SELVA MARINE Grey Whale 200 EFI User manual

YAMAHA MOTOR CO., LTD.
F4A/F4
Goldfish 4
Grey Whale 200 EFI
Fin Whale 225 EFI
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
–+

6AL3J11
GEN
INFO
1
2
3
4
5
6
7
8
9
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
Water separator.......................................................................................1-14
Injector.....................................................................................................1-15
ECM.........................................................................................................1-16
Propeller selection.......................................................................................1-21
Propeller size...........................................................................................1-21
Selection..................................................................................................1-21
Predelivery check ........................................................................................1-22
Checking the fuel system ........................................................................1-22
Checking the engine oil level...................................................................1-22
Checking the gear oil level ......................................................................1-22
Checking the battery................................................................................1-22
Checking the outboard motor mounting height........................................1-23
Checking the remote control cable..........................................................1-23
Checking the steering system .................................................................1-24
Checking the gear shift and throttle operation.........................................1-24
Checking the PTT system .......................................................................1-24
Checking the engine start switch and engine stop lanyard switch ..........1-24
Checking the cooling water pilot hole......................................................1-25
Test run ...................................................................................................1-25
Break-in...................................................................................................1-25
After test run............................................................................................1-25

GEN
INFO General information
1-1 6AL3J11
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.”
5
2
3
41

6AL3J11 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 or illustration indicate the grade of lubricant and the lubri-
cation 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 or illustration indicate the type of sealant or locking agent
and the application 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 6AL3J11
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
LAN Local Area Network
PCV Pressure Control Valve
PORT Port side
PTT Power Trim and Tilt
SAE Society of Automotive Engineers
STBD Starboard side
TCI Transistor controlled ignition
TDC Top Dead Center
TPS Throttle Position Sensor
UP Upside
Ver. Version
WD Wiring diagram
YDIS Diagnostic System

6AL3J11 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 6AL3J11
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.

6AL3J11 1-6
1
2
3
4
5
6
7
8
9
Identification 1
Model
This manual covers the following models.
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
F200CET, FL200CET,
F225BET, FL225BET
Model name Approved
model code Starting serial No.
200 R 6AL 1000001–
200 L 6AM 1000001–
225 R 6AS 1000001–
225 L 6AT 1000001–
Safety while working / Identification

GEN
INFO General information
1-7 6AL3J11
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

6AL3J11 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 6AL3J11
Needle bearing attachment
90890-06607, 90890-06610, 90890-06611,
90890-06612, 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

6AL3J11 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 6AL3J11
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

6AL3J11 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
Selva diagnostic system
60V-85300-05-00
Special service tool

GEN
INFO General information
1-13 6AL3J11
Selva diagnostic system (Ver. 1.32)
60V-WS853-05
Diagnostic flash indicator B
90890-06865

6AL3J11 1-14
1
2
3
4
5
6
7
8
9
Feature and benefit 1
Water separator
For the 2007 models, a fuel filter assembly with a water detection switch has been adopted on the
fuel line as a system to improve engine protection.
The water detection warnings are given only if the fuel filter assembly with a water detection switch
is connected to the 6Y8 Multifunction Meter.
The 6Y8 Multifunction Meter is a meter designed to be used in a local area network (LAN).
1Float (red)
2Water detection switch (black)
32-pin coupler (blue)
ÈIn
ÉOut
When the water detection switch is on, the water detection warnings are given according to the con-
ditions as listed in the following table.
Warning condition table
S6AL1060
3
1
ÉÈ
ÉÈ 2
2006 model F(L)250A
P/N: 6P2-24409-00
Water accumulation capacity: 55 ml
Fuel filter: 40 µm (Paper, Yellow)
2007 model F(L)200C, F(L)225B, F(L)250A
P/N: 6P2-24409-10
Water accumulation capacity: 30 ml
Fuel filter: 10 µm (Paper, Green)
Interchangeability
The new and previous parts are not interchangeable.
Previous parts →previous engine
New parts →new engine
Shift position Buzzer Indicator
Neutral Yes Yes
Forward/Reverse No Yes
Special service tool / Feature and benefit

GEN
INFO General information
1-15 6AL3J11
Injector
The injector for the 2007 models was improved in order to reduce the amount of soot after combus-
tion compared to the injector used for the 2006 model F(L)250A.
Due to the change in the injector spray angle, the ECM fuel injection mapping was also changed.
Therefore, be sure to use the 2007 model injector together with the 2007 model ECMs.
Identification table
Injector body color
2006 model 2007 model
Light gray Violet
6P2-13761-00 6P2-13761-10
Interchangeability
The new and previous parts are not interchangeable.
Previous parts →previous engine
New parts →new engine
S6AL1070
28˚ 28˚
8.5˚
2006 model F(L)250A 2007 model F(L)200C,
F(L)225B, F(L)250A