BLADEZ PB-SE803 Service manual

BLADEZ PB-SE803 Service manual
Service Manual
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
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Moby XL, SE-803
Service Manual
Table of Contents
Torque Limits
Safety & Shop Practices
Routine Maintenance
General Inspection
Engine Repair
Brake System
Wheel Removal
Steering Head Components
Cables / Controls
Belt Adjustment / Replacement
Deck Removal
Warranty Statement
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Moby XL, SE-803
Specification Chart
Cylinder Plating
Piston Rings
Displacement (cc)
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/ (g/
Clutch Diameter
Spark Plug
Ignition System
Spark Plug Electrode Gap
Second Coil Resistance
Coil Air Gap
Engine Dimensions – LxWxH (mm)
Engine Weight – kg (lbs)
Scooter Weight
Overall Length
Height / (folded)
Maximum Speed
Drive Ratio
Tire Air Pressure
Brakes (Front)
Brakes (Rear)
Tire Size / Type
Weight Capacity
Spark Plug
Drive System
Ground Clearance
39.8 x 32
1.8 @ 7500 rpm
1.14 @ 8000 rpm
0.21 (1.5) @ 5500 rpm
3000 +/- 200
1000 (33.8)
345 (469)
WYJ-224, Walbro
76 mm
CJ7 (Champion) / BM7A (NGK)
5.8 KΩ
.014 / .016
170 x 260 x 270
3.9 (8.6)
52 lbs.
40” (17”)
50 psi (max)
10”/4 ply
270 lbs.
Gas/Oil 50:1
BPM6A (or equiv.)
Dual Belt
Torque Limits
Carburetor Insulator
Clutch Shoes
Ignition Coil
Spark Plug
Pawl Carrier
Fan Case
In. - Lb.
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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
Page No.
………………6, 10, 11
…………...7, 8, 11, 12
…………...6, 8, 12, 13
………………8, 12, 13
………………7, 14, 15
Check Function of:
Clutch System
Ignition System: Spark Plug
Ignition System: Poor Spark
Fuel System : Fuel Tank
Fuel System : Carburetor
Air Filter
Exhaust System
Page No.
…………………….7, 8
………………8, 11, 12
…………...6, 8, 12, 13
………….7, 12, 13, 14
………………7, 14, 15
Check Function of:
Clutch System
Ignition System: Poor Spark
Fuel System : Fuel Tank
Fuel System : Carburetor
Air Filter
Exhaust System
Page No.
………………8, 11, 12
…………...6, 8, 12, 13
………….7, 12, 13, 14
………………7, 14, 15
Check Function of:
Ignition System: No Spark
Fuel System : Fuel Tank
Fuel System : Carburetor
Page No.
…………...7, 8, 11, 12
…………...6, 8, 12, 13
………………8, 12, 13
Engine Idles Poorly
Engine Lacks Power
Engine Stops Suddenly
(Trouble Shooting cont.)
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Trouble Shooting cont.
Scooter lacks power / acceleration
Check Function of:
Cables / Controls:
Drive train:
Page No:
…see page 2
Check Function of:
Drive train:
Page No:
…see page 2
Check Function of:
Cables / Controls:
Page No:
…see page 2
Check Function of:
Page No:
Scooter vibrates
Engine does not shut off with kill
Scooter does not adequately stop
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Moby XL, SE-803
Service Manual
Safety & Shop Practices
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.
Maintain a clean and orderly work area that is well lighted and adequately ventilated.
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.)
Scooter should be cleaned before repair work starts. Cleaning will often help reveal a source of trouble.
Before attempting to repair or operate any equipment, read and understand all information provided by the
instruction manual for the equipment.
Never attempt to service a unit that is running or still heated from running unless it is specifically required by the
manufacturer’s instructions.
Wipe-up all spilled liquids immediately. Use non-flammable solvents for cleaning. Clean all parts before
reconditioning or reassembling.
Thoroughly inspect all parts for wear or damage. Replace all parts that show damage or excessive wear.
Always recondition and /or repair equipment strictly according to the Manufacturer’s specifications.
