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Mercury SST120 User Manual

Sst120 mercury
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EPA Emissions Regulations

Outboards manufactured by Mercury Marine in the United
States are certified to the United States Environmental Protec-
tion Agency as conforming to the requirements of the regula-
tions 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, wherev-
er practicable, returned to the original intent of the design.
Maintenance, replacement, or repair of the emission con-
trol devices and systems may be performed by any marine
engine repair establishment or individual.
Engines are labeled with an Emission Control Information de-
cal as permanent evidence of EPA certification.
The engine exhaust from this product contains chemi-
cals known to the state of California to cause cancer,
birth defects or other reproductive harm.
The description and specifications contained herein were in ef-
fect at the time this manual was approved for printing. Mercury
Racing, whose policy is one of continued improvement, re-
serves 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.
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
WARNING
Litho in

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Summary of Contents for Mercury SST120

  • Page 1: Epa Emissions Regulations

    The description and specifications contained herein were in ef- fect at the time this manual was approved for printing. Mercury Racing, whose policy is one of continued improvement, re- serves the right to discontinue models at any time, to change specifications, designs, methods, or procedures without notice and without incurring obligation.
  • Page 2 –2...
  • Page 3 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.
  • Page 4 SST120...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS General Information Boater’s Responsibilities ....... Before Operating Your Outboard .
  • Page 6 TABLE OF CONTENTS Operation Engine Break-In ........Pre-Starting Check List .
  • Page 7 ........Mercury Marine Service Offices .

  • Page 8: General Information

    GENERAL INFORMATION oba1 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 rec- ommended that each operator (driver) read and understand this en- tire manual before operating the outboard.

  • Page 9: Boat Horsepower Capacity

    GENERAL INFORMATION U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY Boat Horsepower Capacity 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.

  • Page 10: Lanyard Stop Switch

    GENERAL INFORMATION Lanyard Stop Switch WARNING Should the operator fall out of the boat, the possibility of seri- ous 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.
  • Page 11 GENERAL INFORMATION Lanyard Stop Switch (Continued) WARNING Avoid serious injury or death from deceleration forces result- ing from in accidental stop switch activation. The boat opera- tor should never leave the operator’s station without first dis- connecting the stop switch lanyard cord from themself. Accidental or unintended activation of the Lanyard Stop Switch dur- ing normal operation is a possibility and could cause any, or all, of the following potentially hazardous situations:...

  • Page 12: Protecting People In The Water

    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.

  • Page 13: Carbon Monoxide Risk

    GENERAL INFORMATION gob4 Courtesy of ABYC Carbon Monoxide Risk WARNING Avoid the combination of a running engine and poor ventila- tion. 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 combus- tion engines.
  • Page 14 GENERAL INFORMATION gob39 Courtesy of ABYC obi3 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.

  • Page 15: Wave And Wake Jumping

    GENERAL INFORMATION gob4 obu1 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.

  • Page 16: Impact With Underwater Hazards

    GENERAL INFORMATION gob4 obt1 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 sus- pected of having underwater obstacles that could be struck by the outboard or the boat bottom.
  • Page 17 GENERAL INFORMATION obt4 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.

  • Page 18: Selecting Accessories 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 oper- ating system. Acquire and read the installation, operation, and main- tenance manuals for all your selected accessories.
  • Page 19 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;...

  • Page 20: Recording Serial Number

    GENERAL INFORMATION obl2 Recording Serial Number Record the following numbers from your engine as shown for future reference. LOCATED ON PORT SIDE OGXXXXXX 19XX XXXX Serial Number Model Year Model Designation Year Manufactured Certified Europe Insignia...

  • Page 21: Specifications (General)

    GENERAL INFORMATION Specifications (General) MODEL SST 120/S2000 Full Throttle 7500/8000 RPM RPM Range Weight 275 lbs. Piston 122 cu. in. (1998 cc) Displacement Bore 3.125 in. (79.4 mm) Stroke 2.650 in. (67.3 mm) Recommended NGK-BUHW (P/N 33-97180) Spark Plug Gear Ratio & Oil 14:15 (1.07:1 VI SSM [Optional 15:17 Capacity (1.13:1) IV SSM] 16 oz.

