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TOHATSU
Outboard Motor
BFT250A
Page 358 (Component Location)
TOHATSU BFT250A - Component Location
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Manual
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ENGINE REMOVA
L/INSTALLATION
ENGINE REMOVAL
/INSTALLATION
COMPONENT LOCATION
75 N·m (7.6 kgf·m, 55
lbf·ft)
44 N·m (4.5 kgf·m,
32 lbf·ft)
44 N·m (4.5 kgf·m, 3
2 lbf·ft)
44 N·m (4.5 kgf·m,
32 lbf·ft)
75 N·m (7.6 kgf·m, 55 lbf·ft)
357
359
Table of Contents
Main Page
Table of Contents
7
General Information
11
Specifications
12
Lower Unit
13
Service Information
17
Maintenance
18
Standard Torque Values
23
Special Tools
24
3. Maintenance
59
Maintenance Schedule
60
Tools
61
Change
62
Engine Oil Level Inspection/Oil
62
Engine Oil Filter Replacement
64
Gear Case Oil Change
65
Timing Belt Inspection
66
Alternator Belt Inspection
67
Adjustment
69
Throttle Linkage Inspection
69
Valve Clearance
73
Spark Plug Inspection
75
Gear Case
77
Inspection
77
Propeller and Cotter Pin
77
Lubrication
83
Fuel Filter (Low Pressure Side) Inspection/Replacement
85
Water Separator Inspection
85
Fuel Filter (High Pressure Side) Inspection/Replacement
87
Fuel Line Inspection
88
Replacement
88
Battery and Cable Connection
89
Crankcase Breather
89
Nuts, Bolts, Fasteners
89
Impeller Housing Inspection
90
Water Passage Cleaning
90
Water Pump Inspection
90
Adjustment
91
Emergency Stop Switch
91
Inspection
91
Power Trim/Tilt Inspection
91
Shift Control Cable Inspection
91
Troubleshooting
93
5. Fuel System
123
Tools
124
Service Precautions
125
System Location
131
Piping Connections
132
Circuit Diagram
133
Ecm Terminal Arrangement
135
Dtc Troubleshooting
137
Mil Troubleshooting
167
Fuel Pressure Relieving
188
Installation
191
Cleaning
194
Installation
194
Intake Manifold Removal
194
Fuel Injectors/Fuel Pressure Regulator
200
Fuel Pump (High Pressure Side)/Vapor Separator Removal/Installation
208
Air Vent Strainer/Air Vent Tube Removal
214
Water Separator/Water Level Sensor Removal/Installation/Cleaning
215
Exhaust Manifold Removal
217
Installation
217
Exhaust Manifold Anode Removal
219
Iat Sensor Removal/Installation
220
Installation
220
Map Sensor Removal/Installation
220
Emt Sensor Removal/Installation
221
Iac Valve Removal/Installation
221
Ho2S Removal/Installation
222
Installation
223
Vtec Solenoid Valve Removal
223
Ckp Sensor Removal/Installation
224
Fuel System
224
Iab Control Solenoid Valve Removal
224
Installation
224
Cmp Sensor Removal/Installation
225
Eop Switch (High Pressure Side) Removal
225
Installation
225
Eop Switch (Low Pressure Side) Removal
226
Installation
226
Knock Sensor Removal
226
Ebt Sensor Removal/Installation
227
Installation
227
Fuel Pump (High Pressure Side)/Fuel Filter Disassembly/Assembly
228
Assembly
231
Vapor Separator Disassembly
231
Fuel Pressure Measurement
232
Fuel Pressure Regulator
233
Inspection
233
Fuel Pump (Low Pressure Side)
234
Inspection
234
Fuel Pump (High Pressure Side)
235
Inspection
235
Vapor Separator Inspection
237
Fuel Injector Inspection
238
Throttle Body Inspection
239
Iab Control Solenoid Valve
240
Inspection
240
Eop Switch (High Pressure Side)
242
Inspection
242
Eop Switch (Low Pressure Side)
243
Inspection
243
Ebt/Emt Sensor Inspection
244
Ckp Sensor Inspection
245
Cmp Sensor Inspection
245
Water Level Sensor Inspection
246
Iac Valve Inspection
247
Inspection
247
Vtec Spool Solenoid Valve
247
Ho2S Inspection
248
Intake Manifold Stud Bolt
249
Replacement
249
6. Engine Cover/Cover Lock
251
Engine Cover/Cover Lock
251
Component Location
252
Front Separate Cover Removal
253
Installation
253
L./R. Engine under Cover Removal
253
Installation
256
Cover Locking Cable Removal
256
Installation
259
Engine Cover Bracket Removal
259
Installation
260
Power Tilt Switch Removal
260
Front Cover Bracket Removal
