Service Manual
Contents
1. 8 Drive train EER EE De eo eie 6 9 Scooter vibrates Check Function of Page No Engine See page 2 Wheels 6 7 Drivetrain 2 8 9 Engine does not shut off with kill button Check Function of Page No Engine 566 page 2 Cables Controls 8 Scooter does not adequately stop Check Function of Page No 0 6 www tanaka usa com 3 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual Safety amp Shop Practices 6 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 6 Maintain a clean and orderly work area that is well lighted and adequately ventilated 6 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 6 Scooter should be cleaned before repair work starts Cleaning will often help reveal a source of trouble 6 Before attempting to repair or operate any equipment read and understand all information provided by the instruction manual for the equipment 0 Never attempt to service a unit that is running or still heated from running unless it is specifically required by the manuf2. 5 n he Muffler 0008 www tanaka usa com Service Manual Page No Page No custsvc tanaka ism com Moby SE 802 Trouble Shooting Check Function of Rewind Starter Ignition System No Spark Fuel System Fuel Tank Fuel System Carburetor Filter Exhaust System Compression Check Function of Clutch System Ignition System Spark Plug Ignition System Poor Spark Fuel System Fuel Tank Fuel System Carburetor Air Filter Exhaust System Compression Check Function of Clutch System Ignition System Poor Spark Fuel System Fuel Tank Fuel System Carburetor Air Filter 0 Exhaust System Compression Check Function of Ignition System No Spark Fuel System Fuel Tank Fuel System Carburetor Compression Trouble Shooting cont Tanaka Engine Will Not Start Engine Idles Poorly Engine Lacks Power Engine Stops Suddenly www tanaka usa com Tanaka Moby SE 802 Service Manual Trouble Shooting cont Scooter lacks power acceleration Check Function of Page No Engine 566 page 2 BIdKOS 8 6 5 6 Cables Controls
3. tanaka usa com 24 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual 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 Additionally six of the mounting bolts are covered by grip tape four rear two front and access to them will require the removal of the grip tape Inspect the board for any damage and replace as necessary When re installing a deck always ensure that all fasteners are used and that an adequate amount of grip tape is re applied to ensure sound footing when in operation www tanaka usa com 25 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual 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 In the event that the product is used for commercial rental or competition purposes the warranty shall be VOID All Tanaka supplied accessories attachments and replacement parts will carry a 90 DAYS
4. 00 www tanaka usa com 26 custsvc tanaka ism com
5. ER WHICH IS INCORPORATED IN TO THE MUFFLER ON THIS ENGINE WHERE A WARRANTABLE CONDITION EXISTS TANAKA WILL REPAIR YOUR ENGINE AT NO COST TO YOU INCLUDING DIAGNOSIS PARTS AND LABOR MANUFACTURER S EMISSION CONTROL WARRANTY COVERAGE THE EMISSION CONTROL SYSTEM ON 1995 AND LATER SMALL OFF ROAD ENGINES ARE WARRANTED FOR TWO YEARS IF ANY EMISSION RELATED PART ON YOUR ENGINE IS DEFECTIVE THE PART WILL BE REPAIRED OR REPLACED BY TANAKA OWNER S WARRANTY RESPONSIBILITIES AS THE SMALL OFF ROAD ENGINE OWNER YOU ARE RESPONSIBLE FOR THE PERFORMANCE OF THE REQUIRED MAINTENANCE LISTED IN YOUR OWNER S MANUAL TANAKA RECOMMENDS THAT YOU RETAIN ALL RECEIPTS COVERING MAINTENANCE ON YOUR SMALL OFF ROAD ENGINE BUT CANNOT DENY WARRANTY SOLELY FOR THE LACK OF RECEIPTS OR FOR YOUR FAILURE TO ENSURE THE PERFORMANCE OF ALL SCHEDULED MAINTENANCE AS THE SMALL OFF ROAD ENGINE OWNER YOU SHOULD BE AWARE HOWEVER THAT TANAKA MAY DENY YOU WARRANTY COVERAGE IF YOUR SMALL OFF ROAD ENGINE OR A PART HAS FAILED DUE TO ABUSE NEGLECT IMPROPER MAINTENANCE OR UNAPPROVED MODIFICATIONS YOU ARE RESPONSIBLE FOR PRESENTING YOUR SMALL OFF ROAD ENGINE TO A TANAKA SERVICE CENTER AS SOON AS A PROBLEM EXISTS THE WARRANTY REPAIRS SHOULD BE COMPLETED IN A REASONABLE AMOUNT OF TIME NOT TO EXCEED 30 DAYS IF YOU HAVE ANY QUESTIONS REGARDING YOUR WARRANTY RIGHTS AND RESPONSIBILITIES YOU SHOULD CONTACT TANAKA C O INTERNATIONAL SALES amp MARKETING INC CUSTOMER SERVICE DEPT AT 253 333 12
6. Sales amp Marketing Inc has the authority to increase or alter the obligations of this warranty IF THE PRODUCT IS USED IN A COMMERCIAL OR COMPETITIVE ENDEAVOR TANAKA WILL NOT BE LIABLE FOR GENERAL DAMAGES INCLUDING BODILY INJURIES EXCEPT AS SET FORTH ABOVE OR FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE LOSS OF PROFITS LOSS OF PRODUCTION EXPENSE OF SUBSTITUTE EQUIPMENT OR OTHER COMMERCIAL LOSS OR DAMAGE THE SAME LIMITATIONS SHALL APPLY TO A PRODUCT USED FOR CONSUMER PURPOSES WITH RESPECT TO ALL NON PERSONAL INJURY GENERAL INCIDENTAL AND CONSEQUENTIAL DAMAGES Some states do not allow the exclusion or limitation of incidental of consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state THE CALIFORNIA AIR RESOURCES BOARD AND TANAKA KOGYO CO LTD TANAKA ARE PLEASED TO EXPLAIN THE EMISSION CONTROL SYSTEM WARRANTY ON YOUR TANAKA ENGINE NEW SMALL OFF ROAD ENGINES MUST BE DESIGNED BUILT AND EQUIPPED TO MEET STRINGENT CALIFORNIA ANTI SMOG STANDARDS TANAKA MUST WARRANT THE EMISSION CONTROL SYSTEM ON SMALL OFF ROAD ENGINE FOR THE PERIODS OF TIME LISTED BELOW PROVIDED THERE HAS BEEN NO ABUSE NEGLECT OR IMPROPER MAINTENANCE OF YOUR LAWN AND GARDEN EQUIPMENT ENGINE YOUR EMISSION CONTROL SYSTEM INCLUDES PARTS SUCH AS THE CARBURETOR THE IGNITION SYSTEM AND THE CATALYTIC CONVERT
