TOHATSU BFT 250A, Service Manual

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SERVICE INFORMATION
*1: With a new belt installed.
*2: After running engine for five minutes.
Part Item Standard Service limit
Crankshaft Journal O.D. Main 71.976 – 72.000 (2.8337 – 2.8346) –
Pin 55.976 – 57.000 (2.2038 – 2.2441) –
Journal taper (Main/Pin) 0.005 (0.0002) Max. 0.010 (0.0004)
Journal roundness (Main/Pin) 0.005 (0.0002) Max. 0.010 (0.0004)
Crankshaft runout 0.025 (0.0010) Max. 0.030 (0.0012)
Crankshaft main bearing oil clearance 0.020 – 0.046 (0.0008 – 0.0018) 0.05 (0.002)
Crankshaft axial clearance 0.10 – 0.35 (0.004 – 0.014) 0.45 (0.018)
Camshaft Camshaft axial clearance 0.05 – 0.20 (0.002 – 0.008) 0.2 (0.01)
Camshaft runout 0.030 (0.0012) Max. 0.040 (0.0016)
Journal O.D. 42.935 – 42.950 (1.6904 – 1.6909) –
Cam height IN PRI/SEC 34.88 – 34.98 (1.3732 – 1.3772) –
MID 36.227 – 36.421 (1.4263 – 1.4339) –
EX 36.289 – 36.474 (1.4287 – 1.4360) –
Camshaft oil clearance 0.050 – 0.089 (0.0020 – 0.0035) 0.15 (0.006)
Timing belt Belt deflection
Measured with 19.6 N (2 kgf, 4.4 lbf) of
force applied to the mid point between the
left side driven pulley and idle puller B.
8.8 – 9.7 (0.35 – 0.38) –
Fuel injector Resistance 11 – 13 Ω –
Oil pump Inner rotor-to-outer rotor clearance 0.04 – 0.16 (0.002 – 0.006) 0.20 (0.008)
Outer rotor-to-oil pump body clearance 0.10 – 0.18 (0.004 – 0.007) 0.20 (0.008)
Outer rotor-to-oil body side clearance 0.02 – 0.07 (0.001 – 0.003) 0.12 (0.005)
Oil pressure 117 – 176 kPa
(1.2 – 1.8 kgf/cm 2 , 17 – 26 psi) at
650 ± 50 min -1 (rpm)
–
Fuel pump Discharge volume
(with pump operated for 2 sec.)
0.06 liter
(2.0 US oz, 2.1 Imp oz) or more
–
Fuel pressure 280 – 330 kPa
(2.9 – 3.4 kgf/cm 2 , 41 – 48 psi)
–
Vapor separator Float height 28.5 – 33.5 (1.12 – 1.32) –
Alternator Brush length 10.5 (0.41) 9.0 (0.35)
Slip ring O.D. 14.2 – 14.4 (0.56 – 0.57) 13.8 (0.54)
Belt tension
Measured between the
pulleys with belt tension
gauge.
Used belt
490 – 590 N
(50 – 60 kgf, 110 – 133 lbf)
–
New belt
880 – 980 N
(90 – 100 kgf, 198 – 220 lbf) (*1)
–
660 – 740 N
(67 – 75 kgf, 148 – 166 lbf) (*2)
–
Belt deflection
Measured with 98 N (10
kgf, 22 lbf) of force
applied to the center of
belt between the
pulleys.
Used belt 5.4 – 6.3 (0.21 – 0.25) –
New belt
3.20 – 3.40 (0.126 – 0.134) (*1) –
4.2 – 4.8 (0.17 – 0.19) (*2) –
Starter motor Brush length 12.3 (0.48) 7.0 (0.28)
Insulation depth 0.40 – 0.50 (0.016 – 0.020) 0.20 (0.008)
Commutator O.D. 29.4 (1.16) 28.8 (1.13)
Commutator runout – 0.10 (0.004)
Thermostat Begin to open 58 – 62 °C (136 – 144 °F) –
Fully open 70 °C (158 °F) –
Valve lift more than 4.3 (0.17) –
CKP sensor Resistance 1,850 – 2,450 Ω –
CMP sensor Resistance 1,850 – 2,450 Ω –
IAB control
solenoid valve
Resistance
37 – 44 Ω –
EBT sensor Resistance 40°C/104°F 1.0 – 1.3 k Ω –
100°C/212°F 0.1 – 0.2 k Ω –