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Illustr ated P ar ts Man ual Illustra Par arts Manual Model Number: P/N 31641 Rev 000 Date 4-1-03 TPB-400GX 40cc PowerBoard Supplier To The Outdoor Power Equipment Industry ISM, Inc. • 1028 4 Street SW • Auburn, WA 98001 • Phone: (253) 333-1200 • Fax: (253) 333-1212 th www.tanaka-usa.com [email protected] PARTS INFORMATION TPB-400GX HANDLE & CONTROLS • FIGURE 1 ITEM 1-1 1-2 1-2-1 1-2-2 1-2-3 1-2-4 1-3 1-3-1 1-3-4 1-4 1-25 1-87 1-111 1-119 1-120 1-121 1-122 1-123 1-124 PART NUMBER DESCRIPTION 31552 HANDLEBAR,RACING 30799 THROTTLE LEVER ASSY 31503 BOLT,M6xP1.0x13 31504 WASHER 31228 CABLE,THROTTLE 31505 NUT,M6 30801 LEVER,BRAKE 31229 CABLE,BRAKE 31506 SPRING,LEVER 30798 GRIP,HANDLE 31658 NUT 30806 SWITCH,BUTTON 30938 COVER,STOP BUTTON 31563 BOLT,M6xP1.0x20 31564 STEERING STEM CAP 31565 STEERING STEM 31566 BOLT,M6xP1.0x15 31567 BOLT,M6xP1.0x42 31568 STEERING PIPE www.tanaka-usa.com QTY 1 1 2 2 1 2 1 1 2 2 2 1 1 4 1 1 1 2 1 Page 1 COMMENTS [email protected] PARTS INFORMATION TPB-400GX HEAD PIPE & FOLDING HANDLE • FIGURE 2 ITEM 2-6 2-8 2-14 2-25 2-26 2-27 2-31 2-32 2-33 2-35 2-110 2-115 2-118 2-128 PART NUMBER DESCRIPTION 30845 SPACER,FRONT HANDLE 31681 TUBE,HEAD (BLUE) 30821 NUT,M8xP1.25 30936 NUT,M6xP1.0 30870 GRIP,FOLDING HANDLE 31682 HANDLE,FOLDING,(BLUE) 30862 RING,E 30863 PIN,HEAD TUBE 30868 BOLT 30864 WASHER 31078 SPACER,T-937 31663 BOLT 31664 PAD,CUSHION 31662 SPRING,FOLDING HANDLE www.tanaka-usa.com Page 2 QTY 1 1 1 3 1 1 2 1 3 2 2 1 2 1 COMMENTS [email protected] PARTS INFORMATION TPB-400GX FRONT BRAKE • FIGURE 3 ITEM 3-12 3-13 3-16 3-17 3-18 3-19 3-20 3-23 3-24 3-25 PART NUMBER DESCRIPTION 30851 KIT,BRAKE ARM HDWE 30852 KIT,BRAKE CABLE RECEIVER 30855 BOLT 30859 BOLT 30854 ARM,BRAKE,(SMALL) 30856 WHEEL,BRAKE 30853 ARM,BRAKE,(LARGE) 30930 BRAKE PAD SET 30860 WASHER 30936 NUT,M6xP1.0 www.tanaka-usa.com Page 3 QTY 1 1 1 1 2 1 1 1 4 2 COMMENTS [email protected] PARTS INFORMATION TPB-400GX FRONT WHEEL & BRAKE DISK • FIGURE 4 ITEM 4-14 4-61 4-68 4-69 4-70 4-77 4-78 4-79 4-80 4-90 4-91 4-102 PART NUMBER DESCRIPTION 30821 NUT,M8xP1.25 30830 WASHER,SPRING M6 30827 SPACER,T-789 30823 TIRE,10" 30825 HUB,(WELD) 30826 BOLT,M8xP1.25x15 30828 SPACER,BRAKE,T-790 30829 DISC,BRAKE 30831 BOLT,M6xP1.0x32 30883 BEARING,6200-2RS 30822 HUB,(5 HOLES) 30911 TUBE,TIRE www.tanaka-usa.com QTY 4 4 1 1 1 4 4 1 4 2 1 1 Page 4 COMMENTS [email protected] PARTS INFORMATION TPB-400GX HEAD KIT • FIGURE 5 ITEM 5-6-1 5-127-8 5-127-9 5-127-10 PART NUMBER DESCRIPTION 31554 OCTAGON 1.25" 31580 TRIPLE CLAMP,BOTTOM 31581 TRIPLE CLAMP,TOP 31671 HEAD BEARING KIT www.tanaka-usa.com Page 5 QTY 1 1 1 1 COMMENTS [email protected] PARTS INFORMATION TPB-400GX SHOCKS & FRONT WHEEL MOUNTING HARDWARE • FIGURE 6 ITEM 6-15 6-29 6-97 6-112 6-116 6-117 6-119 6-125 6-125-1 6-126 6-127 6-127-1 6-128 PART NUMBER DESCRIPTION 31080 SPRING,S-043 30880 NUT,M10xP1.5 31082 CAP,CABLE END 31665 BRAKE WIRE CONDUIT 31667 SPACER 31666 SPACER 31668 SCREW 31569 HANDLE STEM CONNECTOR 31669 SCREW 31571 BOLT,M10xP1.5x160 31572 SHOCK,(R) 31573 SHOCK,(L) 31706 NUT,TOP,TRIPLE CLAMP www.tanaka-usa.com Page 6 QTY COMMENTS 1 1 1 1 1 1 1 1 2 1 1 Caution - Do not disassemble shocks! 