260
Damper Hook Removal
262
Installation
262
Side Cover Bracket Disassembly
262
Assembly
265
Damper Hook Disassembly
265
Damper Hook Adjustment
266
Under Cover Seal B
266
Replacement
266
7. Charging System
267
Charging System
267
System Location
268
System Diagram
268
Junction Box
268
Tools
269
Alternator Removal
271
Installation
271
Alternator Disassembly
272
Assembly
272
Alternator Inspection
281
Ignition System
283
9. Starting System
287
Starting System
288
System Diagram
288
System Location
288
Installation
291
Starter Motor Removal
291
Assembly
292
Installation
292
Neutral Switch Removal
292
Starter Motor Disassembly
292
Starter Motor Inspection
302
Neutral Switch Inspection
306
10. Other Electrical
307
Other Electrical
307
System Location
308
Installation
310
Electric Parts Case Removal
310
Installation
311
Ecm Removal/Installation
311
Ecm Bracket Removal
311
Installation
312
Power Tilt Relay/Power Tilt Relay Case Removal/Installation
312
Switch Panel Indicator Wire
314
Harnesses Removal
314
Installation
314
Relay Removal/Installation
316
Main/Starter Relay Inspection
317
Fuel Pump Relay Inspection
317
Fuse/Relay Junction Box
318
Inspection
318
Power Tilt Relay Inspection
320
Trim Angle Sensor Inspection
321
11. Cooling System
323
Cooling System
323
Component Location
324
Tools
325
Water Line Description
326
Thermostat Removal
327
Installation
327
Water Jacket Removal
328
Installation
328
Water Pump Removal
331
Installation
331
Cylinder Sleeve Water Jacket Anode Removal/Installation
337
Relief Valve Disassembly
339
Assembly
339
Flush Valve Disassembly
340
Assembly
340
Thermostat Inspection
341
12. Lubrication System
343
Lubrication System
343
Component Location
344
Lubrication System Diagram
345
Tools
346
Oil Filler Extension Removal
347
Installation
347
Oil Level Gauge Cover Removal
347
Removal/Installation
347
Oil Pump Removal/Installation
351
Assembly
353
Oil Pressure Test
354
Oil Pump Inspection
355
13. Engine Removal/Installation
357
Engine Removal/Installation
357
Component Location
358
Engine Removal
360
Tool
361
Cylinder Head
361
Engine Installation
362
14. Cylinder Head
369
Component Location
370
Tools
372
Timing Belt Drive/Driven Pulley Removal/Installation
374
Cylinder Block
382
Cylinder Head Cover Removal
387
Installation
387
Cylinder Head Removal
390
Installation
390
Cylinder Head Disassembly
393
Assembly
393
Assembly
396
Cylinder Compression Test
401
Cylinder Head Inspection
401
Valve Guide Replacement
410
Valve Seat Reconditioning
412
15. Cylinder Block
415
Component Location
416
Tools
417
Cylinder Block Anode Removal
418
Flywheel Removal/Installation
418
Installation
418
Flywheel Inspection
440
Bearing Selection
450
16. Gear Case (Standard Rotation)
455
Gear Case (Standard Rotation)
455
Component Location
456
Tools
474
Gear Case (Counter Rotation)
505
Propeller Removal
509
Installation
509
Mount
513
GEAR CASE/EXTENSION SEPARATOR (XXA Type) REMOVAL/INSTALLATION
516
INSTALLATION (XA and XXA Types)
516
Installation
529
Vertical Shaft/Removal
529
Installation
532
Assembly
534
Propeller Shaft Holder
534
Disassembly/Assembly
534
Vertical Shaft Disassembly
535
Assembly
535
Shim Selection
538
Backlash Inspection
544
Clutch Shifter Inspection
547
Propeller Shaft Inspection
548
Vertical Shaft Inspection
548
Vertical Shaft Bush Inspection
549
Gear Case Stud Bolt Replacement
549
Extension Separator Stud Bolt
550
REPLACEMENT (XXA Type)
550
Gear Case Needle Bearing
550
19. Trim/Tilt
563
Trim/Tilt
563
Atf Line Description
565
Swivel Case/Mount Frame Disassembly/Assembly
573
Power Trim/Tilt Disassembly
581
Air Bleeding
593
Power Tilt Motor Disassembly
598
Power Tilt Motor Inspection
603
Power Tilt Switch Inspection
605
Controls
607
Throttle Control Cable
612
Technical Features
621
Wiring Diagrams
625
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