7. Tanaka service Manual MOBY SE 802 Date10 10 02 35cc PowerBoard Revison 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 Tanaka Moby SE 802 Service Manual Table of Contents Specifications 1 Torque Limits 1 Troubleshooting 2 3 Safety amp Shop Practices 4 Routine Maintenance 4 Tools 5 General Inspection 6 8 Engine Repair 9 17 Brake System 18 Wheel Removal 19 20 Steering Head Components 21 Cables Controls 22 Belt Adjustment Replacement 23 24 Deck Removal 25 Warranty Statement 26 custsvc tanaka ism com www tanaka usa com Service Manual Moby SE 802 Specification Chart Cylinder Plating 38 x 30 o 98x30 O Tanaka Maxmumhp Maxmumkw Maximumtorque kg m ft Ibs MaxmumRPM Idling RPM Starting System Fuel capacity cc fl oz 900 30 2 8 Maximum torque kg m ft Ibs Fuel consumption g hp hr g kw hr 437 594 WYJ 112 Walbro Clutch Diameter Spark Plug CJ7 Champion BM7A NGK Ignition System Spark Plug Electrode Gap Rotation recoil side Second Coil Resistance Coil Air Gap 014 6 3 45 7 6 custsvc tanaka ism com N M Engine Dimensions LxWxH mm 176 x 243 x247 Engine Weight kg Ibs Torque Limits 200 185 150 Lb 0 0 5 5 5 0 4 4 4 2 3
8. acturer s instructions o Wipe up all spilled liquids immediately Use non flammable solvents for cleaning Clean all parts before reconditioning or reassembling o Thoroughly inspect all parts for wear or damage Replace all parts that show damage or excessive wear o Always recondition and or repair equipment strictly according to the Manufacturer s specifications o Be sure all shields and safety devices are correctly installed before performing any final operating tests o After completion of any service or repair the equipment should be thoroughly cleaned Routine Maintenance Guide 1 Each Use 20 Hrs 25 Hrs 100 Hrs AirFilter Clean O All Fasteners Tighten O J Cooling Fins Clean O J o Spark Arrestor Clean O FuelFilter Clean O _ Spark Plug Clean O Muffler amp Exhaust Ports Clean O Daily Weekly Monthly All Fasteners Tighten O Drive Belts Inspect Adjust O Brake front Inspect Adjust O Steering Head InspectlAdjust O www tanaka usa com 4 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual Engine Diagnostic Tools Engine Tachometer Digital Type Three Point Spark Tester EDS Part No 001 29000 000 Engine Disassembly amp Assembly Tools Flywheel Remover Set 1 Handle 006 29326 002 2 Center Bolt 007 29326 000 3 Fl
9. an indication that the brake pads may be worn beyond their service limits and or the cable has stretched In either case spares should be installed Brake pads are simply slid into place Fig 4 but it requires that tension be taken off of the cable to allow the new pads to be fitted Note that the pads are not identical and it is necessary to match the pad with the appropriate brake actuator arm www tanaka usa com 18 custsvc tanaka ism com Tanaka Moby SE 802 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 To disassemble the wheel for servicing the tire and or tube you must first remove the brake disc Removal requires a 4mm 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 assembly together Fig 6 CAUTION BE SURE TO DEFLATE THE TIRE PRIOR TO ATTEMPTING TO DISASSEMBLE THE TWO WHEEL HALVES The hardware securing the two wheel halves will require a 13mm wrench or socket and a 6mm hex wrench With the wheel disassembled it is advisable to check the integrity of the two ball bearings that ride within the hub of the whe
10. arter spring 10 custsvc tanaka ism com www tanaka usa com Tanaka Moby SE 802 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 ELECTRICAL SYSTEM The electrical system includes the flywheel 1 the coil 2 high tension lead assembly 3 and the spark plug 4 To remove the flywheel it is first necessary to effectively stop the piston from moving within the cylinder This is easiest accomplished by rotating the crankshaft until the piston is ona 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 its cycle or crankshaft rotation This will allow the flywheel mounting nut to be removed The flywheel nut is right hand threaded Removal is in the counter clock wise direction Electrical Systems cont www tanaka usa com 11 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual Engine Repair Cont Electrical Systems cont With the flywhe
