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Mercury SST 120/S2000, User Manual, Page: 2 / 62

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Mercury SST 120/S2000 User Manual Download Page 2

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Summary of Contents for SST 120/S2000

Page 1: ...ntrol 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 o...

Page 2: ...2...

Page 3: ...cts 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 car...

Page 4: ...0 SST120...

Page 5: ...mping 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 Compone...

Page 6: ...g 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...

Page 7: ...se 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 Se...

Page 8: ...river 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 preven...

Page 9: ...oat 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...

Page 10: ...y 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 a...

Page 11: ...l 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 1 Occupants could be thrown...

Page 12: ...caution any time you are boating in an area where there might be people in the water WHILE BOAT IS STATIONARY Shut off the engine before allowing people to swim or be in the water near your boat WARNI...

Page 13: ...monoxide is a deadly gas that is odorless colorless and tasteless and is present in the exhaust fumes of all internal combus tion engines Early symptoms of carbon monoxide poisoning which should not b...

Page 14: ...ough 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 F...

Page 15: ...use 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...

Page 16: ...id serious injury or death from all or part of an outboard coming into the boat after striking a floating or underwater ob stacle maintain a top speed no greater than minimum planing speed Striking a...

Page 17: ...resent or suspected the outboard should be taken to an au thorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractures transom frac tures water...

Page 18: ...ntal 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...

Page 19: ...r 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 hearin...

Page 20: ...Serial Number Record the following numbers from your engine as shown for future reference 19XX XX OGXXXXXX XXXX LOCATED ON PORT SIDE a b d c e a Serial Number b Model Year c Model Designation d Year...

Page 21: ...k Plug NGK BUHW P N 33 97180 Gear Ratio Oil Capacity 14 15 1 07 1 VI SSM Optional 15 17 1 13 1 IV SSM 16 oz 474 ml Recommended Gasoline Min Octane Rating of R M 2 92 or RON of 98 Recommended Oil Quick...

Page 22: ...Hsg 100 lb in 11 Nm 271 Loctite Reed Block to Reed Block Hsg 100 lb in 11 Nm 271 Loctite Connecting Rods 30 lb ft 41 Nm 271 Loctite Crankcase Cover to Block 3 8 in 40 lb ft 54 Nm Light Oil 5 16 in 20...

Page 23: ...n 1 2 3 4 5 6 7 8 9 10 11 1 Top Cowl 7 Tilt Tube 2 Cowl Latch 8 Transom Mounting Bracket 3 Water Pump Indicator Hose Tell Tail 9 Serial Number Location Port Side 4 Drive Shaft Housing 10 Gear Case 5 P...

Page 24: ...imum 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 recommende...

Page 25: ...e Section Leaded Gasoline is acceptable to use in areas where unleaded is not available However exhaust passageway corrosion may occur due to the accumulation of exhausted lead particles ALCOHOL IN GA...

Page 26: ...Recommendations All oils used must be NMMA certified TC W3 2 Cycle oil Mercury 2 Cycle oil is recommended above other manufacturers oil Recommended Oil Mercury Precision 2 Cycle Performance Blend Oil...

Page 27: ...23 GASOLINE OIL MIXING RATIO CHART Gas Oil Ratio 1 Gallon Gas 3 8 Liters 3 Gallons Gas 11 5 Liters 6 Gallons Gas 23 Liters 32 1 3 1 4 fl oz 118 ml Oil 12 fl oz 355 ml Oil 24 fl oz 710 ml Oil...

Page 28: ...ling portable fuel tanks must be removed from the boat and placed directly on the ground for filling Fill fuel tanks outdoors away from heat sparks and open flames Remove portable fuel tanks from boat...

Page 29: ...ut beyond a neutral steering condition a pull on the steering wheel in either direction may result Failure to keep a continuous firm grip on the steering wheel when this condition exists can result in...

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Page 31: ...d is trimmed extremely in or down and there is a pull on the steering wheel Trimming Out or Up can Lift the bow higher out of the water Generally increase top speed Gain clearance over submerged objec...

Page 32: ...other operation of the boat and to maintain adequate water supply to the engine at all times WARNING Avoid possible serious injury or death Do not operate your outboard at a height adjustment that co...

Page 33: ...O T for more than 1 minute CAUTION It is the boat operators responsibility to always drive in a safe manner Improper trim angle of the outboard when driving at speed can be difficult and dangerous Tri...

Page 34: ...and causing possible damage to the water pump and other components If there is a chance of ice forming on the water the outboard should be removed and drained completely of water If ice should form a...

Page 35: ...exteri or electrical components and other metal surfaces do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes Operating at High Elevations A propeller with a di...

Page 36: ...the Operation Section CAUTION Never start or run your outboard even momentarily without water circulating through all the cooling water intake holes in the gear case to prevent damage to the water pu...

