TPB 400GX
Contents
1. DESCRIPTION NUT M8xP1 25 WASHER NUT M10xP1 5 BOLT AXLE 10x145 WASHER SPRING M6 SCREW REAR AXLE TENSION BASE ADJUSTER NUT ADJUSTER SPACER REAR WHEEL L SPACER TIRE 10 HUB WELD PULLEY REAR DRIVE GUARD BELT BOLT 6x20 SCREW BOLT M8xP1 25x15 BEARING 6200 2RS HUB 5 HOLES TUBE TIRE SPACER REAR WHEEL R Page 10 COMMENTS custsvc tanaka ism com Janaka PARTS INFORMATION TPB 400GX SPROCKET amp DRIVE SHAFT e FIGURE 11 ITEM PART NUMBER DESCRIPTION QTY COMMENTS T 11 47 30834 BEARING 6000 2RS 2 11 54 30835 GEAR LARGE 1 11 59 30833 RING C 4 www tanaka usa com Page 11 custsvc tanaka ism com Janaka PARTS INFORMATION TPB 400GX CLUTCH DRUM amp MOUNTING RING e FIGURE 12 ITEM PART NUMBER DESCRIPTION COMMENTS SPROCKET SMALL HOLDER BEARING RING C PLATE MOUNTING MOUNTING RING BEARING 6000 2RS WASHER RUBBER www tanaka usa com Page 12 custsvc tanaka ism com Janaka ITEM PART NUMBER 25504200200 15711666900 01804075200 0010440590 99461050204 0170440020 04104050200 0300440090 0370100020 03905004200 0460440080 99962101004 06802000200 56020517200 1782054320 1672054390 1790007080 99011040182 99416040183 1820186 201 19805015800 www tanaka usa com PARTS INFORMATION CYLINDER PISTON IGNITION DESCRIPTION COVER SPARK PLUG RUBBER CAP SPARK PLUG ASS Y PLUG SPARK SET CYLINDER BOLT HEXHOLE 5X20 S GASKET CYLINDER RING PISTON SET PISTON2. NUMBER DESCRIPTION 4550440090 SET CARBURETOR 51425100200 SCREW THROTTLE SET 54425164200 STAY ADJUST CABLE 93925120200 SWIVEL 5492516520 WASHER THRUST 48925100200 RING STOP 61425137200 ADJUSTER CABLE O RING JET MAIN LONG 44 NUT 6 GASKET PUMP DIAPHRAGM PUMP SCREEN INLET BODY PUMP GASKET DIAPHRAGM DIAPHRAGM METERING COVER DIAPHRAGM 6 22 5482515120 SCREW SET 6 24 4310634C200 GASKET CLEANER 525 PUMP PRIMING 6 26 447251086200 BULB PRIMING www tanaka usa com Page 20 custsvc tanaka ism com COMMENTS Includes carburetor gasket Contained in Carb Repair Kit P N 650 25124 900 Not available individually Tanaka Moby XL SE 803 Service Manual 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 72 inch of play when measured 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 behind the wheel Fig 16 The belt should have approximately 77 inch of play Make sure that the wheel is lined up in the center of the frame After adjustment test ride the unit for a short distance to en
3. 20 S GROMMET PRIMARY CORD 1 1 1 1 1 1 1 1 1 2 2 V V V V V 4 1 1 1 1 1 1 1 4 1 www tanakapowerequipment com custsvc tanaka ism com Page 15 Janaka 7380440 21 99461050124 99461050164 99053060653 99201060011 7040440090 99201050061 99201050061 7210440020 99434040081 7320440020 1330440020 99463050204 99463050204 99201050061 35910112203 2900420081 34204200200 99204100030 35704201200 30790 www tanaka usa com PARTS INFORMATION DESCRIPTION PROTECTOR MUFFLER BOLT HEX 5X125 5 16 5 SCREW HEX 6X65 WASHER 6 SET MUFFLER GASKET MUFFLER