Tanaka MOBY XL Service Manual Download Page 2

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Service

Manual

Moby XL, SE-803

Table of Contents

Specifications

Torque Limits

Troubleshooting

2-3

Safety & Shop Practices

Routine Maintenance

Tools

General Inspection

6-8

Engine Repair

9-16

Brake System

Wheel Removal

18-19

Steering Head Components

Cables / Controls

Belt Adjustment / Replacement

22-23

Deck Removal

Warranty Statement

Summary of Contents for MOBY XL

Page 1: ...Service Manual MOBY XL SE 803 40cc PowerBoard Date 09 16 02 ISM Inc 1028 4th Street SW Auburn WA 98001 Phone 253 333 1200 Fax 253 333 1212 www tanaka usa com custsvc tanaka ism com Revision 001...

Page 2: ...cations 1 Torque Limits 1 Troubleshooting 2 3 Safety Shop Practices 4 Routine Maintenance 4 Tools 5 General Inspection 6 8 Engine Repair 9 16 Brake System 17 Wheel Removal 18 19 Steering Head Componen...

Page 3: ...lug CJ7 Champion BM7A NGK Ignition System TCI Spark Plug Electrode Gap 024 Second Coil Resistance 5 8 K Coil Air Gap 014 016 Engine Dimensions LxWxH mm 170 x 260 x 270 Engine Weight kg lbs 3 9 8 6 Sco...

Page 4: ...ge No Clutch System 9 Ignition System Poor Spark 8 11 12 Fuel System Fuel Tank 6 8 12 13 Fuel System Carburetor 7 12 13 14 Air Filter 6 Exhaust System 7 14 15 Compression 7 Engine Stops Suddenly Check...

Page 5: ...ine see page 2 Wheels 6 7 Drive train 8 9 Engine does not shut off with kill button Check Function of Page No Engine see page 2 Cables Controls 8 Scooter does not adequately stop Check Function of Pag...

Page 6: ...truction manual for the equipment o Never attempt to service a unit that is running or still heated from running unless it is specifically required by the manufacturer s instructions o Wipe up all spi...

Page 7: ...wing is a minimum list of tools required to service the Moby Moby XL PowerBoard frames Allen wrenches 3 4 5 6mm Wrenches 8 10 13 16 17mm Spark plug socket 19mm Crescent wrench Large Screwdrivers Slot...

Page 8: ...during this initial inspection as the exposed fuel on the engine components may attract dirt This provides a good visual reference Recoil Starter Ensure that the engine turns freely when the recoil s...

Page 9: ...plug that has fouled due to carbon build up All of these conditions will prevent the spark plug from functioning properly and will require replacement Picture D depicts a plug characteristic of healt...

Page 10: ...esistance when tested this way should indicate 5 8 1 K If the reading is not within this range replace with a new coil previous tests for spark using a three point tester should have indicated a weak...

Page 11: ...ed from the engine and pose a risk of flying objects The clutch system is made up of the clutch shoes clutch spring and the bolts and washers flat and waved securing them to the flywheel Using an impa...

Page 12: ...s broken it will be necessary to replace the pawl cup The spring is retained within the starter body by the spool as well as clips formed in both ends of the spring Check to ensure that the spring is...

Page 13: ...e piston is on a downward stroke then inserting several inches of starter rope into the spark plug hole Upon rising in the cylinder the piston will contact the rope and will not be allowed to complete...

Page 14: ...een the coil and flywheel A Gap should be measured with a feeler gauge and set at 0 014 FUEL SYSTEM The fuel system consists of the carburetor 1 fuel tank 2 fuel supply line 3 fuel return line 4 fuel...

Page 15: ...used with the fitting that accommodates the purge bulb return line The carburetor should hold 7 PSI Readings less than this indicate a problem within the carburetor The pump body of the carburetor is...

Page 16: ...m underneath the tank and through the tank mounting bracket Additionally there are three small spacers that fit within the bolt holes in the fuel tank itself Inspect the tank tank cap tank vent and fu...

Page 17: ...ston rings Further the crankcase also contains the main crankshaft support bearings and the crankshaft seals The cylinder is attached to the crankcase with four screws which are accessed from the top...

Page 18: ...iston with the hole aligned to allow the passage of the piston pin It may be necessary to insert a small screw between the remover and the piston pin as the remover may have a smaller diameter than th...

Page 19: ...ake lever Figure 2 Figure 3 The design of the brake lever mounted on the handlebar provides another type of adjustment to the brake cable Simply loosen the lock nut and turn the adjuster out counter c...

Page 20: ...hex wrench Note that each of the four bolts use spacers between the disc and the wheel With the disc removed it is possible to access the four bolts and nuts that secure the two halves of the wheel a...

Page 21: ...le the wheel begin by removing the outer pulley cover which is attached with four phillips screws Next remove the four bolts either large phillips head screws or allen head bolts CAUTION BE SURE TO DE...

Page 22: ...head assembly from the top and bottom It is not necessary to remove the large top nut The steering head is held in place by two bottom 40mm nuts One is intended to provide adjustment and is closest to...

Page 23: ...lever are providing full range of motion first disconnect the cable from the carburetor Fig 13 This is accomplished by first removing the air cleaner cover then rotating the throttle to the full speed...

Page 24: ...asured between the pulleys Next loosen the rear axle lock nut using a 17mm wrench or socket Adjust the tension in the larger belt by using the rear wheel adjusters located at the rear of the frame beh...

Page 25: ...from the left side of the frame as well as the three screws that secure the left hand side plate to the frame Fig 18 Figure 18 With the side plate removed it is possible to remove both belts from the...

Page 26: ...e frame itself For those bolts secured with nuts on the underside remove the nuts prior to attempting to remove the bolts from the top Additionally six of the mounting bolts are covered by grip tape f...

Page 27: ...ACH OF ANY WARRANTY HEREUNDER INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY MUST BE BROUGHT WITHIN A PERIOD OF SIX MONTHS FROM THE END OF THE APPLICABLE WARRANTY PERIOD Some sta...

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