Mercury SST120, SST 120/S2000 User Manual
EPA Emissions Regulations
Outboards manufactured by Mercury Marine in the United
States are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors.
This certification is contingent on certain adjustments being
set to factory standards. For this reason, the factory procedure
for servicing the product must be strictly followed and, wherever practicable, returned to the original intent of the design.
Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine
engine repair establishment or individual.
Engines are labeled with an Emission Control Information decal as permanent evidence of EPA certification.
WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer,
birth defects or other reproductive harm.
The description and specifications contained herein were in effect at the time this manual was approved for printing. Mercury
Racing, whose policy is one of continued improvement, reserves the right to discontinue models at any time, to change
specifications, designs, methods, or procedures without notice
and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A. Litho in
U.S.A.
2000, Mercury Marine
The following are registered trademarks of Brunswick
Corporation: AutoBlend, Force, Jet-Prop, Mariner, Merc,
MerCathode, MerCruiser, Mercury, Mercury Marine, Mercury
Racing, Quicksilver, Mercury Precision Parts, RideGuide and
Thruster
90-848719000 100
SST 120 S2000
2000 Mercury Marine
–2
–1
for your purchase of one of the finest outboards available. You have
made a sound investment in boating pleasure. Your outboard has
been manufactured by Mercury Racing, a unit of Mercury Marine, the
world leader in marine technology and outboard manufacturing since
1939. These years of experience have been committed to the goal
of producing the finest quality products. This has led to Mercury Racing’s reputation for strict quality control, excellence, durability, lasting
performance and being the best at providing after-the-sale support.
Please read this manual carefully before operating your outboard.
This manual has been prepared to assist you in the operation, safe
use and care of your outboard.
All of us at Mercury Racing took pride in building your outboard and
wish you many years of happy and safe boating.
Again, thank you for your confidence in Mercury Marine.
Mercury Racing
N7480 County Road “UU”
Fond du Lac, WI 54935-9585
0
SST120
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TABLE OF CONTENTS
General Information
Boater’s Responsibilities 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating Your Outboard 4. . . . . . . . . . . . . . . . . . . . . . . .
Boat Horsepower Capacity 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Speed and High-Performance Boat Operation 5. . . . . . . .
Lanyard Stop Switch 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting People In The Water 8. . . . . . . . . . . . . . . . . . . . . . . . .
Carbon Monoxide Risk 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wave And Wake Jumping 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impact With Underwater Hazards 12. . . . . . . . . . . . . . . . . . . . . . . .
Selecting Accessories For Your Outboard 14. . . . . . . . . . . . . . . .
Safe Boating Suggestions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recording Serial Number 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications (General) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications (Torques) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Selection 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel & Oil
Gasoline Recommendations 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Recommendation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
New Engine Gasoline/Oil Break-In Mixture 22. . . . . . . . . . . . . . . .
Filling Gasoline Tank 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features & Controls
Power Trim 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Up/Down Adjustment 26. . . . . . . . . . . . . . . . . . . . . . . . .
Trim Pump Thermal Switch Operation 26. . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
Operation
Engine Break-In 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Starting Check List 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Freezing Temperatures 28. . . . . . . . . . . . . . . . . . . . .
Operating In Salt Water or Polluted Water 28. . . . . . . . . . . . . . . .
Operating at High Elevations 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Engine 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Engine 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Overheating 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance
Outboard Care 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Submerged Outboard 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Replacement Parts For Your Outboard 33. . . . . . . . . .
Inspection and Maintenance Schedule 34. . . . . . . . . . . . . . . . . . .
Fuel System 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering and Throttle Systems 37. . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Repair 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Replacement 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug Inspection 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Inspection 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Points 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Power Trim or Hydraulic Up/Down Fluid 41. . . . . . . . .
Maintenance Log
Maintenance Log 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
Storage
Storage Preparation 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting Internal Engine Components 45. . . . . . . . . . . . . . . . . .