11. attract dirt This provides a good visual reference Ensure that the engine turns freely when the recoil starter is pulled and that the recoil starter rope retracts positively into the starter housing gasoline is present in the fuel tank take the opportunity to empty it into a clear container This may reveal contamination such as water as depicted in the photo phase separation of gasoline and water is very obvious sediment or the lack of two cycle oil fuel mixture Air Cleaner Remove the air cleaner cover A and inspect the air cleaner element D Ensure that it is clean and lightly oiled Make sure the inside of the housing that accommodates the cleaner element is free of dirt and dust The vented area of the crankcase visible in the photo between the fuel tank and the air cleaner body B allows air from the flywheel fins C to be circulated to the exterior of the engine and is critical to proper cooling Ensure that there is no debris within the vent fins that would impede the circulation of air www tanaka usa com 6 custsvc tanaka ism com Tanaka Moby SE 802 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 Remove the spark plug rubber protection boot and high tension lead and remove inspect the spark pl
12. cylinder will slide off of the crankcase and piston rings The piston is attached to the connecting rod with a press fit wrist pin Removal of this pin first requires the removal of the piston pin retaining circlips installed in the side of the piston at either end of the pin These are removed with a pair of needled nose pliers and are not re usable New spares should be installed upon re assembly Crankcase Engine cont www tanaka usa com 16 custsvc tanaka ism com Tanaka Moby SE 802 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 its best to re assemble with new rings However if servicing requires the removal of the piston fitting of new rings to the piston should not be done until the piston has been re assembled to the connecting rod as the piston pin remover tool can cause damage to the rings Using a piston pin remover loop the strap end around the piston 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 the inside of the piston pin The crankcase halves are joined with four screws Removing these screws will allow the entire contents of the crankcase to be ex
13. el If they feel worn or do not turn freely replace them Upon re assembly ensure that the three axle spacers are properly positioned www tanaka usa com 19 custsvc tanaka ism com Tanaka Moby SE 802 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 7 To disassemble 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 DEFLATE THE TIRE PRIOR TO ATTEMPTING TO DISASSEMBLE THE TWO WHEEL HALVES The hardware securing the two wheel halves will require a 13mm socket and a 6mm hex wrench With the wheel disassembled Fig 8 it is advisable to check the integrity of the two ball bearings that ride within the hub of the wheel If they feel worn or do not turn freely replace them Upon re assembly ensure that the three axle spacers are properly positioned For belt adjustment procedures see page 11 www tanaka usa com 20 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual Steering Head Components Service to t
14. el nut removed a flywheel puller can be attached to separate it from its press fit to the crankshaft Align the center bolt of the puller with the indent in the end of the crankshaft and thread at least two carrier bolts through the puller and into the flywheel Make sure that at least several threads are utilized in attaching the carrier bolts as they will bear the load of pulling the flywheel loose Damage to these threads will require replacing the flywheel itself With the puller properly attached to the flywheel use the T handle to turn the center pivot point until the flywheel comes loose from the crankshaft 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 keyway 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 Gap should be measured with a feeler gauge and set at 0 014 www tanaka usa com 12 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual Engine Repair Cont 0 FUEL SYSTEM The fuel system consists of the carburetor 1 fuel tank 2 fuel supply line 3 and fuel filter 4 The carburetor is held in place between the air cleaner body and the heat insulator block with two screws that are accessed
15. embly www tanaka usa com 14 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual 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 necessary to remove the throttle valve for inspection rotate it by hand to ensure that it is able to freely rotate with the carburetor body and that it can reach the full range of motion permitted between the idle adjustment screw and the full RPM stopper on the carburetor body Any binding should be addressed by blowing forced air into the throttle valve body area If it still does not rotate freely the entire carburetor will need to be replaced Also ensure that the o ring mounted to the carburetor body on the air cleaner side is not torn or dried Replace as necessary The o ring is a component contained within the carburetor repair kit The fuel tank is mounted to the crankcase with three screws that extend from 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 fuel lines for any signs of leakage or damage Replace as needed With the fuel supply line disconnected from the carburetor it is possible to check the integrity of the fuel filter With the tank cap securely
