Related Manuals for Tanaka MOBY XL
Summary of Contents for Tanaka MOBY XL
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Page 1: Service Manual
Service Manual MOBY XL, SE-803 Date 09-16-02 40cc PowerBoard Revision 001 ISM, Inc. • 1028 4 Street SW • Auburn, WA 98001 • Phone: (253) 333-1200 • Fax: (253) 333-1212 www.tanaka-usa.com custsvc@tanaka-ism.com... -
Page 2: Table Of Contents
Service Manual Moby XL, SE-803 Table of Contents Specifications Torque Limits Troubleshooting Safety & Shop Practices Routine Maintenance Tools General Inspection Engine Repair 9-16 Brake System Wheel Removal 18-19 Steering Head Components Cables / Controls Belt Adjustment / Replacement 22-23... -
Page 3: Specifications
Service Manual Moby XL, SE-803 Specification Chart Cylinder Plating Chrome Piston Rings Displacement (cc) 39.8 Horsepower Bore x Stroke (mm) 39.8 x 32 Compression ratio 7.2:1 Maximum hp 1.8 @ 7500 rpm Maximum kw 1.14 @ 8000 rpm Maximum torque – kg-m (ft. lbs) 0.21 (1.5) @ 5500 rpm... -
Page 4: Troubleshooting
Service Manual Moby XL, SE-803 Trouble Shooting Engine Will Not Start Check Function of: Page No. Rewind Starter ………………6, 10, 11 Ignition System: No Spark …………...7, 8, 11, 12 Fuel System : Fuel Tank …………...6, 8, 12, 13 Fuel System : Carburetor ………………8, 12, 13... - Page 5 Moby XL, SE-803 Service Manual Trouble Shooting cont. Scooter lacks power / acceleration Check Function of: Page No: Engine: …see page 2 Brakes: ………….……………6 Wheels: ………….……………6 Cables / Controls: …………………….…8 Drive train: ……………………..8,9 Scooter vibrates Check Function of: Page No: Engine: …see page 2...
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Page 6: Safety & Shop Practices
Tools, instruments, and parts needed for work should be clean and readily available before any job is started. (Special tools available for servicing TANAKA equipment are listed in this manual.) Scooter should be cleaned before repair work starts. Cleaning will often help reveal a source of trouble. -
Page 7: Tools
2. Center Bolt (007-29326-000) Part No. 009-29326-00 3. Flywheel Puller (006-2932-002) 4. Bolts (021-29355-00) The following is a minimum list of tools required to service the Moby / Moby XL PowerBoard frames: Allen wrenches - 3, 4, 5, 6mm Wrenches... -
Page 8: General Inspection
Service Manual Moby XL, SE-803 General Inspection Once the engine is removed from the equipment, this is an ideal time to inspect for damage as well as potential areas that may require repair. Some of the diagnostic evaluation cannot be effectively performed after disassembly has begun. - Page 9 Service Manual Moby XL, SE-803 General Inspection Cont. Choke Lever Check to ensure that the choke lever (A) is able to rotate freely within the air cleaner body, and that it has not been bent as to prevent a good seal when closing over the air intake.
- Page 10 Service Manual Moby XL, SE-803 General Inspection Cont. Spark Testing While the rubber spark plug boot / high-tension lead are removed from the spark plug, this is an ideal time to test the quality of the current being delivered to the spark plug. Insert a three point spark tester into the spark plug boot and briskly pull the recoil starter.
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Page 11: Engine Repair
Service Manual Moby XL, SE-803 Engine Repair ENGINE SERVICE Troubleshooting should alert you to problem areas, and these problem areas can be addressed as major sub-components of the engine: • Centrifugal Clutch • Recoil Starter • Electrical System • Fuel System Components •... - Page 12 Service Manual Moby XL, SE-803 Engine Repair Cont. RECOIL STARTER CAUTION: The recoil spring is wound with significant force. When removed from the starter body, it will rapidly unwind. It is recommended that you wear gloves and eye protection when removing the starter spring.
- Page 13 Service Manual Moby XL, SE-803 Engine Repair Cont. Recoil Starter cont. It is necessary to increase the spring tension in the starter prior to use. Rotate the spool counterclockwise several times with the rope hooked into notch (A). Hold the spool to prevent it from rewinding and pull the starter grip out to take up the rope slack.
