Service Manual MOBY XL, SE-803 40cc PowerBoard Date 09-16-02 Revision 001 ISM, Inc. • 1028 4th Street SW • Auburn, WA 98001 • Phone: (253) 333-1200 • Fax: (253) 333-1212 www.tanaka-usa.com custsvc@tanaka-ism.
Moby XL, SE-803 Service Manual Table of Contents Specifications 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 Components 20 Cables / Controls 21 Belt Adjustment / Replacement 22-23 Deck Removal 24 Warranty Statement 25 www.tanaka-usa.com custsvc@tanaka-ism.
Service Manual Moby XL, SE-803 Specification Chart Cylinder Plating Piston Rings Displacement (cc) Horsepower Bore x Stroke (mm) Compression ratio Maximum hp Maximum kw Maximum torque – kg-m (ft. lbs) Maximum RPM Idling RPM Starting System Rotation (recoil side) Fuel capacity – cc (fl. oz) Fuel consumption – g/hp.hr (g/kw.
Service Manual Moby XL, SE-803 Trouble Shooting Engine Will Not Start Check Function of: Rewind Starter Ignition System: No Spark Fuel System : Fuel Tank Fuel System : Carburetor Air Filter Exhaust System Compression Page No. ………………6, 10, 11 …………...7, 8, 11, 12 …………...6, 8, 12, 13 ………………8, 12, 13 ……………………….6 ………………7, 14, 15 ……………………….
Moby XL, SE-803 Service Manual Trouble Shooting cont. Scooter lacks power / acceleration Check Function of: Engine: Brakes: Wheels: Cables / Controls: Drive train: Page No: …see page 2 ………….……………6 ………….……………6 …………………….…8 ……………………..8,9 Check Function of: Engine: Wheels: Drive train: Page No: …see page 2 ………….………….6,7 ………….………….8,9 Check Function of: Engine: Cables / Controls: Page No: …see page 2 …………………….…8 Check Function of: Page No: Brakes: ……………………….
Moby XL, SE-803 Service Manual Safety & Shop Practices o The most successful and profitable service shops consistently seem to maintain the best habits of safety, cleanliness, and orderly procedure. The following information is intended as a guide towards developing habits that are necessary to accomplish satisfactory service work. o Maintain a clean and orderly work area that is well lighted and adequately ventilated.
Moby XL. SE-803 Service Manual Engine Diagnostic Tools Compression Gauge Part No. 27286 Pressure Tester Part No. 070-2000W-500 Engine Tachometer (Digital Type) Part No. 001-29000-000 Ohmmeter (Digital Type) Three Point Spark Tester Engine Disassembly & Assembly Tools Flywheel Remover Set 1. Handle (006-29326-002) 2. Center Bolt (007-29326-000) 3. Flywheel Puller (006-2932-002) 4. Bolts (021-29355-00) Pin Remover Part No.
Moby XL, SE-803 Service Manual 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. Cover, Shroud, Fan Case Inspect covers, shrouds, and fan case to identify damage or cracks due to vibration, ground contact, etc.
Moby XL, SE-803 Service Manual 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. Spark Arrestor Screen Remove the spark arrestor retaining screw and holder. Remove any carbon deposits from the screen. If the screen has heavy deposits of carbon build-up, replace it with a new part.
Moby XL, SE-803 Service Manual 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. The tester should reveal a strong spark with a blue color.
Moby XL, SE-803 Service Manual 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 • Exhaust System • Crank Case It is important to properly identify which areas of the engine require service to avoid any unnecessary tear down of components not requiring service.
Moby XL, SE-803 Service Manual 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. The recoil starter is made up of the rope, spool and rewind spring. On the engine side is the starter pawl and the nut securing it to the crankshaft.
Moby XL, SE-803 Service Manual 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. Let the starter rewind slowly. Pull starter several times to check the spring rewind tension. If the starter is not rewinding fully, repeat the process described above.
Moby XL, SE-803 Service Manual 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. After identifying the integrity of the coil (refer to page 8 for coil testing procedure), or replacing it with a new one, check the air gap between the coil and flywheel (A).
Moby XL, SE-803 Service Manual 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. Using a carburetor pressure tester, test the pressure-holding ability of the carburetor. Attach the tester line to the intake fitting of the carburetor (not to be confused with the fitting that accommodates the purge bulb return line). The carburetor should hold 7 PSI.
Moby XL, SE-803 Service Manual 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.
Moby XL, SE-803 Service Manual 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. The engine components include the crankcase, crankshaft / connecting rod, cylinder, piston and piston rings.
Moby XL, SE-803 Service Manual 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 rings.
Moby XL, SE-803 Service Manual Brake Adjustment Figure 1 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. 2). Once adjusted, tighten the lock nut to hold that position. Make sure the brake caliper is not loose. Conversely, overtightening will not allow the wheel to turn.
Moby XL, SE-803 Service Manual 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. This will free the wheel assembly from the frame. (Fig. 5) Figure 5 To disassemble the wheel for servicing the tire and/or tube, you must first remove the brake disc. Removal requires a 4mm hex wrench.
Moby XL, SE-803 Service Manual 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. Gently tap the axle through the wheel. This will allow the rear wheel assembly and the rear drive sprocket to be freed from the frame. (Fig.
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. First, remove the two bolts, four spacers and lock nuts that secure the forks to the steering head. This requires either a 5mm or 6mm hex wrench, and a 13mm wrench or socket.
Moby XL, SE-803 Service Manual 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. Cables that have been kinked, corroded, frayed or worn significantly should be replaced.
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. 15) in equal increments until the small belt has approximately ½ inch of play when measured between the pulleys. Next, loosen the rear axle lock nut, using a 17mm wrench or socket.
Moby XL, SE-803 Service Manual 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. Figure 17 To replace the belts begin by removing the air cleaner cover, and disconnect the throttle wire and stop cord wire from engine.
Moby XL, SE-803 Service Manual 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. For those bolts secured with nuts on the underside, remove the nuts prior to attempting to remove the bolts from the top.
