Mercury SST120 User manual

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.

WARNING

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. 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 Rac-

ing’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

SST120

oa 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. . . . . . . . . . . . . . . . . . . .

oa 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

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.

obb1

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, con-

tact 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.

GENERAL INFORMATION

U.S. COAST GUARD CAPACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON

CAPACITY (POUNDS) XXX

MAXIMUM WEIGHT

CAPACITY XXX

Boat Horsepower Capacity

1Do 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

2If 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.

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.

1The 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.

2While activation of the lanyard stop switch will stop the engine im-

mediately, a boat will continue to coast for some distance de-

pending 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 se-

riously as the boat would when under power.

(continued on next page)

This manual suits for next models

Table of contents

Other Mercury Outboard Motor manuals

Mercury

Mercury Sea Pro User manual

Mercury

Mercury 5 HP FourStroke Propane User manual

Mercury

Mercury 200 Optimax User manual

Mercury

Mercury GO BOLDLY SeaPro 500hp User manual

Mercury

Mercury OUTBOARD MOTOR User manual

Mercury

Mercury FourStroke 2.5 User manual

Mercury

Mercury 75 User manual

Mercury

Mercury Avator 20e User manual

Mercury

Mercury 10 EFI FourStroke Instruction manual

Mercury

Mercury 40 jet fourstroke User manual

Mercury

Mercury Four Stroke User manual

Mercury

Mercury VesselView 4 User manual

Mercury

Mercury 25 EFI FourStroke User manual

Mercury

Mercury 5 SERIES User manual

Mercury

Mercury 9.9 User manual

Mercury

Mercury Marathon - 30 User manual

Mercury

Mercury 73012 User manual

Mercury

Mercury 40 FourStroke User manual

Mercury

Mercury 40 FourStroke User manual

Mercury

Mercury 4 TwoStroke User manual

Mercury

Mercury 300XS OptiMax User manual

Mercury

Mercury 10 TwoStroke User manual

Mercury

Mercury 75 User manual

Mercury

Mercury GO BOLDLY 25 EFI User manual

Popular Outboard Motor manuals by other brands

Yamaha

Yamaha VF150 owner's manual

Sleipner

Sleipner SEP-IP30 installation guide

Suzuki

Suzuki DF 40 Service manual

SELVA MARINE

SELVA MARINE Corse owner's manual

TOHATSU

TOHATSU BFT 250A owner's manual

KONRAD

KONRAD Series 600B Maintenance manual

Sleipner

Sleipner E-Vision Electric Thruster E300 installation guide

Suzuki

Suzuki DF40A manual

IST

IST 18.BF200D manual

Side-Power

Side-Power SP 155 TC i Installation and user manual

Quick

Quick BTR250 user manual

Yamaha

Yamaha VF90 owner's manual

Yamaha

Yamaha D150H owner's manual

Yanmar

Yanmar ZT350 series Operation manual

MotorGuide

MotorGuide X3-40 Operation and maintenance manual

Yamaha

Yamaha 20D owner's manual

Torqeedo

Torqeedo Ultralight 403 operating manual

Vetus

Vetus BOWPRO65 installation manual