  • Page 22: Specifications (Torques)

    GENERAL INFORMATION Specifications (Torques) MODEL SST 120/S2000 Cyl. Head Bolts 30 lb-ft (41 Nm) + 90° (1/4 turn) Light Oil Exhaust 200 lb-in. (23 Nm) Divider Plate Lower End Cap 100 lb-in. (11 Nm) 271 Loctite Upper End Cap 200 lb-in. (23 Nm) Carb Adaptor to 100 lb-in.

  • Page 23: Component Identification

    GENERAL INFORMATION Component Identification 1. Top Cowl 7. Tilt Tube 2. Cowl Latch 8. Transom Mounting Bracket 3. Water Pump Indicator Hose 9. Serial Number Location (Tell-Tail) (Port Side) 4. Drive Shaft Housing 10. Gear Case 5. Propeller 11. Cooling Water Intake Holes 6.

  • Page 24: Propeller Selection

    GENERAL INFORMATION Propeller Selection Select a propeller that allows the engine to operate at the recom- mended full throttle RPM range with the boat normally loaded (refer to Specifications). This RPM range allows for better acceleration while maintaining maximum boat speed. If changing conditions (such as warmer, more humid weather, opera- tion at higher elevations, increased boat load, or a dirty boat bottom/ gear case) cause the RPM to drop below the recommended range...

  • Page 25: Fuel & Oil

    FUEL & OIL Gasoline Recommendations UNITED STATES AND CANADA Use a major brand of automotive unleaded gasoline with a minimum ÷ posted octane rating (R + M 2) of 92. Automotive gasolines that contain fuel injector cleaner are recommended for added internal en- gine cleanliness.

  • Page 26: Oil Recommendation

    Oil Recommendation Oil Recommendations • All oils used must be NMMA certified TC-W3 2-Cycle oil • Mercury 2-Cycle oil is recommended above other manufacturers oil Mercury Precision 2-Cycle Performance Recommended Oil Blend Oil For Emergency Use Only...
  • Page 27 GASOLINE/OIL MIXING RATIO CHART Gas/ 1 Gallon 3 Gallons 6 Gallons Ratio (3.8 Liters) (11.5 Liters) (23 Liters) 32:1 4 fl. oz. 12 fl. oz. 24 fl. oz. (3.1%) (118 ml) Oil (355 ml) Oil (710 ml) Oil...

  • Page 28: Filling Gasoline Tank

    FUEL & OIL Filling Gasoline Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while filling fuel tanks. To help pre- vent a static charge during filling, portable fuel tanks must be removed from the boat and placed directly on the ground for filling.

  • Page 29: Features & Controls

    FEATURES & CONTROLS Power Trim Outboard position can be adjusted by pressing trim switch. This range is used while operating your boat on plane. • Pressing (DN): Moves the outboard in closer to the boat transom, called trimming “in” or “down.” •...
  • Page 30 (continued on next page)
  • Page 31 FEATURES & CONTROLS Power Trim (continued) POWER TRIM OPERATION (CONTINUED) WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin-out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel.

  • Page 32: Hydraulic Up/Down Adjustment

    FEATURES & CONTROLS Hydraulic Up/Down Adjustment Your outboard can be raised up and down approximately 1” (2.54 cm) hydraulically. The hydraulic system allows the operator to raise or lower the outboard while on plane. HYDRAULIC UP/DOWN OPERATION The optimum height adjustment for your boat will depend on many variables such as water conditions, boat design, propeller size and design, weight distribution, etc.

  • Page 33: Operation

    OPERATION Engine Break-In CAUTION Severe damage to the engine can result by not complying with the Engine Break-in Procedure. BREAK-IN PROCEDURE Partial break-in is done at the factory. Additional break-in is recommended. During and after break-in, use a 32:1 gasoline/ oil mixture in your fuel tank.