1 Extreme pressure and not serviceable! 2 [email protected] PARTS INFORMATION TPB-400GX DECK, DECK TAPE & MOUNTING HARDWARE • FIGURE 7 Optional Seat Kit #31699 ITEM 7-25 7-36 7-37 7-37-1 7-129 PART NUMBER DESCRIPTION 30936 NUT,M6xP1.0 30912 SCREW,BOARD 31083 DECK,WOOD,PAVERUNNER 350 31672 DECAL,DECK,PAVERUNNER 31673 GRIP TAPE,PAVERUNNER www.tanaka-usa.com Page 7 QTY 5 12 1 1 1 COMMENTS [email protected] PARTS INFORMATION TPB-400GX FRAME, REAR BRAKE & KICK STAND • FIGURE 8 ITEM 8-10 8-14 8-25 8-38 8-39 8-40 8-81 8-82 8-83 8-84 8-88 8-89 8-92 8-100 8-104 8-105 8-106 8-107 8-118 PART NUMBER DESCRIPTION 30819 WASHER,SPRING 30821 NUT,M8xP1.25 30936 NUT,M6xP1.0 31683 FRAME,PAVERUNNER,BLUE 30817 PEDAL,REAR BRAKE 30816 BOLT,K-236 30812 STAND,KICK 30810 BOLT,M5xP0.8x15 30936 NUT,M6xP1.0 30809 NUT,M5xP0.8 30818 WASHER 30813 WASHER 30811 SPRING,KICK STAND 30815 WASHER,RUBBER 31087 CAP,FLAT 30810 BOLT,M5xP0.8x15 31675 BOLT 31676 WASHER 31664 PAD,CUSHION www.tanaka-usa.com Page 8 QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 14 1 1 1 2 1 COMMENTS [email protected] PARTS INFORMATION TPB-400GX BELTS, FENDER & MOUNTING RING • FIGURE 9 Belt Adjustment / Replacement Procedures ITEM 9-29 9-41 9-41 9-41 9-43 9-45 9-47 9-48 9-49 9-52 9-55 9-56 9-57 9-60 9-61 9-62 9-63 9-63-1 9-64 9-65 9-73 9-93 PART NUMBER 30880 TC-355 PF-4000 TC-4700 30917 31150 30834 31091 31383 31092 30923 31093 30915 31094 30830 31095 31096 31677 31097 31684 30921 30959 www.tanaka-usa.com DESCRIPTION NUT,M10xP1.5 Complete Replacement Engine,35cc Complete Replacement Engine,40cc Complete Replacement Engine,47cc 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 QTY 1 1 1 1 3 1 2 1 1 2 1 1 1 1 7 2 2 1 3 1 1 1 COMMENTS [email protected] PARTS INFORMATION TPB-400GX REAR WHEEL & REAR DRIVE PULLEY • FIGURE 10 ITEM 10-14 10-24 10-29 10-46 10-61 10-66 10-66-1 10-66-2 10-67 10-68 10-69 10-70 10-72 10-74 10-75 10-76 10-77 10-90 10-91 10-102 10-103 PART NUMBER DESCRIPTION 30821 NUT,M8xP1.25 31100 WASHER 30880 NUT,M10xP1.5 30891 BOLT,AXLE 10x145 30830 WASHER,SPRING M6 30881 SCREW,REAR AXLE TENSION 31679 BASE,ADJUSTER 31680 NUT,ADJUSTER 30886 SPACER,REAR WHEEL,(L) 30884 SPACER 30823 TIRE,10" 30825 HUB,(WELD) 30887 PULLEY,REAR DRIVE 30888 GUARD,BELT 30889 BOLT,6x20 30890 SCREW 30826 BOLT,M8xP1.25x15 30883 BEARING,6200-2RS 30822 HUB,(5 HOLES) 30911 TUBE,TIRE 30882 SPACER,REAR WHEEL (R) www.tanaka-usa.com Page 10 QTY 4 4 1 1 4 2 1 1 1 1 1 1 1 1 4 4 4 2 1 1 1 COMMENTS [email protected] PARTS INFORMATION TPB-400GX SPROCKET & DRIVE SHAFT • FIGURE 11 ITEM 11-47 11-50 11-54 11-59 PART NUMBER DESCRIPTION 30834 BEARING,6000-2RS 30832 SHAFT,T-796 30835 GEAR,LARGE 30833 RING,C www.tanaka-usa.com Page 11 QTY 2 1 1 4 COMMENTS [email protected] PARTS INFORMATION TPB-400GX CLUTCH DRUM & MOUNTING RING • FIGURE 12 ITEM PART NUMBER 12-42 30836 12-44 30839 12-51 30838 12-53 30840 12-58 30842 12-59 30841 12-86 30837 12-93 30959 12-96 30834 12-100 30844 www.tanaka-usa.com DESCRIPTION DRUM,CLUTCH BOLT,M5xP0.8x5 