Protecting External Outboard Components 46. . . . . . . . . . . . . . .
Gear Case 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Troubleshooting 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams
Engine Wiring Diagram
All 12v Run-24v Start 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boat Wiring Diagram
All 12v Run-24v Start 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Owner Service Assistance
Local Repair Service 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Away From Home 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts And Accessories Inquiries 52. . . . . . . . . . . . . . . . . . . . . . . . .
Service Assistance 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercury Marine Service Offices 54. . . . . . . . . . . . . . . . . . . . . . . . .
Ordering Literature
Ordering Literature 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL INFORMATION
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Boater’s Responsibilities
The boat (driver) is responsible for correct and safe operation of the
boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard.
Be sure at least one additional person on board is instructed in the
basics of starting and operating the outboard and boat handling in
case the driver is unable to operate the boat.
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Before Operating Your Outboard
Read this manual carefully. Safety and operating information that is
practiced along with using good common sense can help prevent
personal injury and product damage. If you have any questions, contact your dealer.
This manual as well as safety labels posted on the outboard use
safety alerts to draw your attention to special safety instructions that
must be followed.
WARNING
WARNING – Hazards or unsafe practices which COULD result
in severe personal injury or death.
CAUTION
CAUTION – Hazards or unsafe practices which could result in
minor injury or product or property damage.
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GENERAL INFORMATION
1
2
U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS)
XXX
MAXIMUM WEIGHT
CAPACITY
XXX
Boat Horsepower Capacity
1
Do not overpower or overload your boat. Most boats will carry a
required capacity plate indicating the maximum acceptable pow-
er and load as determined by the manufacturer following certain
federal guidelines. If in doubt, contact your dealer or the boat
manufacturer.
WARNING
Overpowering a Boat Can Cause:
• Serious injury, death, or boat damage.
• Loss of Boat Control.
• Flotation Characteristics of Boat to be Altered from Placing
Too Much Weight on Transom.
• Boat to Break Apart, Particularly Around the Transom Area.
High-Speed and High-Performance Boat
Operation
2
If you are not familiar with high-performance boat operation we
recommend that you first request an orientation/demonstration
ride with your dealer or an operator experienced with your boat/
outboard combination. Refer to the “Guide to Hi-Performance
Boat Operation” booklet included in your literature packet.
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GENERAL INFORMATION
Lanyard Stop Switch
WARNING
Should the operator fall out of the boat, the possibility of serious injury or death from being run over by the boat can be
greatly reduced by stopping the engine immediately. Always
properly connect both ends of the stop switch lanyard – to the
stop switch and the operator.
1 The purpose of a lanyard stop switch is to turn off the engine
when the operator moves far enough away from the operator’s
position (as in accidental ejection from the operator’s position) to
activate the switch. A lanyard stop switch can be installed as an
accessory – generally on the dashboard or side adjacent to the
operator’s position.
2 While activation of the lanyard stop switch will stop the engine im-
mediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut-down.
However, the boat will not complete a full circle. While the boat
is coasting, it can cause injury to anyone in the boat’s path as s eriously as the boat would when under power.
(continued on next page)
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GENERAL INFORMATION
Lanyard Stop Switch (Continued)
WARNING
Avoid serious injury or death from deceleration forces resulting from in accidental stop switch activation. The boat operator should never leave the operator’s station without first disconnecting the stop switch lanyard cord from themself.
Accidental or unintended activation of the Lanyard Stop Switch during normal operation is a possibility and could cause any, or all , of t he
following potentially hazardous situations:
1. Occupants could be thrown forward due to unexpected loss of
forward motion – a particular concern for passengers in the front
of the boat who could be ejected over the bow and possibly struck
by the gear case or propeller.
2. Loss of power and directional control in heavy seas, strong current or high winds.
3. Loss of control when docking.
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GENERAL INFORMATION
Protecting People In The Water
WHILE YOU ARE CRUISING
It is very difficult for a person standing or floating in the water to take
quick action to avoid a boat heading in his/her direction even at slow
speed.