  • Page 34: Pre-Starting Check List

    OPERATION Pre-Starting Check List j Engine lowered to run position with all water intake holes submerged. j Fuel supply OK. (Vent cap open or fuel petcock “On”). j Fuel mixture OK. j Lanyard stop switch in “Run” position and cord connected. j Top cowl latches secure.

  • Page 35: Operating At High Elevations

    OPERATION Operating In Salt Water or Polluted Water (cont.) Wash down the outboard exterior and flush out the exhaust outlet of the propeller and gear case with fresh water after each use. After each usage spray Quicksilver Corrosion Guard on the engine exteri- or, electrical components and other metal surfaces (do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes).

  • Page 36: Starting The Engine

    OPERATION Starting the Engine WARNING Avoid possible serious injury or death. Your racing outboard can only be started in forward gear. Extreme care must be tak- en by the operator to assure that the area around the boat is safe for starting and that he/she is in control of the boat when the start switch is engaged.

  • Page 37: Stopping The Engine

    OPERATION FUEL PRIME START FUEL FUEL FUEL PRIME PRIME PRIME START START START Starting the Engine (cont.) Toggle the fuel pump switch to the ON position. Your racing outboard is always in forward gear. You must be pre- pared for immediate forward thrust as soon as the start switch is engaged.

  • Page 38: Engine Overheating

    OPERATION Engine Overheating If the engine overheats, immediately reduce throttle speed to idle and check for a steady stream of water coming out of the water pump indicator hoses (a). CAUTION Operating the engine while overheated will cause engine dam- age.

  • Page 39: Maintenance

    Selecting Replacement Parts For Your Outboard We recommend using original Mercury Precision replacement parts and Lubricants. WARNING Using a replacement part that is inferior to the original part...

  • Page 40: Inspection And Maintenance Schedule

    MAINTENANCE Inspection and Maintenance Schedule Before Each Race 1. Check that lanyard stop switch stops the engine. 2. Visually inspect the fuel system for deterioration or leaks. 3. Check fuel pressure. 4. Check outboard for tightness on transom. 5. Check steering system for binding or loose components. 6.

  • Page 41: Fuel System

    MAINTENANCE Inspection and Maintenance Schedule (cont.) EVERY 25 HOURS OF USE OR ONCE A MONTH (CONT.) 3. Drain and replace gear case lubricant. ∗ 4. Lubricate drive shaft splines. 5. Check power trim pump oil level. 6. Lubricate all lubrication points. (More frequently in salt water). 7.
  • Page 42 MAINTENANCE Fuel System (cont.) Final 10 Micron Fuel Filter CAUTION The fuel in this filter is under high pressure. The fuel system will have to be relieved of pressure before servicing. You should have this filter serviced by an authorized dealer. Replace element every 2 or 3 races.

  • Page 43: Steering And Throttle Systems

    Be alert for unusual looseness, sticking or jamming and, if prob- lems exist, follow instructions in “Safety Warning” immediately preceding. Propeller Repair Some damaged Mercury Marine propellers can be repaired. Consult Mercury Racing for available repairs and costs: Mercury Racing N7480 County RD. “UU”...

  • Page 44: Propeller Replacement

    MAINTENANCE Propeller Replacement WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propel- ler, always remove spark plug leads when you are servicing the propeller.

  • Page 45: Spark Plug Inspection

    MAINTENANCE Spark Plug Inspection Inspect spark plugs at the recommended intervals. Remove the spark plug leads by twisting the rubber boots slightly and pull off. Inspect spark plug boots and replace if cracked. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn or the insulator is rough, cracked, bro- ken, blistered, or fouled.

  • Page 46: Lubrication Points

    MAINTENANCE Lubrication Points Mercury Marine Anti-Corrosion Grease (92-78376A6) Mercury Marine 2-4-C (92-825407A1) or Special Lubricant 101 (92-13872A1) Lubricate through fitting. NOTE: Propeller Shaft – Refer to Propeller Replacement for remov- al and installation.

  • Page 47: Checking Power Trim Or Hydraulic Up/Down Fluid

    MAINTENANCE Checking Power Trim or Hydraulic Up/Down Fluid Place outboard in the full down (in) position. Remove trim pump fill/vent screw (a) • Wipe fill/vent screw with a clean, lint-free cloth and reinstall - DO NOT THREAD INTO PUMP. • Remove fill/vent screw and note oil level.