Be sure all shields and safety devices are correctly installed before performing any final operating tests.
After completion of any service or repair, the equipment should be thoroughly cleaned.
Routine Maintenance Guide
Air Filter
All Fasteners
Cooling Fins
Spark Arrestor
Fuel Filter
Spark Plug
Muffler & Exhaust Ports
Each Use 20 Hrs. 25 Hrs. 100 Hrs.
Daily Weekly Monthly
All Fasteners Tighten
Drive Belts
Brake (front)
Steering Head Inspect/Adjust
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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. 009-29326-00
The following is a minimum list of tools required to service the Moby / Moby XL PowerBoard frames:
Allen wrenches Wrenches
Spark plug socket Crescent wrench
Screwdrivers Pliers
3, 4, 5, 6mm
8, 10, 13, 16, 17mm
Slot / Phillips
Other tools may be preferable; however, complete service can be performed with the tools indicated above.
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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 attract dirt. This provides a good
visual reference.
Recoil Starter
Ensure that the engine turns freely when the recoil starter is pulled, and
that the recoil starter rope retracts positively into the starter housing.
If 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, and inspect the air cleaner element (A).
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 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.
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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.
Spark Plug
Remove the spark plug rubber protection boot and high-tension lead, and
remove/inspect the spark plug.
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
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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. Lack of spark, weak spark, or yellow spark may
indicate a problem with another electrical component within the engine.
Ignition Coil Testing
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 5.8 (+/- 1) KΩ.
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.
Fuel Filter
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.
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Service Manual
Engine Repair
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.
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. Replace 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.
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Service Manual
Engine Repair Cont.
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.
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 in 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.
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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.
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 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 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.
With the flywheel 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.
Electrical Systems cont.
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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).
Gap should be measured with a feeler gauge and set at 0.014”.
The fuel system consists of the carburetor (1), fuel tank (2), fuel
supply line (3), fuel return line (4), fuel filter and fuel tank vent (5).
The carburetor is held in place between the air cleaner body and the
heat insulator block with two screws that are accessed on the
exterior of the cleaner body (with the cover and cleaner element
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.
Fuel System cont.
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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.
Readings less than this indicate a problem within the carburetor.
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-assembly.
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Engine Repair Cont.
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 tightened, and
the clear fuel return line still attached or blocked off, 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.
The exhaust system consists of the muffler / catalytic converter (1),
heat shield (2) and muffler gasket (1).
The muffler is a sealed, non-serviceable unit that houses the catalyst. If
the muffler is damaged or the integrity of the catalyst is in question, 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 twocycle engine, and removal is a matter of routine maintenance.
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Engine Repair Cont.
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
The cylinder is attached to the crankcase with four screws, which are
accessed from the top of the cylinder. With the screws removed, the
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.
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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. 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
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 exposed.
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 upand-down motion (B) is unacceptable. This indicates the need for a
replacement crankshaft. The connecting rod and crankshaft are one,
non-serviceable part.
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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
Make sure the brake caliper is not loose. Conversely, overtightening will not allow the wheel to turn. Full braking
action should occur with approximately one-third to twothirds throw of the brake lever.
Figure 2
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).
Figure 3
When neither of these adjustments allows an acceptable
amount of braking action, it’s 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
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.
Figure 4
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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. 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.
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 wheel. If they feel worn or do not turn freely, replace
Upon re-assembly, ensure that the three axle spacers are
properly positioned.
Figure 6
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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:
WHEEL HALVES. The hardware securing the two
wheel halves will require a 13mm socket and a 6mm
hex wrench.
Figure 7
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.
Figure 8
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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. 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
Figure 9
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.
Figure 10
With these bottom nuts removed, remove the lower
bearing and spacer. This will enable the entire downtube, 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 allow
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.
Figure 11
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.
Figure 12
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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
Throttle Cable
Figure 13
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, actuate 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.
Figure 14
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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
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. 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 ½
inch of play. Make sure that the wheel is lined up
in the center of the frame.
Figure 15
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.
Figure 16
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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.
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)
Figure 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). 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
Figure 19
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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.
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
Figure 20
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