SHIELD HEAT BOLT HEX 5X20 BOLT HEX 5X20 GROMMET BOLT HEX HOLE 5X25S WASHER 5 WASHER CLUTCH B SHOE CLUTCH SPRING CLUTCH WASHER WAVE 10 BOLT CLUTCH STEP CLUTCH ASS Y Page 16 4000 MUFFLER MUFFLER COVER e FIGURE 3 l COMMENTS Before S N U207704 Before S N U207704 S N U207705 and after Before S N U207704 S N U207705 and after S N U207705 and after S N U207705 and after lt custsvc tanaka ism com PARTS INFORMATION 4000 FUEL SYSTEM AIR FILTER e FIGURE 4 www tanakapowerequipment com Page 17 custsvc tanaka ism com Janaka ITEM PART NUMBER 4030430020 4040430090 4020430020 4530637 200 47601700200 4460138020 99204080030 4520138091 3800637C200 99011050602 99210050012 4550440090 78600601200 68000731201 67501630900 5910440021 6463252L90 9650
4. 440020 9640661190 99463050204 9400430020 70003005100 68000206200 6420608A200 www tanakapowerequipment com PARTS INFORMATION FUEL SYSTEM AIR FILTER e FIGURE 4 DESCRIPTION GASKET INLET MANIFOLD SET CARB INSULATOR GASKET CARBURETOR COLLAR COLLAR CLEANER BODY CLEANER VALVE CHOKE BOARD BLOW OVER CHECK ELEMENT CLEANER WASHER 8 COVER CLEANER ASSY BOLT CLEANER COVER CARBURETOR WASHER RECOIL STARTER BOLT HEX HOLE 5X25WS COLLAR TANK FIXING PIPE FUEL 3X5X230 CLIP 6 3 FILTER FUEL TANK FUEL ORANGE TANK FUEL WHITE COLLAR C CAP FUEL BLACK NON VENT AIR VENT VALVE ASSY PIPE AIR VENT VENT AIR ASSY BOLT HEX 5X20 BOLT HEX 5X20 STAND ENGINE PIPE FUEL 3X5X100 CLIP 5 5 GROMMET FUEL PIPE 5 305 WASHER 5 GASKET TANK Page 18 4000 COMMENTS S N U207705 and after Before S N U207704 S N U207705 and after S N U207705 and after S N U207705 and after custsvc tanaka ism com Tanaka PARTS INFORMATION PF 4000 RECOIL STARTER e FIGURE 5 ITEM PART NUMBER DESCRIPTION QTY COMMENTS 7620422090 STARTER RECOIL ASS Y 1 7720422080 BODY RECOIL STARTER 1 7690422020 REEL STARTER ROPE 1 7790422020 SPRING RECOIL 1 7830422020 ROPE STARTER 1 8350422020 CAP HANDLE 7850422020 HANDLE STARTER 1 8390422020 SCREW SET 1 www tanaka usa com Page 19 custsvc tanaka ism com Janaka PARTS INFORMATION 4000 CARBURETOR e FIGURE 6 ITEM PART
5. LARGE BRAKE PAD SET WASHER NUT M6xP1 0 www tanaka usa com Page 3 custsvc tanaka ism com Janaka PARTS INFORMATION TPB 400GX FRONT WHEEL amp BRAKE DISK e FIGURE 4 ITEM PART NUMBER www tanaka usa com DESCRIPTION NUT M8xP1 25 WASHER SPRING M6 SPACER T 789 TIRE 10 HUB WELD BOLT M8xP1 25x15 SPACER BRAKE T 790 DISC BRAKE BOLT M6xP1 0x32 BEARING 6200 2RS HUB 5 HOLES TUBE TIRE Page 4 o COMMENTS custsvc tanaka ism com Janaka PARTS INFORMATION TPB 400GX HEAD KIT e FIGURE 5 B _ 40mm Head Wrench Part 31254 127 8 ITEM PART NUMBER DESCRIPTION COMMENTS 5 6 1 31554 1 25 5 127 8 31580 TRIPLE CLAMP BOTTOM 5 127 9 31581 TRIPLE CLAMP TOP 5 127 10 31671 HEAD BEARING KIT www tanaka usa com Page 5 custsvc tanaka ism com Janaka PARTS INFORMATION TPB 400GX 127 1 126 112 PART NUMBER DESCRIPTION COMMENTS SPRING S 043 NUT M10xP1 5 CAP CABLE END BRAKE WIRE CONDUIT HANDLE STEM CONNECTOR SCREW BOLT M10xP1 5x160 6 127 31572 SHOCK R 1 Do not disassemble shocks 6 127 1 31573 SHOCK L 1 Extreme pressure and not serviceable 6 128 31706 NUT TOP TRIPLE CLAMP 2 www tanaka usa com Page 6 custsvc tanaka ism com Janaka PARTS INFORMATION TPB 400GX DECK DECK TAPE amp MOUNTING HARDWARE e FIGURE 7 37 Optional Seat Kit 31699 ITEM PART NUMBER DE