- Page 14 Service Manual Moby XL, SE-803 Engine Repair Cont. Electrical Systems cont. Remove the flywheel (refer to page 11 for disassembly procedure), and inspect the integrity of the flywheel keyway, the crankshaft keyway and the key itself. Any deformation of the key or keyways will require replacement of those components.
- Page 15 Service Manual Moby XL, SE-803 Engine Repair Cont. Fuel System cont. Using a straight edge such as a metal ruler, check the carburetor insulator for any possible warping. If the insulator shows sign of warping replace it with a new one.
- Page 16 Service Manual Moby XL, SE-803 Engine Repair Cont. CARBURETOR SERVICE The main body of the carburetor consists of the carburetor body (A), the throttle shaft (B) and the throttle wire receiver (C). Two screws secure the throttle wire receiver and the throttle shaft to the carburetor body. While it’s not...
- Page 17 Service Manual Moby XL, SE-803 Engine Repair Cont. CRANKCASE / ENGINE When re-assembling the muffler components, be sure that the heat shield is properly installed with the muffler locator tabs properly inserted. The heat shield is crucial to the cooling of the engine, and improper installation can lead to overheating of the engine.
- Page 18 Service Manual Moby XL, SE-803 Engine Repair Cont. Crankcase / Engine cont. With the engine taken down to this level, it is generally accepted that the piston rings should be replaced. They provide the engine with the proper amount of compression, and due to their inaccessibility, it’s best to re-assemble with new...
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Page 19: Brake Adjustment
Service Manual Moby XL, SE-803 Brake Adjustment Two adjustments can be made to the brake system. First, use the adjustment located on the caliper, near the wheel (Fig. 1). Begin by loosening the lock-nut with an 8mm wrench, and then turn the adjuster out (counter-clockwise) (Fig. - Page 20 Service Manual Moby XL, SE-803 Wheel Removal - Front Wheel The front wheel is held in place with a solid axle, and can be removed with two 17mm wrenches and/or sockets. Remove the locking nut from one side of the wheel, and gently tap the axle through the wheel.
- Page 21 Service Manual Moby XL, SE-803 Wheel Removal - Rear Wheel Rear wheel removal does not require the drive train components be removed. However service to the drive train components will require removal of the wheel. Begin by removing the axle lock-nut with a 17mm wrench or socket.
- Page 22 Service Manual Moby XL, SE-803 Steering Head Components Service to the steering head components requires the removal of the front wheel, and the forks that the front wheel mounts to. NOTE: If it is not necessary to disassemble the wheel, the entire front wheel assembly can be removed from the frame with the forks attached.
- Page 23 Service Manual Moby XL, SE-803 Cables / Controls On the Moby PowerBoard, the front disc brake and throttle are cable actuated. Cables should be periodically inspected to ensure that they move smoothly, and offer full range of motion in order to maximize braking ability and full range of throttle.
- Page 24 Service Manual Moby XL, SE-803 Belt Adjustment The Moby PowerBoard uses a dual stage, belt driven system to transmit power to the rear wheel. Belts should be regularly inspected for adjustment. Both belts are adjusted with two procedures. Tighten both belt adjusters on either side of the frame (Fig.
- Page 25 Service Manual Moby XL, SE-803 Belt Replacement Both drive belts carry a similar load, and should wear at a very similar rate. If one of the belts should break or one or both appear worn to the point of needing replacement, it may be preferable to replace both belts simultaneously, as the repair is somewhat involved.
- Page 26 Service Manual Moby XL, SE-803 Deck Removal The Moby deck is fastened to the frame with 10 bolts requiring a 4mm hex wrench and a 10mm open-end wrench. Some of these bolts are secured on the bottom side with locking nuts, and some of the bolts are simply threaded into the frame itself.
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Page 27: Air Filter
WARRANTY STATEMENT Tanaka Kogyo Co., Ltd. ("Tanaka") hereby warrants its utility engines to be free from defects in material or workmanship for a period of 180 DAYS after delivery to the first consumer end user in a non-commercial application. All components on PureFire engines related to the emission control system will carry a 2 YEAR warranty.