SELVA MARINE Blue Whale 250 EFI User manual

YAMAHA MOTOR CO., LTD.
F4A/F4
Goldfish 4
Blue Whale 250(),
SERVICE MANUAL

NOTICE
This manual has been prepared by Selva primarily for use by Selva dealers and their trained
mechanics when performing maintenance procedures and repairs to Selva equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Selva has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Selva dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information 1
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.

Contents
General information 1
GEN
INFO
Specification 2
SPEC
Periodic check and adjustment 3
CHK
ADJ
Fuel system 4
FUEL
Power unit 5
POWR
Lower unit 6
LOWR
Bracket unit 7
BRKT
Electrical system 8
ELEC
Troubleshooting 9
TRBL
SHTG
Index
–+

GEN
INFO
6P23H11
General information
How to use this manual.................................................................................1-1
Manual format............................................................................................1-1
Symbol.......................................................................................................1-2
Abbreviation...............................................................................................1-3
Safety while working......................................................................................1-4
Fire prevention...........................................................................................1-4
Ventilation..................................................................................................1-4
Self-protection ...........................................................................................1-4
Part, lubricant, and sealant........................................................................1-4
Good working practice...............................................................................1-5
Disassembly and assembly.......................................................................1-5
Identification...................................................................................................1-6
Model.........................................................................................................1-6
Serial number............................................................................................1-6
Special service tool .......................................................................................1-7
Feature and benefit......................................................................................1-14
ECM system............................................................................................1-14
Electronic fuel injection control system....................................................1-22
Ignition timing control system..................................................................1-25
Knock control system ..............................................................................1-27
Variable camshaft timing control system.................................................1-29
Electronic throttle valve control system...................................................1-33
Engine speed control system ..................................................................1-35
Lower unit................................................................................................1-38
Propeller selection.......................................................................................1-39
Propeller size...........................................................................................1-39
Selection..................................................................................................1-39

6P23H11
1
2
3
4
5
6
7
8
9
Predelivery check ........................................................................................1-40
Checking the fuel system ........................................................................1-40
Checking the engine oil level...................................................................1-40
Checking the gear oil level ......................................................................1-40
Checking the battery................................................................................1-40
Checking the outboard motor mounting height........................................1-41
Checking the remote control cable..........................................................1-41
Checking the steering system .................................................................1-42
Checking the gear shift and throttle operation.........................................1-42
Checking the PTT system .......................................................................1-42
Checking the engine start switch and engine stop lanyard switch ..........1-42
Checking the cooling water pilot hole......................................................1-43
Test run ...................................................................................................1-43
Break-in...................................................................................................1-43
After test run............................................................................................1-43

GEN
INFO General information
1-1 6P23H11
How to use this manual 1
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
•Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1
in the figure below for an example page).
•The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2in the figure below).
•Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
lubrication point (see 3in the figure below).
•Tightening torque specifications are provided in the exploded diagrams (see 4in the figure below
for an example), and in the related detailed instructions. Some torque specifications are listed in
stages as torque figures or angles in degrees.
•Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see 5in the figure below for an example page).
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
LOWR
Lower unit
6-5
62Y5A11
Lower unit
No. Part name Q’ty Remarks
1 Lower unit 1
2 Plastic tie 1 Not reusable
3Hose 1
4 Check screw 1
5 Gasket 2 Not reusable
6 Dowel pin 2
7 Bolt 4 M10 40 mm
8 Drain screw 1
9Grommet 1
10 Bolt 1 M10 45 mm
11 Bolt 1 M8 60 mm
12 Thrust washer 1
13 Propeller 1
14 Washer 1
15 Washer 1
16 Cotter pin 1 Not reusable
17 Propeller nut 1
18 Trim tab 1
LOWR
Lower unit
6-19
62Y5A11
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
Disassembling the drive shaft
1. Install the pinion nut 1, tighten it finger
tight, and then remove the drive shaft
bearing 2using a press.
CAUTION:
•Do not press the drive shaft threads a
directly.
•Do not reuse the bearing, always
replace it with a new one.
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
2. Remove the needle bearing from the for-
ward gear.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
Bearing inner race attachment 3:
90890-06639
Bearing separator 1: 90890-06534
Stopper guide plate 2: 90890-06501
Stopper guide stand 3:
90890-06538
Bearing puller 4: 90890-06535
Bearing puller claw 1 5:
90890-06536
S62Y6740K
Drive shaft holder 4 1: 90890-06518
Pinion nut holder 2:
New: 90890-06715
Current: 90890-06505
S68S6360J
1
2
5
2
341