16. he 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 Remove the lock nuts on the bolts and gently tap them through the steering head assembly Fig 9 Use caution not to damage the threads as you remove the bolts With the entire front wheel and forks removed Fig 10 the steering head can now be disassembled Slide the upper plastic cover up the handlebar stem and out of the way Remove the lower plastic cap Removal of these caps reveals the large 40mm nuts that secure the steering 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 the steering head and the one directly beneath it is a jamb nut to ensure they do not come loose in operation With these bottom nuts removed remove the lower bearing and spacer This will enable the entire down tube with the upper bearing to be slid out the top of the steering head It will be necessary to fold the front steering handle to the down position Fig 11 to allo
17. il ratio 2 Misuse or abuse 3 Negligence 4 Accident or physical damage 5 Repairs made by unauthorized parties and or with unauthorized parts 6 Improper set up or altering the engine 7 Improper adjustments e g carburetor etc 8 Operation of engine speeds above Tanaka recommendations 9 Failures due to contaminated fuel 10 Failure to operate the unit in the manner specified by the owner s manual 11 Use of non approved accessories or attachments or anything that alters the emission control system Normal maintenance of the fuel system spark plug spark arrester or air filter adjustments to the carburetor or replacement of wear items such as clutch components are not considered the responsibility of Tanaka under this warranty THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER EXPRESS WARRANTIES OBLIGATIONS OR LIABILITIES ANY IMPLIED WARRANTIES OBLIGATIONS OR LIABILITIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY SHALL BE LIMITED IN DURATION TO THE APPLICABLE WARRANTY PERIOD AS STATED PREVIOUSLY ANY ACTION FOR BREACH 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 states do not allow limitations on how long an implied warranty lasts so the previously stated limitations may not apply to you No agent representative dealer or employee of Tanaka or International
18. lace as needed When re installing the clutch components attach the spring between the shoes then add the bolts with the wave washers Hold in place with the flat washers between the backside of the clutch arms and the flywheel and tighten the stepped bolts to 185 in lbs www tanaka usa com 9 custsvc tanaka ism com Moby SE 802 Service Manual Engine Repair Cont fanaka 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 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 If the recoil starter fails to retract the rope or if the rope is broken or frayed it will be necessary to disassemble the starter Remove the small screw located in the center of the rope spool that secures the spool to the starter body This will expose all of the starter components Inspect the spool for any sign of warping cracks or chips Replace as necessary Ensure that the rope is not frayed and is tightly secured with knots to both the starter handle and the spool Inspect the starter body for any cracks or other damage Replace as needed Inspect the starter pawl cup and the spring loaded pawl located within the cup The pawl pivots on a spring and should have constant tension keeping it i
19. n be addressed as major sub components of the engine e 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 CLUTCH SYSTEM CAUTION Never attempt to run the engine with the clutch exposed The clutch is designed to overcome the force of the spring thus allowing contact with the clutch drum ultimately providing drive to the PTO side of the equipment If the clutch is not contained within the clutch drum while the engine is running the clutch components may come detached 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 impact wrench or a sharp blow to a socket wrench remove the bolts securing the clutch to the flywheel right hand threaded counter clockwise for removal This will enable all of the components to be inspected Check for any signs of damage to clutch shoes or excessive wear on the lining of the shoes When new the shoes have approximately two millimeters of lining Order spares as needed Inspect the wave washers mounted between the bolt and the clutch shoes to ensure that they are not cracked and still provide spring tension Ensure that the spring is not cracked or broken Rep
20. n place If the starter pawl spring is 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 not broken and that the ends are properly installed in the starter body If the spring shows no signs of breakage it may not be necessary to remove it from the starter body When installing a new spring use caution as it is wound with significant force New replacement springs come pre wound and wrapped with tie wire Carefully grasp the spring with needle nosed pliers and hold it oriented in place prior to removal of the tie wire With the tie wire carefully removed it will be possible to insert the spring into the starter housing Ensure that the outside end of the spring A is properly positioned in the recoil starter housing and when the spool is placed over the top of the spring the tab on the inside of the spring B is properly located in the provision on the spool Prior to placing the spool over the rewind spring apply a small amount of grease to the inner wall of the center hole on the spool Wind the rope on the spool about three turns counterclockwise as viewed from the starter pawl side Install the starter spool into the case making sure that the spool engages with the inner end of the rewind spring Install washer and screw holding starter spool in the case Recoil Starter cont st
