SELVA MARINE Wahoo 15 User manual

YAMAHA MOTOR CO., LTD.
F4A/F4
Goldfish 4
Wahoo 15
Wahoo 20
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
–+

6AG3J11
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
Sealant and locking agent table ................................................................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
Propeller selection.......................................................................................1-12
Propeller size...........................................................................................1-12
Selection..................................................................................................1-12
Predelivery check ........................................................................................1-12
Checking the outboard motor mounting height........................................1-13
Removing the intake silencer protective covering...................................1-13
Checking the fuel system ........................................................................1-13
Checking the engine oil level...................................................................1-13
Checking the gear oil level ......................................................................1-14
Checking the battery (electric starter model)...........................................1-14
Setting the remote control cable (remote control model).........................1-14
Checking the gear shift and throttle operation.........................................1-15
Checking the steering system .................................................................1-16
Checking the tilt system (manual tilt model)............................................1-17
Checking the power tilt system (power tilt model)...................................1-17
Checking the engine start button or switch and engine stop lanyard
switch.....................................................................................................1-18
Checking the cooling water pilot hole......................................................1-18
Test run ...................................................................................................1-19
Break-in...................................................................................................1-19
After test run............................................................................................1-19
Precaution when transporting or storing the outboard motor ..................1-19

GEN
INFO General information
1-1 6AG3J11
How to use this manual 1
Manual format 1
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

6AG3J11 1-2
1
2
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5
6
7
8
9
Symbol 1
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 (Yamaha grease A)
0Apply molybdenum disulfide grease
AApply corrosion resistant grease
(Yamaha grease D)
BApply low temperature resistant grease
(Yamaha grease C)
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 silicone 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 6AG3J11
Abbreviation 1
The following abbreviations are used in this service manual.
Sealant and locking agent table 1
The following table contains sealants, locking agents, and greases used in this service manual that
are not listed on page 1-2.
Abbreviation Description
API American Petroleum Institute
BOW Bow end
CCA Cold Cranking Ampere
CDI Capacitor Discharge Ignition
EN European Norm (European standard)
EX Exhaust
IEC International Electrotechnical Commission
IN Intake
PORT Port side
SAE Society of Automotive Engineers
STBD Starboard side
TDC Top Dead Center
WD Wiring Diagram
Symbol Name Application Manufacturer
LOCTITE 518 Sealant Henkel
S518

6AG3J11 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 1
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Ventilation 1
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 1
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 1
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. Avoid contact with skin. Do not, for
example, place a soiled rag in your
pocket.
2. 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.
3. Change and wash clothing as soon as
possible if soiled with lubricants.
4. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
5. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
How to use this manual / Safety while working

GEN
INFO General information
1-5 6AG3J11
6. Maintain good standards of personal and
industrial hygiene.
Good working practice 1
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
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.

6AG3J11 1-6
1
2
3
4
5
6
7
8
9
Identification 1
Model 1
This manual covers the following models.


Serial number 1
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
ÈManual tilt model
ÉPower tilt model
1Model name
2Approved model code
3Transom height
4Serial number
Applicable model
:DKRR
:DKRR
S6AG1010
È
S6AG1020
É
Model name Approved
model code Starting serial No.
1AG000001–
20 6AH 1000001–
Safety while working / Identification

GEN
INFO General information
1-7 6AG3J11
Special service tool 1
Oil filter wrench
90890-01426
Digital tachometer
90890-06760
Timing light
90890-03141
Leakage tester
90890-06840
Vacuum/pressure pump gauge set
90890-06756
Pilot screw adjusting tool
90890-03154
Compression gauge
90890-03160
Flywheel holder
90890-06522
Flywheel puller
90890-06521
Shaft holder
90890-06069

6AG3J11 1-8
1
2
3
4
5
6
7
8
9
Valve spring compressor
90890-04019
Valve spring compressor attachment
90890-06320
Valve guide remover/installer
90890-06801
Valve guide reamer
90890-06804
Valve seat cutter holder
90890-06316
Valve seat cutter
90890-06312, 90890-06315, 90890-06323,
90890-06555, 90890-06818, 90890-06819
Needle bearing attachment
90890-06612, 90890-06613, 90890-06614,
90890-06616, 90890-06653
Driver rod L3
90890-06652
Piston slider
90890-06529
Stopper guide plate
90890-06501
Special service tool

GEN
INFO General information
1-9 6AG3J11
Center bolt
90890-06504
Bearing housing puller claw S
90890-06564
Bearing puller assembly
90890-06535
Stopper guide stand
90890-06538
Driver rod SS
90890-06604
Driver rod LS
90890-06606
Ball bearing attachment
90890-06632
Drive shaft holder 1
90890-06515
Bushing attachment
90890-06649
Bearing separator
90890-06534

6AG3J11 1-10
1
2
3
4
5
6
7
8
9
Needle bearing attachment
90890-06617, 90890-06618
Bearing outer race attachment
90890-06625
Driver rod LL
90890-06605
Driver rod SL
90890-06602
Bearing depth plate
90890-06603
Bearing inner race attachment
90890-06644
Shimming plate
90890-06701
Digital caliper
90890-06704
Backlash indicator
90890-06706
Magnet base plate
90890-07003
Special service tool

GEN
INFO General information
1-11 6AG3J11
Dial gauge set
90890-01252
Magnet base B
90890-06844
Power tilt wrench
90890-06560
Digital circuit tester
90890-03174
Peak voltage adapter B
90890-03172
Ignition tester
90890-06754

