replace any cable with damaged insulation immediately.
- The motor controller (PCBA) is ESD-sensitive. Handle it with care and avoid contact with PCB components.
Handling a damaged or swollen battery
DANGER
A swollen, punctured, crushed or otherwise damaged lithium battery pack can catch fire or reignite hours after the damage occurred (thermal runaway).
- Do not attempt to charge, discharge or continue using a battery identified as swollen, punctured, crushed or otherwise damaged.
- Isolate it immediately in a non-flammable, non-conductive container, away from flammable materials, other batteries and heat sources.
- Store it outdoors or in a designated fire-safe isolation area, away from the main building, until it is collected for disposal. Monitor it for heat or smoke.
- Label it clearly as a damaged lithium battery.
- Dispose of it through a certified battery/e-waste recycler, in accordance with local hazardous waste regulations for lithium batteries. Never put it in regular waste.
NOTE
This is a draft procedure based on standard lithium-battery safety practice — confirm it against local regulations and Suzuki’s own EHS policy before treating it as final.
Chemical safety
| Chemical | Hazard | Precautions |
|---|---|---|
| Permabond A126 (010010004) | Cyanoacrylate adhesive — bonds skin instantly, eye irritant | Wear nitrile gloves and safety glasses. Work in a ventilated area. Keep away from skin and eyes. |
| Permabond A130 (010010005) | Cyanoacrylate adhesive — bonds skin instantly, eye irritant | Wear nitrile gloves and safety glasses. Work in a ventilated area. |
| Molykote 111 Grease (010020001) | Low hazard — mineral oil based | Avoid prolonged skin contact. |
| Molykote O-ring grease 55 (010020003) | Low hazard | Avoid prolonged skin contact. |
| Silicone Dowsil 7091 (010010001) | Skin and eye irritant before cure | Wear nitrile gloves when applying. Handle interface with gloves during and after degreasing. |
| Isopropanol | Flammable, eye and skin irritant | No open flames. Ensure ventilation. Wear nitrile gloves. |
| TermoPasty Varnish PVB 16, PVB 60 | Solvent-based — flammable, inhalation hazard | Work in a well-ventilated area. Wear gloves. |
Torque specifications
Follow specified torque values for all fasteners. Do not estimate by feel.
| Fastener | Torque |
|---|---|
| M3 screws | 1.3 Nm |
| M4 screws | Refer to relevant service step |
| Safety nut M12 | Refer to relevant service step |
Cutting tools
- When cutting silicone around the interface, do not cut deeper than 2–3 mm. Cutting too deep can damage cables or the sealing surface.
- Use a fresh blade for Exacto knife / razor blade work. Dull blades require more force and increase the risk of slipping.
Bearing and press operations
- Always use the correct press tools. Improvised presses can damage bearings, housings or shaft seals.
- Verify bearing depth with a digital caliper after pressing. Do not assume correct seating.
- Inspect radial shaft seals after pressing. Seals with damaged lips must be replaced before reassembly.
After service
- Verify all connectors are fully seated before closing the interface.
- Verify silicone coverage is complete and continuous around the interface sealing surface before curing.
- Allow silicone to cure fully before immersing the motor in water. Refer to the silicone datasheet for cure time.
- Check propeller rotation by hand before first use after service to confirm no internal obstruction.