SHAFT,CLUTCH SPROCKET,(SMALL) HOLDER,BEARING RING,C PLATE,MOUNTING MOUNTING RING BEARING,6000-2RS WASHER,RUBBER Page 12 QTY 1 1 1 1 1 1 1 1 2 4 COMMENTS [email protected] PARTS INFORMATION PF- 4000 CYLINDER, PISTON, IGNITION • FIGURE 1 ITEM 1-5 1-6 1-8 1-11 1-12 1-14 1-15 1-16 1-17 1-18 1-21 1-22 1-31 1-44 1-45 1-46 1-50 1-56 1-56 1-59 1-63 PART NUMBER 25504200200 15711666900 01804075200 0010440590 99461050204 0170440020 04104050200 0300440090 0370100020 03905004200 0460440080 99962101004 06802000200 56020517200 1782054320 1672054390 1790007080 99011040182 99416040183 1820186A201 19805015800 www.tanaka-usa.com DESCRIPTION COVER,SPARK PLUG,RUBBER CAP,SPARK PLUG ASS'Y PLUG,SPARK SET,CYLINDER BOLT,HEX,HOLE,5X20,S GASKET,CYLINDER RING,PISTON SET,PISTON PIN,PISTON CIRCLIP,PISTON PIN CRANKSHAFT BEARING,NEEDLE,F1010B KEY,WOODRUFF,3X13X5 CAP,RUBBER CORD,HIGH TENSION ASSY,IGNITION COIL STOP CORD,220MM SCREW,4X18 SCREW 4X18/WS WASHER,SPECIAL CLAMP,CORD Page 13 QTY COMMENTS 1 1 1 1 4 1 2 1 1 2 1 1 1 1 1 1 2 2 Before S/N U112140 2 S/N U112141 and after 2 1 [email protected] PARTS INFORMATION PF- 4000 CRANKCASE, FLYWHEEL, STARTER PULLEY • FIGURE 2 www.tanaka-usa.com Page 14 [email protected] PARTS INFORMATION PF- 4000 CRANKCASE, FLYWHEEL, STARTER PULLEY • FIGURE 2 ITEM 2-9 2-19 2-20 2-23 2-24 2-25 2-26 2-26 2-27 2-28 2-29 2-32 2-32 2-32 2-32 2-32 2-36 2-51 2-52 2-54 2-55 2-60 2-66 2-66 2-67 2-69 PART NUMBER 99463050204 7880162V20 99355050000 99111100013 7900162V200 7980422090 0720440090 0720440091 0900440020 99966152511 99961620200 07102007200 07102007210 07102007220 07111600230 07111600240 99461050304 1552053880 99201100011 99101100011 99414050101 1320440020 1120440021 1120441321 99461050204 20311660200 DESCRIPTION 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,#VE15X25X7 BEARING,BALL,#6202 SHIM,15.2X20X.05 SHIM,15.2X20X.10 SHIM,15.2X20X.15 SHIM,16X21X.20 SHIM,16X21X.30 BOLT,HEX,5X30S ROTOR,MAGNETO WASHER,10 NUT,10 SCREW,S,5X10 DEFLECTOR,AIR CASE,FAN (ORANGE) CASE,FAN (POLISHED) BOLT,HEX,HOLE,5X20,S GROMMET,PRIMARY CORD www.tanakapowerequipment.com QTY 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 Page 15 COMMENTS 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 [email protected] PARTS INFORMATION PF- 4000 MUFFLER, MUFFLER COVER • FIGURE 3 86 ITEM 3-1 3-3 3-4 3-5 3-6 3-7 3-8 3-8 3-10 3-11 3-13 3-14 3-16 3-23 3-23 3-24 3-25 3-26 3-81 3-82 3-83 3-84 3-85 3-86 PART NUMBER 7380440A21 99461050124 99461050164 99053060653 99201060011 7040440090 99201050061 99201050061 7210440020 99434040081 7320440020 73704230200 1330440020 99463050204 99463050204 2030604A202 99461050254 99201050061 35910112203 2900420081 34204200200 99204100030 35704201200 30790 www.tanaka-usa.com DESCRIPTION PROTECTOR,MUFFLER BOLT,HEX,5X12S BOLT,HEX,5X16,S SCREW,HEX,6X65 WASHER,6 SET,MUFFLER WASHER,5 WASHER,5 PIPE,TAIL SCREW,4X8/S ARRESTER,SPARK 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 QTY 1 1 1 2 2 1 2 1 1 1 1 1 1 4 2 1 2 2 2 2 1 2 2 1 Page 16 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 [email protected] PARTS INFORMATION PF- 4000 FUEL SYSTEM, AIR FILTER • FIGURE 4 www.tanakapowerequipment.com Page 17 [email protected] PARTS INFORMATION PF- 4000 FUEL SYSTEM, AIR FILTER • FIGURE 4 ITEM 4-31 4-32 4-33 4-34 4-35 4-36 4-37 4-38 4-39 4-40 4-41 4-42 4-43 4-44 4-45 4-46 4-49 4-62 4-63 4-64 4-65 4-66 4-66 4-68 4-70 4-73 4-74 4-75 4-76 4-76 4-77 4-78 4-79 4-80 4-86 4-87 4-88 PART NUMBER 4030430020 4040430090 4020430020 4530637C200 4700138020 4230138082 5280138021 47601700200 4460138020 99204080030 4520138091 3800637C200 99011050602 99210050012 4550440090 78600601200 99416050253 6490168020 22301251901 68000731201 67501630900 5910440021 5910441321 6590430020 5950656B90 6463252L90 5650440020 5640661190 99463050204 99463050204 9400430020 70003005100 68000206200 22206300200 99461050304 99201050061 6420608A200 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 SCREW,5X60 WASHER,S,5 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 BOLT,HEX,5X30S WASHER,5 GASKET,TANK CAP www.tanakapowerequipment.com Page 18 QTY 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 2 1 1 1 1 1 1 3 1 1 1 1 3 2 1 1 1 1 1 1 1 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 [email protected] PARTS INFORMATION PF- 4000 RECOIL STARTER • FIGURE 5 ITEM 5-0 5-1 5-2 5-3 5-9 5-12 5-14 5-17 PART NUMBER 7620422090 7720422080 7690422020 7790422020 7830422020 8350422020 7850422020 8390422020 www.tanaka-usa.com DESCRIPTION STARTER,RECOIL ASS'Y BODY,RECOIL STARTER REEL,STARTER ROPE SPRING,RECOIL ROPE,STARTER CAP,HANDLE HANDLE,STARTER SCREW,SET QTY 1 1 1 1 1 1 1 1 Page 19 COMMENTS [email protected] PARTS INFORMATION PF- 4000 CARBURETOR • FIGURE 6 ITEM 6-0 6-1 6-4 6-5 6-6 6-7 6-9 6-10 6-11 6-12 6-13 6-14 6-17 6-18 6-19 6-20 6-21 6-22 6-24 6-25 6-26 PART NUMBER 4550440090 51425100200 54425164200 53925120200 5492516520 48925100200 61425137200 55025100200 5992001W44 99101060013 ~~~ ~~~ 57825007200 5752515380 ~~~ ~~~ 4762515120 5482515120 4310634C200 4422515180 44725108200 www.tanaka-usa.com DESCRIPTION SET,CARBURETOR SCREW,THROTTLE SET STAY,ADJUST,CABLE SWIVEL WASHER,THRUST RING,STOP ADJUSTER,CABLE O-RING JET,MAIN,LONG,#44 NUT,6 GASKET,PUMP DIAPHRAGM,PUMP SCREEN,INLET BODY,PUMP GASKET,DIAPHRAGM DIAPHRAGM,METERING COVER,DIAPHRAGM SCREW,SET GASKET,CLEANER PUMP,PRIMING BULB,PRIMING QTY COMMENTS 1 Includes carburetor gasket 2 1 1 1 ~ Contained in Carb Repair Kit 1 P/N 650-25124-900 1 (Not available individually) 1 1 1 1 1 1 1 1 1 1 4 1 1 1 Page 20 [email protected] Service Manual Moby XL, SE-803 Belt Adjustment The Moby PowerBoard uses a dual stage, belt driven system to transmit power to the rear wheel. Belts should be regularly inspected for adjustment. Both belts are adjusted with two procedures. Tighten both belt adjusters on either side of the frame (Fig. 15) in equal increments until the small belt has approximately ½ inch of play when measured between the pulleys. Next, loosen the rear axle lock nut, using a 17mm wrench or socket. 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 www.tanaka-usa.com 22 [email protected] 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 section. Figure 19 www.tanaka-usa.com 23 [email protected]