6P23H11 1-2
1
2
3
4
5
6
7
8
9
Symbol
The symbols below are designed to indicate the content of a chapter.
General information
Specification
Periodic check and adjustment
Fuel system
Power unit
Lower unit
Bracket unit
Electrical system
Troubleshooting
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
ELEC
TRBL
SHTG
–+
Symbols 1to 6indicate specific data.
1Special service tool
2Specified oil or fluid
3Specified engine speed
4Specified tightening torque
5Specified measurement
6Specified electrical value
(resistance, voltage, electric current)
Symbols 7to Cin an exploded diagram indicate the grade of lubricant and the lubrication point.
7Apply 4-stroke motor oil
8Apply gear oil
9Apply water resistant grease
0Apply molybdenum disulfide grease
AApply corrosion resistant grease
BApply low temperature resistant grease
CApply injector grease
Symbols Dto Iin an exploded diagram indicate the type of sealant or locking agent and the appli-
cation point.
DApply Gasket Maker
EApply ThreeBond 1104J
FApply LOCTITE 271 (red)
GApply LOCTITE 242 (blue)
HApply LOCTITE 572
IApply silicon sealant
123456
T
R
.
.
7890ABC
E G A M D C I
DEFGHI
GM
1104J
271
LT
242
LT
572
LT SS
How to use this manual

GEN
INFO General information
1-3 6P23H11
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
AFT Aft end
API American Petroleum Institute
BOW Bow end
CCA Cold Cranking Ampere
DES Dual Engine System
ECM Electronic Control Module
EN European Norm (European standard)
EX Exhaust
IEC International Electrotechnical Commission
IN Intake
PCV Pressure Control Valve
PON Pump Octane Number = (RON + Motor Octane Number)/2
PORT Port side
PTT Power Trim and Tilt
RON Research Octane Number
SAE Society of Automotive Engineers
STBD Starboard side
TDC Top Dead Center
TPS Throttle Position Sensor
UP Upside
YDIS Diagnostic System

6P23H11 1-4
1
2
3
4
5
6
7
8
9
Safety while working 1
To prevent an accident or injury and to
ensure quality service, follow the safety pro-
cedures provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where ade-
quate ventilation can be maintained.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
Part, lubricant, and sealant
Use only genuine Selva parts, lubricants,
and sealants or those recommended by
Selva, when servicing or repairing the out-
board motor.
Under normal conditions, the lubricants men-
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for
example, place a soiled rag in your
pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
How to use this manual / Safety while working

GEN
INFO General information
1-5 6P23H11
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
Good working practice
Special service tool
Use the recommended special service tools
to protect parts from damage. Use the right
tool in the right manner—do not improvise.
Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable part
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or
assembling parts.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces
of moving parts before assembly.
3. Install bearings with the manufacture
identification mark in the direction indi-
cated in the installation procedure. In
addition, be sure to lubricate the bearings
liberally.
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate nor-
mally after assembly.

6P23H11 1-6
1
2
3
4
5
6
7
8
9
Identification 1
Model
This manual covers the following model.
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
1Model name
2Approved model code
3Transom height
4Serial number
Applicable model
F250AET, FL250AET
Model name Approved
model code Starting
serial No.
250 R6P2 1003034–
250 L6P3 1000996–
Safety while working / Identification

GEN
INFO General information
1-7 6P23H11
Special service tool 1
Oil filter wrench
90890-06830
Leakage tester
90890-06840
Fuel pressure gauge adapter B
90890-06942
Fuel pressure gauge
90890-06786
Vacuum/pressure pump gauge set
90890-06756
Compression gauge
90890-03160
Compression gauge extension
90890-06563
Test harness (3 pins)
90890-06869
Flywheel holder
90890-06522
Flywheel puller
90890-06521

6P23H11 1-8
1
2
3
4
5
6
7
8
9
Sheave holder
90890-01701
Valve spring compressor
90890-04019
Valve spring compressor attachment
90890-06320
Valve guide remover/installer
90890-06801
Valve guide installer
90890-06810
Valve guide reamer
90890-06804
Valve seat cutter holder
90890-06316
Valve seat cutter
90890-06324, 90890-06325, 90890-06326,
90890-06816, 90890-06817
Bearing inner race attachment
90890-06640, 90890-06659, 90890-06661
Driver rod L3
90890-06652
Special service tool