Always slow down and exercise extreme caution any time you are
boating in an area where there might be people in the water.
WHILE BOAT IS STATIONARY
Shut of f the engine before allowing people to swim or be in the water
near your boat.
WARNING
Stop your engine immediately whenever anyone in the water
is near your boat. Serious injury to the person in the water is
likely if contacted by a rotating propeller, a moving boat, a
moving gear case, or any solid device rigidly attached to a
moving boat or gear case.
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GENERAL INFORMATION
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Courtesy of ABYC
1
a
Carbon Monoxide Risk
WARNING
Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon monoxide in sufficient
concentration can lead to unconsciousness, brain damage, or
death.
Carbon monoxide is a deadly gas that is odorless, colorless and
tasteless and is present in the exhaust fumes of all internal combustion engines.
Early symptoms of carbon monoxide poisoning which should not be
confused with seasickness or intoxication, include headache, dizziness, drowsiness, and nausea.
SUFFICIENT FRESH AIR FLOW
1 Example of desired air flow through the boat;
a. Ventilate passenger area, open side curtains, or forward
hatches to remove carbon monoxide fumes.
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GENERAL INFORMATION
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Courtesy of ABYC
3
b
a
2
a
b
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Carbon Monoxide Risk (Continued)
INSUFFICIENT FRESH AIR FLOW
Under certain conditions, enclosed or canvas enclosed cabins or
cockpits with insufficient ventilation may draw in carbon monoxide.
Install one or more carbon monoxide detectors in your boat.
Although rare, on a very calm day, swimmers and passengers in an
open stationary boat with a running engine, or near a running engine
may be exposed to a hazardous level of carbon monoxide.
Insufficient Air Flow Could Occur If:
2 While boat is stationary:
a-Boat moored in a confined space with the engine running.
b-Boat is moored close to another boat with its engine running.
3 While boat is moving:
a-Running the boat with the trim angle of the bow too high.
b-Running the boat with no forward hatches open (station wag-
on effect).
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GENERAL INFORMATION
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Wave And Wake Jumping
Operating recreational boats over waves and wakes is a natural part
of boating. However, when this activity is done with speed to force the
boat hull partially or completely out of the water, certain hazards
arise, particularly when the boat re-enters the water.
The primary concern is the boat changing direction while in the midst
of the jump. In such case the landing may cause the boat to violently
veer in a new direction. Such a sharp change in direction or turn can
cause occupants to be thrown out of their seats or out of the boat.
There is another less common hazardous result from allowing your
boat to launch off a wave or wake. If the bow of your boat pitches
down far enough while airborne, upon water contact it may penetrate
under the water surface and “submarine” for an instant. This will bring
the boat nearly to a stop in an instant and can send the occupants
flying forward. The boat may also steer sharply to one side.
WARNING
Avoid serious injury or death from being thrown within or out
of a boat when it lands after jumping a wave or wake. Avoid
wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on
to any boat hand hold.
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GENERAL INFORMATION
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Impact With Underwater Hazards
Reduce speed and proceed with caution whenever you’re driving a
boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the
outboard or the boat bottom. The most important thing you can do
to help reduce injury or impact damage from striking a floating
or underwater object is control the boat speed. Under these
conditions, boat speed should be kept to a minimum planing
speed (15 to 25 MPH).
WARNING
T o avoid serious injury or death from all or part of an outboard
coming into the boat after striking a floating or underwater obstacle maintain a top speed no greater than minimum planing
speed.
Striking a floating or underwater object could result in an infinite number of situations. Some of these situations could result in the following:
• Part of the outboard or the entire outboard could break loose and
fly into the boat.
• The boat could move suddenly in a new direction. Such a sharp
change in direction or turn can cause occupants to be thrown out
of their seats or out of the boat.
• A rapid reduction in speed. This will cause occupants to be thrown
forward, even out of the boat.
• Impact damage to the outboard and/or boat.