6. Note that the lower section of the large rear belt must ride on top of the idler arm with two ball bearings in tandem protruding from the side plate Carefully adjust the tension of the belts as indicated in the previous section www tanaka usa com 23 custsvc tanaka ism com
7. PIN PISTON CIRCLIP PISTON PIN CRANKSHAFT BEARING NEEDLE F1010B KEY WOODRUFF 3X13X5 CAP RUBBER CORD HIGH TENSION ASSY IGNITION COIL STOP CORD 220MM SCREW 4 18 SCREW 4 18 5 WASHER SPECIAL CLAMP CORD Page 13 4000 COMMENTS Before S N U112140 S N U112141 and after custsvc tanaka ism com FIGURE 1 Janaka PARTS INFORMATION 4000 CRANKCASE FLYWHEEL STARTER PULLEY e FIGURE 2 www tanaka usa com Page 14 custsvc tanaka ism com Janaka PARTS INFORMATION PF 4000 PART NUMBER DESCRIPTION COMMENTS 99463050204 880162V20 99355050000 99111100013 7 900162V200 980422090 0720440090 0720440091 0900440020 9996615251 1 9996 1620200 07102007200 07102007210 07102007220 07111600230 07111600240 99461050304 1552053880 99201100011 99101100011 99414050101 1320440020 1120440021 BOLT HEX 5X20 PAWL STARTER RING STOP 5 NUT 10 SPRING PAWL STARTER PAWL STARTER ASS Y CASE CRANK CASE CRANK GASKET CRANKCASE SEAL OIL AVE15X25X7 BEARING BALL 6202 SHIM 15 2X20X 05 SHIM 15 2X20X 10 SHIM 15 2K20K 15 SHIM 16X21X 20 SHIM 16X21X 30 BOLT HEX 5X30S ROTOR MAGNETO WASHER 10 NUT 10 SCREW S 5X10 DEFLECTOR AIR CASE FAN ORANGE Before S N U207704 S N U207705 and after Crankcase assy includes bearings seals and gaskets Shims are as needed to obtain correct side clearance 1120441321 99461050204 20311660200 CASE FAN POLISHED BOLT HEXHOLE 5X
8. SCRIPTION COMMENTS NUT M6xP1 0 SCREW BOARD DECK WOOD PAVERUNNER 350 DECAL DECK PAVERUNNER GRIP TAPE PAVERUNNER www tanaka usa com Page 7 custsvc tanaka ism com PARTS INFORMATION TPB 400GX FRAME REAR BRAKE amp KICK STAND e FIGURE 8 ITEM PART NUMBER DESCRIPTION COMMENTS WASHER SPRING NUT M8xP1 25 NUT M6xP1 0 FRAME PAVERUNNER BLUE PEDAL REAR BRAKE BOLT K 236 STAND KICK BOLT M5xPO0 8x15 NUT M6xP1 0 NUT M5xP0 8 WASHER SPRING KICK STAND WASHER RUBBER CAP FLAT BOLT M5xPO0 8x15 PAD CUSHION www tanaka usa com Page 8 custsvc tanaka ism com PARTS INFORMATION TPB 400GX ITEM PART NUMBER www tanaka usa com Belt Adjustment Replacement Procedures DESCRIPTION NUT M10xP1 5 Complete Replacement Engine 35cc Complete Replacement Engine 40cc Complete Replacement Engine 4 cc SPACER SHORT BOLT M6xP1 0x35 RD HD BEARING 6000 2RS SPACER T 804 BOLT M6XP1 0X25 RD HD