Service manual moby xl, se-803 40cc powerboard date 09-16-02 ism, inc. • 1028 4 th street sw • auburn, wa 98001 • phone: (253) 333-1200 • fax: (253) 333-1212 www.Tanaka-usa.Com custsvc@tanaka-ism.Com revision 001.
Www.Tanaka-usa.Com custsvc@tanaka-ism.Com service manual moby xl, se-803 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 componen...
Www.Tanaka-usa.Com 1 custsvc@tanaka-ism.Com service manual moby xl, se-803 specification chart cylinder plating chrome piston rings 2 displacement (cc) 39.8 horsepower 1.8 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 ...
Www.Tanaka-usa.Com 2 custsvc@tanaka-ism.Com service manual moby xl, se-803 trouble shooting engine idles poorly check function of: page no. Clutch system ……………………….9 ignition system: spark plug …………………….7, 8 ignition system: poor spark ………………8, 11, 12 fuel system : fuel tank …………...6, 8, 12, 13 fuel...
Www.Tanaka-usa.Com 3 custsvc@tanaka-ism.Com service manual moby xl, se-803 trouble shooting cont. Scooter vibrates check function of: page no: engine: …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 ...
Www.Tanaka-usa.Com 4 custsvc@tanaka-ism.Com service manual moby xl, se-803 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 ...
Www.Tanaka-usa.Com 5 custsvc@tanaka-ism.Com moby xl. Se-803 service manual engine diagnostic tools engine disassembly & assembly tools pin remover part no. 009-29326-00 flywheel remover set 1. Handle (006-29326-002) 2. Center bolt (007-29326-000) 3. Flywheel puller (006-2932-002) 4. Bolts (021-29355...
Www.Tanaka-usa.Com 6 custsvc@tanaka-ism.Com 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 perform...
Www.Tanaka-usa.Com 7 custsvc@tanaka-ism.Com 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. Spa...
Www.Tanaka-usa.Com 8 custsvc@tanaka-ism.Com 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...
Www.Tanaka-usa.Com 9 custsvc@tanaka-ism.Com 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 ...
Www.Tanaka-usa.Com 10 custsvc@tanaka-ism.Com 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 removi...
Www.Tanaka-usa.Com 11 custsvc@tanaka-ism.Com 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 prev...
Www.Tanaka-usa.Com 12 custsvc@tanaka-ism.Com 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 th...
Www.Tanaka-usa.Com 13 custsvc@tanaka-ism.Com 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. Using a carburetor...
Www.Tanaka-usa.Com 14 custsvc@tanaka-ism.Com 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 thro...
Www.Tanaka-usa.Com 15 custsvc@tanaka-ism.Com 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 ...
Www.Tanaka-usa.Com 16 custsvc@tanaka-ism.Com 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...
Www.Tanaka-usa.Com 17 custsvc@tanaka-ism.Com service manual moby xl, se-803 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 adju...
Www.Tanaka-usa.Com 18 custsvc@tanaka-ism.Com service manual moby xl, se-803 wheel removal - front wheel figure 5 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 th...
Www.Tanaka-usa.Com 19 custsvc@tanaka-ism.Com 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. Figure 7 begin by removing the axle lock-...
Www.Tanaka-usa.Com 20 custsvc@tanaka-ism.Com 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 ...
Www.Tanaka-usa.Com 21 custsvc@tanaka-ism.Com 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 b...
Www.Tanaka-usa.Com 22 custsvc@tanaka-ism.Com service manual moby xl, se-803 belt adjustment figure 15 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. Tighte...
Www.Tanaka-usa.Com 23 custsvc@tanaka-ism.Com service manual moby xl, se-803 belt replacement figure 17 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 ...
Www.Tanaka-usa.Com 24 custsvc@tanaka-ism.Com 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 ...
Www.Tanaka-usa.Com 25 custsvc@tanaka-ism.Com service manual moby xl, se-803 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-comm...