6AG3J11 1-12
1
2
3
4
5
6
7
8
9
Propeller selection 1
The performance of a boat and outboard
motor will be critically affected by the size
and type of propeller you choose. Propellers
greatly affect boat speed, acceleration,
engine life, fuel economy, and even boating
and steering capabilities. An incorrect choice
could adversely affect performance and
could also seriously damage the engine.
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and the outboard
motor.
Propeller size 1
The size of the propeller is indicated on a
propeller blade, on the propeller boss end,
and on the side of the propeller boss.
aPropeller diameter (in inches)
bPropeller pitch (in inches)
cPropeller type (propeller mark)
Selection 1
When the engine speed is at the full throttle
operating range (5,000–6,000 r/min), the
ideal propeller for the boat is one that pro-
vides maximum performance in relation to
boat speed and fuel consumption.
Predelivery check 1
To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below.
S69W1030
× -
abc
S69W1040
× -
abc
S69W1050
× -
abc
Propeller size (in) Material
9 1/4 ×9 3/4 - J
Aluminum
9 1/4 ×10 1/2 - J
9 1/4 ×12 - J
9 1/4 ×9 - J1
9 1/4 ×10 - J1
9 1/4 ×11 - J1
9 1/4 ×12 - J1
Special service tool / Propeller selection / Predelivery check

GEN
INFO General information
1-13 6AG3J11
Checking the outboard motor
mounting height 1
1. Check that the anti-cavitation plate is
between the bottom of the boat and a
maximum of 25 mm (1 in) abelow it. If
the mounting height is too high, cavita-
tion will occur and propulsion will be
reduced. Also, the engine speed will
increase abnormally and cause the
engine to overheat. If the mounting
height is too low, water resistance will
increase and reduce engine efficiency.
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at differ-
ent heights.
2. Check that the clamp brackets are
secured with the clamp bolts.
Removing the intake silencer
protective covering 1
1. Remove the protective covering 1from
the intake silencer.
CAUTION:
A protective covering 1is installed on
the intake silencer when the outboard
motor is shipped from the factory and
must be removed before starting the
engine for the first time.
Checking the fuel system 1
1. Check that the fuel hoses are securely
connected and that the fuel tank is full
with fuel.
CAUTION:
This is a 4-stroke engine. Never use pre-
mixed fuel or 2-stroke outboard motor oil.
Checking the engine oil level 1
1. Check the engine oil level.
S6D51030
a
S6AG1030
1
S6AG1040
S6AG1050
b
a

6AG3J11 1-14
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3
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5
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9
NOTE:
If the engine oil is below the minimum level
mark a, add sufficient oil until the level is
between aand b.
Checking the gear oil level 1
1. Check the gear oil level.
NOTE:
If the oil is at the correct level, a small
amount of oil should overflow out of the
check hole when the gear oil check screw is
removed.
Checking the battery (electric starter
model) 1
1. Check the battery capacity, electrolyte
level, and specific gravity of the electro-
lyte.
2. Check that the positive and negative bat-
tery cables are securely connected.
Setting the remote control cable
(remote control model) 1
NOTE:
To adjust the throttle cable and shift cable,
see “Adjusting the throttle cable (remote con-
trol model)”(3-8) or “Checking the gear shift
operation (remote control model)”(3-10).
1. Set the remote control lever to the neu-
tral position and the throttle lever to the
fully closed position.
2. Check that the fully closed stopper aon
the throttle cam contacts the throttle cam
bracket 1. Connect the throttle cable 2
to the throttle cam 3and install the clip
4.
NOTE:
Pull the throttle cable 2toward the engine to
remove any free play in the cable before con-
necting the throttle cable joint.
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, SJ, or SL
SAE: 5W-30, 10W-30, or 10W-40
Engine oil quantity:
Without oil filter replacement:
1.6 L (1.69 US qt, 1.41 Imp qt)
Recommended battery capacity:
CCA/EN: 347.0 A
20HR/IEC: 40.0 Ah
Electrolyte specific gravity:
1.280 at 20 °C (68 °F)
S6AG1060
S6AG1070
1
a
342
Predelivery check

GEN
INFO General information
1-15 6AG3J11
3. Check that the shift rod lever joint 5is in
the neutral position as shown. Connect
the shift cable 6to the shift rod lever
joint 5and install the clip 7.
WARNING
The shift/throttle cable joint must be
screwed in a minimum of 8.0 mm (0.31 in)
b.
Checking the gear shift and throttle
operation 1
1. Check that the throttle operates smoothly
when the throttle grip is turned from the
fully closed position to the fully open
position a. (Tiller handle model)
Check that the throttle operates smoothly
when the remote control lever is shifted
from forward or reverse to the fully open
position a. (Remote control model)
2. Check that the gear shift operates
smoothly when the shift lever or remote
control lever is shifted from the neutral
position to forward or reverse.
ÈTiller handle model
ÉRemote control model
NOTE:
•The shift lever cannot be operated unless
the throttle grip is in the fully closed posi-
tion. (Tiller handle model)
•The resistance of the throttle grip (tiller han-
dle model) or remote control lever (remote
control model) can be adjusted using the
throttle friction adjuster 1.
3. Check that the shift lever cannot be set to
the forward or reverse position when the
grip is not in the fully closed position.
(Tiller handle model)
S6AG1080
5
FR
76
5N
76
S6AG1090
b
S6AG1120
N
Fa
1
R
È
S6AG1280
FNR
a
a
1
É
S6AG1125
N
F
R