Page 37: ...start switch is engaged See preceding warning Start engine Stopping the Engine 6 Bring boat off plane and reduce engine speed to an idle Toggle ignition start switch to the OFF position WARNING Avoid...

Page 38: ...a If no water is coming out of the water pump indicator hose a or flow is intermittent Stop engine and check cooling water intake holes for obstruction If no obstruction is found this may indicate a b...

Page 39: ...enance or repairs you are not familiar with could re sult in personal injury death or product failure Submerged Outboard A submerged outboard will require service within a few hours by an authorized d...

Page 40: ...f gear case lubricant 9 Check propeller blades for damage 10 Check propeller for tightness 11 Inspect battery 12 Clean and inspect motor exterior AFTER EACH USE OR RACE 1 Flush out the outboard coolin...

Page 41: ...Carefully follow all fuel system service instructions Always stop the engine and DO NOT smoke or allow open flames or sparks in the area while servicing any part of the fuel system Before servicing an...

Page 42: ...el This filter should be installed in the fuel supply line before the electric fuel pump which is sup plied with your engine If the filter becomes filled with water the water can be removed If the fil...

Page 43: ...epairs are made 1 Check the steering system for ease of operation Be alert to any changes in steering action 2 Check throttle and throttle linkages for ease of operation and make sure that all anchor...

Page 44: ...nut and washer 3 Pull propeller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an au thorized dealer 4 Remove splined forward thrust washer...

Page 45: ...dirt on the spark plug seats Install plugs finger tight and tighten 1 4 turn or torque to 20 lb ft 27 N m Battery Inspection The battery should be periodically inspected IMPORTANT Read the safety and...

Page 46: ...oints a Mercury Marine Anti Corrosion Grease 92 78376A6 b Mercury Marine 2 4 C 92 825407A1 or Special Lubricant 101 92 13872A1 Lubricate through fitting NOTE Propeller Shaft Refer to Propeller Replace...

Page 47: ...f necessary add Quicksilver Power Trim Steering Fluid or SAE 10W 30 or 10W 40 motor oil thru the fill vent screw hole to bring level up to the FULL mark on the dipstick DO NOT OVERFILL 3 To purge syst...

Page 48: ...44 ok MAINTENANCE LOG Record here all maintenance performed on your outboard Be sure to save all work orders and receipts DATE MAINTENANCE PERFORMED ENGINE HOURS...

Page 49: ...45 ok MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS...

Page 50: ...er may enter the propeller exhaust outlet in the gear case and could freeze causing damage to the outboard hib1 Fuel System IMPORTANT Gasoline containing alcohol ethanol or metha nol can cause a forma...

Page 51: ...er supply to the engine 3 Place the outboard in water or connect flushing attachment for circulating cooling water Run the engine for ten minutes to allow treated fuel to fill the fuel system hid1 Pro...

Page 52: ...8 55 on external metal surfaces Do not apply on corrosion control anodes oie1 Gear Case 1 Drain and refill the gear case lubricant refer to maintenance pro cedure BATTERY STORAGE 1 Follow the battery...

Page 53: ...ard stop switch not in RUN position Incorrect starting procedure Refer to Operating Section Old or contaminated gasoline Engine flooded Refer to Operating Section Fuel is not reaching the engine a Fue...

Page 54: ...ng filter or In Line filter clogged c Stuck anti siphon valve on built in fuel tank d Fuel line is kinked or pinched e Reed valve open or broken Fuel pump failure Ignition system component failure 4 P...

Page 55: ...in battery Inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator 6 ENGINE OVERHEATING POSSIBLE CAUSES Cooling system clogged Incorrect igniti...

Page 56: ...52 WIRING DIAGRAMS Engine Wiring Diagram All 12v Run 24v Start...

Page 57: ...53 WIRING DIAGRAMS Boat Wiring Diagram All 12v Run 24v Start ECU BOX RED PUR RED PUR...

Page 58: ...ice contact the nearest authorized dealer 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...

Page 59: ...service manager If this has already been done then contact the owner of the dealer ship 2 Should you have a question concern or problem that cannot be resolved by your dealership please contact Mercu...

Page 60: ...7480 County Rd UU Fond du Lac WI 54935 9585 Canada 905 567 6372 905 567 8515 Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario Canada L5N 7W6 Australia Pacific 61 3 9791 5822 61 3 9793 5880...

Page 61: ...ices cont Telephone Fax Mail Japan 81 543 34 2500 81 543 34 2022 Mercury Marine Japan No 27 2 Muramatsu Chisaki Shinden Shimizu City Shizuoka Prefecture Japan 424 Asia Singapore 65 546 6160 65 546 778...

Page 62: ...particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 920 929 4894 Mercury Marine Attn Publ...

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