GEN
INFO General information
1-9 6P23H11
Needle bearing attachment
90890-06607, 90890-06610, 90890-06611,
90890-06613, 90890-06653, 90890-06654
Piston ring compressor
90890-05158
Bearing housing puller claw L
90890-06502
Stopper guide plate
90890-06501
Center bolt
90890-06504
Bearing separator
90890-06534
Stopper guide stand
90890-06538
Bearing puller assembly
90890-06535
Slide hammer
90890-06531
Bearing outer race puller assembly
90890-06523

6P23H11 1-10
1
2
3
4
5
6
7
8
9
Outer race puller claw A
90890-06532
Driver rod SS
90890-06604
Bearing depth plate
90890-06603
Ball bearing attachment
90890-06656, 90890-06657
Driver rod LS
90890-06606
Bearing outer race attachment
90890-06622, 90890-06628, 90890-06658
Drive shaft holder 6
90890-06520
Pinion nut holder
90890-06715
Ball bearing attachment
90890-06655
Driver rod LL
90890-06605
Special service tool

GEN
INFO General information
1-11 6P23H11
Shift rod push arm
90890-06052
Pinion height gauge
90890-06710
Digital caliper
90890-06704
Shimming plate
90890-06701
Backlash indicator
90890-06706
Magnet base plate
90890-07003
Dial gauge set
90890-01252
Magnet base B
90890-06844
Puller head
90890-06514
Ring nut wrench
90890-06578

6P23H11 1-12
1
2
3
4
5
6
7
8
9
PTT oil pressure gauge assembly
90890-06580
Cylinder-end screw wrench
90890-06568
PTT piston vice attachment
90890-06572
Tilt rod wrench
90890-06569
Digital circuit tester
90890-03174
Peak voltage adapter B
90890-03172
Ignition tester
90890-06754
Test harness (2 pins)
90890-06867
Test harness (1 pin)
90890-06888
Diagnostic system
60V-85300-05-00
Special service tool

GEN
INFO General information
1-13 6P23H11
Diagnostic system
60V-WS853-05
Diagnostic flash indicator B
90890-06865

6P23H11 1-14
1
2
3
4
5
6
7
8
9
Feature and benefit 1
ECM system
In the engine of the Blue Whale 250, the ECM controls the fuel injection volume, ignition timing, intake
valve opening and closing timing, and the electronic throttle valve opening angle as well as the
engine speed when the engine overheats and when the engine oil pressure is low. Reliable starting,
stabilized trolling, excellent acceleration, maximum output, low fuel consumption, and low emissions
are achieved by maintaining the optimum air-fuel ration and ignition timing under various engine
conditions.
Electronic control module system diagram
S6P21110
:
:
:
High-pressure
fuel pump Vapor
separator
tank
Low-
pressure
fuel pump
Oil control valve (PORT)
Cam position sensor
(PORT IN)
Camposition
sensor
(PORT EX)
Control
signal
Cam position
sensor (STBD IN)
Oil control valve (STBD)
Variable camshaft timing control
Fuel injection control
Ignition timing control
Air
Fuel
Vapor gas
Filter Canister
Check
valve Fuel
flow
Vapor
gas flow
Fuel filter
with water
separator
Vapor shut-off
valve
Air flow
Electronicthrottle
valve assembly
TPS and
Electronicthrottle
valve motor
Accelerator position sensor
Electronic throttle valve control
Battery
ECM
Crank position sensor
Intake air pressure sensor
Oil pressure sensor
Engine temperature sensor
Intake air temperature sensor
Knock sensor
Shift cut switch
Neutral switch
Fuel injector
Special service tool / Feature and benefit

GEN
INFO General information
1-15 6P23H11
ECM component
1Crank position sensor
2Oil control valve (PORT)
3Cam position sensor (PORT IN)
4Oil control valve (STBD)
5Cam position sensor (PORT EX)
6ECM
7Cam position sensor (STBD IN)
8Knock sensor
9Fuel injector
0Vapor separator tank
AHigh-pressure fuel pump
BCheck valve
CLow-pressure fuel pump
DFilter
EIntake air temperature sensor
FEngine temperature sensor
3
5
7
E
6
8
1
F2
4
C
D
B
9
0
A
S6P21111
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