21. olor Lack of spark weak spark or yellow spark may indicate a problem with another electrical component within the engine Connect an ohmmeter to the ignition coil with one lead inserted into the spark plug boot and the other making contact with the cylinder fins of the engine as shown Secondary resistance when tested this way should indicate 4 2 1 KQ 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 spark or none at all If the reading is within range and still weak or no spark is evident replace the ignition coil Check to ensure that all fasteners are tight prior to disassembly Loosening of fasteners on the carburetor side may cause erratic running conditions or even engine failure It s always best to know if fasteners are properly torqued prior to engine service as problematic running conditions may be the result Using a hooked wire reach into the filler neck of the fuel tank and grasp the fuel line Gently pull the fuel line with the fuel filter attached through the filler neck The filter should be white in color and should be compressible between two fingers If it appears discolored or hard replace with a new one www tanaka usa com 8 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual Engine Repair ENGINE SERVICE Troubleshooting should alert you to problem areas and these problem areas ca
22. on the exterior of the cleaner body with the cover and cleaner element removed After removing the carburetor inspect the gasket that mounts between the carburetor and insulator block Often times a compromised gasket will show signs that it has allowed fuel to escape Replace all mounting gaskets when servicing the carburetor 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 Readings less than this indicate a problem within the carburetor Fuel Systems cont www tanaka usa com 13 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual Engine Repair Cont Fuel Systems cont The pump body of the carburetor is held together with four screws With these screws removed it will be possible to inspect all of the pump components of the carburetor Inspect all gaskets and diaphragms to ensure that they have not lost their pliability and show no signs of cracking or drying If any of these components are in question replace all of them with a carburetor repair kit 650 25124 90 Pay careful attention to their position in the carburetor during re ass
23. part replacement warranty This warranty is limited to repair or replacement by Tanaka or at the premises of Tanaka Authorized Service Dealers of such parts as appear to Tanaka upon inspection to be defective in material and or workmanship The above warranties are extended to the first end user and no warranty is made nor authorized to be made assignable on resale by the first end user Tanaka makes no warranty with respect to accessories or replacement parts not manufactured by Tanaka or sold by it Such items are subject to the warranty policy of their respective manufacturers For the name and address of your nearest Authorized Tanaka Service Dealer call or write Tanaka c o International Sales amp Marketing Inc at 1028 4th Street S W Bldg B Auburn WA 98001 253 333 1200 or visit their website www tanaka usa com To obtain performance of any obligation under this warranty for failure during the applicable warranty period deliver the Tanaka product shipping prepaid to Tanaka c o International Sales amp Marketing Inc or to the nearest Tanaka Authorized Service Dealer Tanaka reserves the right to inspect the claimed defective part s to determine if the malfunction is the result of a defect covered by this warranty This warranty will cover only defects arising under normal usage and shall not apply nor will Tanaka assume any responsibility if the failure was caused by the following 1 Operation of product with incorrect fuel to o
24. posed Inspect the main support bearings if they are in question replace them Upon re assembly install a new crankcase gasket between the halves Carefully inspect the crankshaft paying particular attention to the amount of play between the connecting rod and the crankshaft pin Side to side play A is normal However any detectable play in an up and down motion B is unacceptable This indicates the need for a replacement crankshaft The connecting rod and crankshaft are one non serviceable part www tanaka usa com 17 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual 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 over tightening will not allow the wheel to turn Full braking action should occur with approximately one third to two thirds throw of the brake lever 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 clock wise until the desired adjustment is reached then re tighten the lock nut Fig 3 When neither of these adjustments allows an acceptable amount of braking action it s