SPACER T 693 BELT CLUTCH SMALL SPACER T 797 FENDER BOLT M10xP1 5x45 WASHER SPRING M6 BOLT K 222 SCREW M6xP1 0x40 NUT BOLT M6xP1 0x10 PLATE SUPPORT BLUE BELT DRIVE LARGE MOUNTING RING Page 9 BELTS FENDER amp MOUNTING RING FIGURE 9 COMMENTS custsvc tanaka ism com PARTS INFORMATION TPB 400GX REAR WHEEL amp REAR DRIVE PULLEY e FIGURE 10 Custom Gold Valve Caps Part 31257 10 91 30822 10 102 30911 10 103 30882 www tanaka usa com Custom Chrome Valve Caps Part 31256 102
9. Tanaka Illustrated Parts Manual Model Number P N 31641 TPB 400GX Rev 000 Date 4 1 03 40cc PowerBoard SS FILE TE FAVERUNINEEF POWERBOARD BY THIS CATALOG 00 Searchable PDF File FREE Acrobat Reader Supplier To The Outdoor Power Equipment Industry 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 PARTS INFORMATION TPB 400GX HANDLE amp CONTROLS FIGURE 1 ITEM PART NUMBER www tanaka usa com DESCRIPTION HANDLEBAR RACING THROTTLE LEVER ASSY BOLT M6xP1 0x13 WASHER CABLE THROTTLE SPRING LEVER GRIP HANDLE NUT SWITCH BUTTON COVER STOP BUTTON BOLT M6xP1 0x20 STEERING STEM CAP STEERING STEM BOLT M6xP1 0x15 BOLT M6xP1 0x42 STEERING PIPE Page 1 lt COMMENTS custsvc tanaka ism com ITEM PART NUMBER www tanaka usa com PARTS INFORMATION TPB 400GX DESCRIPTION SPACER FRONT HANDLE TUBE HEAD BLUE NUT M8xP1 25 NUT M6xP1 0 GRIP FOLDING HANDLE HANDLE FOLDING BLUE RING E PIN HEAD TUBE SPACER T 937 BOLT PAD CUSHION SPRING FOLDING HANDLE Page 2 HEAD PIPE amp FOLDING HANDLE e FIGURE 2 COMMENTS custsvc tanaka ism com Janaka PARTS INFORMATION TPB 400GX FRONT BRAKE e FIGURE 3 PART NUMBER DESCRIPTION COMMENTS KIT BRAKE ARM HDWE KIT BRAKE CABLE RECEIVER ARM BRAKE SMALL WHEEL BRAKE ARM BRAKE
10. sure that the belts ride in the center of their pulleys If they tend to ride on one side of the pulley s adjust the opposite side adjuster until the belt centers on the pulley being careful to maintain the correct belt tension www tanaka usa com 22 custsvc tanaka ism com Tanaka Moby XL SE 803 Service Manual 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 To replace the belts begin by removing the air cleaner cover and disconnect the throttle wire and stop cord wire from engine Next remove the 2 top engine mount bolts with their spacers as well as the fender Fig 17 Loosen and remove the belt tension adjuster 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 With the side plate removed it is possible to remove both belts from the frontward pulleys Inspect the pulleys Fig 19 to ensure that they are not damaged Also inspect the bearings on the pulley shaft as well as the support bearing that rides in the side plate If integrity of any bearings are questionable install new ones If it is necessary to replace the large rear belt it will require that the rear wheel be completely removed Carefully position new belt s
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