  • Page 48: Maintenance Log

    MAINTENANCE LOG Record here all maintenance performed on your outboard. Be sure to save all work orders and receipts. MAINTENANCE PERFORMED ENGINE DATE HOURS...
  • Page 49 MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS...

  • Page 50: Storage Preparation

    To prevent varnish or gum buildup during extended storage, we rec- ommend adding Mercury Precision Fuel System Treatment and Sta- bilizer (92-802875A1) to the fuel tank and operation of the engine to introduce the additives to the system.

  • Page 51: Protecting Internal Engine Components

    STORAGE hib1 Fuel System (Continued) 1. Portable Fuel Tank – Pour the required amount of Mercury Preci- sion Fuel System Treatment and Stabilizer (92-802875A1) (fol- low instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel.

  • Page 52: Protecting External Outboard Components

    1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule. 2. Touch up any paint nicks. See dealer for touch-up paint. 3. Spray Mercury Precision Corrosion Guard (92-802878-55) on external metal surfaces, (Do not apply on corrosion control anodes).

  • Page 53: Troubleshooting

    TROUBLESHOOTING ojc1 – STARTER MOTOR WILL NOT CRANK THE ENGINE POSSIBLE CAUSES • Weak battery or battery connections are loose or corroded. • Ignition key switch failure. • Wiring or electrical connection faulty. • Starter motor or starter solenoid failure. –...
  • Page 54 TROUBLESHOOTING – ENGINE RUNS ERRATICALLY POSSIBLE CAUSES • Spark plugs fouled or defective. Refer to Maintenance Section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a. Fuel tank filter obstructed. b. Water separating filter or In-Line filter clogged. c.
  • Page 55 TROUBLESHOOTING – BATTERY WILL NOT HOLD CHARGE POSSIBLE CAUSES • Battery connections are loose or corroded. • Low electrolyte level in battery. • Inefficient battery. • Excessive use of electrical accessories. • Defective rectifier, alternator, or voltage regulator. – ENGINE OVERHEATING POSSIBLE CAUSES •...

  • Page 56: Wiring Diagrams

    WIRING DIAGRAMS Engine Wiring Diagram All 12v Run-24v Start...

  • Page 57: Boat Wiring Diagram

    WIRING DIAGRAMS Boat Wiring Diagram All 12v Run-24v Start RED/PUR...

  • Page 58: Owner Service Assistance

    Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Outside the United States and Canada, contact the nearest Marine Power International Service Center.

  • Page 59: Service Assistance

    The following information will be needed by the service office: • Your name and address • Daytime telephone number • Model and serial number of your outboard • The name and address of your dealership • Nature of problem Mercury Marine Service Offices are listed on the next pages.

  • Page 60: Mercury Marine Service Offices

    Parc Industriel de Petit-Rechain (32) (87) 32-3211 (32) (87) 31-1965 B-4800 Verviers Belgium Mexico, Central America, South America, Caribbean Mercury Marine - Latin America & Caribbean (305) 385-9585 (305) 385-5507 9010 S.W. 137th Ave. Suite 226 Miami, FL 33186 U.S.A.
  • Page 61 OWNER SERVICE ASSISTANCE Mercury Marine Service Offices (cont.) Telephone Mail Japan Mercury Marine - Japan No. 27-2 Muramatsu Chisaki- Shinden (81) 543/34-2500 (81) 543/34-2022 Shimizu City Shizuoka Prefecture Japan 424 Asia, Singapore Mercury Marine Singapore (65) 546-6160 (65) 546-7789 72 Loyang Way...

  • Page 62: Ordering Literature

    Model __________ Horsepower__________ Serial Number_____________ Year_______ United States and Canada For information on additional literature that is available for your particular Mercury/MerCruiser power package and how to order that literature contact your nearest dealer or contact: Mercury Marine Telephone Mail...

This manual is also suitable for:

Sst 120/s2000

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