25. sa com 23 custsvc tanaka ism com Tanaka Moby SE 802 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 it is necessary to replace the large rear belt it will require that the rear wheel be completely removed Carefully position new belt s 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
26. te the carburetor throttle and observe the full range of motion Re attach the wire and make sure that this full range is achievable with the throttle lever Fig 14 If not adjustments can be made at the carburetor as well as the handlebar mounted lever For proper adjustment of the front brake cable refer to the section addressing brakes www tanaka usa com 22 custsvc tanaka ism com Tanaka Moby SE 802 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 ensure 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 u
27. tightened gently shake the tank while partially filled with gasoline If the filter is allowing gas to flow the agitation of the fuel in the tank will force fuel up and out of the fuel line If the fuel filter is in question replace it EXHAUST SYSTEM The exhaust system consists of the muffler muffler gasket 1 and heat shield 2 The muffler is a sealed non serviceable unit If the muffler is damaged the entire unit needs to be replaced Remove the shroud covering the muffler and cylinder Remove the muffler and inspect the exhaust port and mating portion of muffler for any build of carbon Carbon build up is a normal occurrence in a two cycle engine and removal is a matter of routine maintenance www tanaka usa com 15 custsvc tanaka ism com Tanaka Moby SE 802 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 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 of the cylinder With the screws removed the
28. ug Picture A depicts a spark plug that has a broken insulator Picture B depicts a spark plug that has fouled due to a rich fuel oil mixture Picture C depicts a 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 healthy running conditions The electrode should have a golden tan color and no damage is present Whenever the integrity of a spark plug comes into question it should be replaced Whether the plug to be installed is new used or cleaned it should be checked for correct electrode gap which is 024 Cylinder Compression Insert a compression gauge into the empty spark plug hole and pull the recoil starter handle briskly several times until the needle on the gauge stops climbing This reading represents the compression in the cylinder and is a good gauge of the piston rings ability to hold pressure The unit will struggle to run with compression less than approximately 90 psi Such low readings indicate the need for service to the cylinder piston or piston rings www tanaka usa com 7 custsvc tanaka ism com Tanaka Moby SE 802 Service Manual General Inspection Cont Spark Testing 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 c
29. w enough slack in the control cables for the steering stem to be lifted from the steering head Note within the steering head there is a rubber bushing that acts as a shim between the down tube and the inside of the steering head Remove the bushing and thoroughly grease both the inner and outer surfaces of the bushing Fig 12 A lack of grease on this bushing will result in difficult turning of the handle bars Take the opportunity to thoroughly clean all parts with cleaning solvent and inspect bearings If they feel worn or do not turn freely replace them Re grease the bearings and carefully re assemble www tanaka usa com 21 custsvc tanaka ism com Tanaka Moby SE 802 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 Throttle Cable To identify if the throttle cable 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 position This will allow the throttle wire end to be removed from the receiver on the carburetor With the throttle wire removed actua
30. ywheel Puller 006 2932 002 4 Bolts 021 29355 00 Pin Remover Part No 009 29326 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 8 10 13 16 17mm Spark plug socket 19mm ___ _ Slot Phillips Pliers Snap Ring Other tools may be preferable however complete service can be performed with the tools indicated above www tanaka usa com 5 custsvc tanaka ism com Tanaka Moby SE 802 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 All of the shroud components are designed for routing the flow of cooling air around the engine Any broken or missing components could lead to over heating of the engine during operation Order replacements as need Inspect the rubber spark plug boot for any damage that may cause a potential shock hazard Ensure that the fuel tank is not damaged in any way due to possible ground contact excessive vibration etc Any potential fuel leaks may be apparent during this initial inspection as the exposed fuel on the engine components may
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