(continued on next page)
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GENERAL INFORMATION
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Impact With Underwater Hazards (Continued)
Keep in mind, one of the most important things you can do to help
reduce injury or impact damage in these situations is control the boat
speed. Boat speed should be kept to a minimum planing speed when
driving in waters known to have underwater obstacles.
After striking a submerged object, stop the engine as soon as possible and inspect the outboard for any broken or loose parts. If damage is present or suspected, the outboard should be taken to an authorized dealer for a thorough inspection and necessary repair.
The boat should also be checked for any hull fractures, transom fractures, water leaks.
Operating a damaged outboard could cause additional damage to
other parts of the outboard, or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds.
WARNING
Avoid serious injury or death from loss of boat control. Continued boating with major impact damage can result in sudden
outboard component failure with or without subsequent impacts. Have the outboard thoroughly inspected and any necessary repairs made.
14
GENERAL INFORMATION
Selecting Accessories For Your Outboard
Genuine Mercury Marine Quicksilver Accessories have been specifically designed and tested for your outboard.
Mercury Marine Quicksilver accessories are available from Mercury
Marine dealers.
Some accessories not manufactured or sold by Mercury Marine are
not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.
WARNING
Check with your dealer before installing accessories. Misuse
of acceptable accessories or the use of unacceptable accessories can result in serious injury, death, or product failure.
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Safe Boating Suggestions
In order to safely enjoy the waterways, familiarize yourself with local
and other governmental boating regulations and restrictions, and
consider the following suggestions.
Use Life Jackets. Have an approved life jacket of suitable size for
each person aboard and have it readily accessible (it is the law).
However, we strongly recommend that everyone aboard wear their
life jacket.
Do not overload your boat. Most boats are rated and certified for
maximum load (weight) capacities (refer to your boat capacity plate).
If in doubt, contact your dealer or the boats manufacturer.
Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs are properly made.
Know and obey all nautical rules and laws of the waterways.
Boat operators should complete a boating safety course. Courses
are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary, (2)
The Power Squadron, (3) The Red Cross and (4) your state boating
law enforcement agency . Inquiries may be made to the Boating Hotline, 1-800-368-5647 or the Boat U.S. Foundation information number 1-800-336-BOAT.
(continued on next page)
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GENERAL INFORMATION
Safe Boating Suggestions (Continued)
Make sure everyone in the boat is properly seated. Don’t allow
anyone to sit or ride on any part of the boat that was not intended for
such use. This includes backs of seats, gunwales, transom, bow,
decks, raised fishing seats, any rotating fishing seat; anywhere that
sudden unexpected acceleration, sudden stopping, unexpected loss
of boat control or sudden boat movement could cause a person to be
thrown overboard or into the boat.
Never be under the influence of alcohol or drugs while boating
(it is the law). They impair your judgment and greatly reduce your
ability to react quickly.
Prepare other boat operators. Instruct at least one person on board
in the basics of starting and operating the outboard and boat handling
in case the driver becomes disabled or falls overboard.
Passenger boarding. Stop the engine whenever passengers are
boarding, unloading or are near the back (stern) of the boat. Just
shifting the outboard into neutral is not sufficient.
Be alert. The operator of the boat is responsible by law to “maintain
a proper lookout by sight (and hearing).” The operator must have an
unobstructed view particularly to the front. No passengers, load, or
fishing seats should block the operators view when operating the
boat above idle speed.
Never drive your boat directly behind a water skier in case the
skier falls. As an example, your boat traveling at 25 miles per hour
(40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet
(61m) in front of you.
Boat operators are required by law to file a Boating Accident R e port with their state boating law enforcement agency when their boat
is involved in certain boating accidents. A boating accident must be
reported if: 1. there is loss of life or probable loss of life, 2. there is
personal injury requiring medical treatment beyond first aid, 3. there
is damage to boats or other property where the damage value exceeds $500.00 or 4. there is complete loss of the boat. Seek further
assistance from local law enforcement.
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