2002 Mercury Bigfoot 60HP Complete Rebuild

klze

Cadet
Joined
Jul 22, 2009
Messages
20
Hello everyone!
I'm a member on all other major forums that involve cars,jetskies,snowmobiles.

now that i'm working on my friends outboard engine i decided to register here as well.
he just had a major detonation and i'm doing all the work for him so we can get out there as fast as possible.

center piston hit the head so hard that on impact broke:
  • connecting rod
  • bearing
  • damaged cylinder wall
  • and shredded the woodrof key, skeeping flywheel tooth and timing i would assume

while taking everything apart, i realized that this setup is nothing i have ever worked on excpet maybe for bombardier on some parts.
since most of the components are made to be one piece!
I think thats a big disadvantage in servicing!

I ended up getting a good deal on exact same engine with light sieze and water in 3rd cylinder.

so here is the deal, I'm putting 1 complete motor together from 2 broken motors. I'm using the block and cases from the water siezed motor i got, the rest of the stuff i will mix and match to make complete, and ebay left overs most likely :cool:

tomorrow I'm dropping the block to get honed and cleaned as well as the crank to get trued and cleaned as well, might also consider changing the bearings if i can match them at the local bearing shop as i have always done with my other rebuilds, except that this mercury bearings are bigger and not sealed: does anyone know what type of general market bearings they are ??

have a couple question to ask:

  • can someone please share service manual that i can refer to for specs??
  • can i delete oil pump and just premix on this type of motor/setup??
 

klze

Cadet
Joined
Jul 22, 2009
Messages
20
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

old motor apart
 

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klze

Cadet
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Jul 22, 2009
Messages
20
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

new motor apart
 

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j_martin

Admiral
Joined
Sep 22, 2006
Messages
7,474
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

The only comment I have is you should get an OEM maintainance manual for it. There's all the clearances, torques, and detailed step by step procedures for assembly.

hope it helps.
John
 

klze

Cadet
Joined
Jul 22, 2009
Messages
20
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

The only comment I have is you should get an OEM maintainance manual for it. There's all the clearances, torques, and detailed step by step procedures for assembly.

hope it helps.
John

thanks a alot, i cant seem to locate my shop manual, thats why i'm asking if someone has pdf file with manual that i can use??
 

CharlieB

Vice Admiral
Joined
Apr 10, 2007
Messages
5,617
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

From the pictures I can only surmise that #2 carb was lean and toasted the piston hot enough to stick it, he must have been running WOT at the time to pull the small end of the rod apart. Was the crank journal 'blued' from the heat caused by a lack of oil?

Clean/rebuild ALL carbs and fuel pump before running again, or your fresh rebuild is going to toast again.

If you gave that crank to a standard automotive crank grinder then you had better go get it before he touches it as all it will be good for is tying a rope on it and using it as an anchor.

Do your homework and find a reputable TWO-STROKE crankshop, there is a world of difference in the journal hardening to run those needle bearings directly against the crank and rods.

Needle bearings ARE available from most decent bearing supply houses, the catch is the MINIMUM order, he may have to order a bag of 1000, you only want 29, what's he gonna do with the rest?

Can you measure better than + or - .0001, cause rollers are ground pretty finely in incremental sizes of .0001 and there isn't room for error, the oil isn't heavy enough to fill in the difference.

A quality 2 stroke crankshop will make sure your crank is AT factory size, so you can rely on OEM bearings to fit correctly.
 

klze

Cadet
Joined
Jul 22, 2009
Messages
20
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

sure is 2stroke machine shop, this guys know what they are doing!
they mostly work on snowmobiles and motocross, but been around long enough to know the market: www.bondiengines.com

also went to local bearing shop and was able to match pto and mag crank bearings, both center bearings seem to be fine and not catching or skipping.

should get back the crank and block sometime early next week, lets hope its not bent and easily reusable.

i plan to check and clean all 3 carbs and fuel filter/line/pump
i'm getting overall engine gasket kit: p/n 27812867A97 would be nice if someone can confirm that this kit has all required gaskets??

also i'm trying to clean all crabon deposit on the pistons, what would be the best way of cleaning them??
 

klze

Cadet
Joined
Jul 22, 2009
Messages
20
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

Shop Manual Anybody ??
 

klze

Cadet
Joined
Jul 22, 2009
Messages
20
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

Hey guys hope you all had great weekend!

I'm just wondering if there is a pdf service manual that i can use and refer to??

can someone share please??

thank you!
 

klze

Cadet
Joined
Jul 22, 2009
Messages
20
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

where is the serial number on the engine?
cant seem to find it, to match service manual...

thanks!
 

klze

Cadet
Joined
Jul 22, 2009
Messages
20
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

Hey guys,

Here is th serial number i found on the engine:
0T520420

seems like no one on here shares service manuals?
can someone atleast tell me the ring gap clearance and cylinder to piston?

please post here or pm/email: kl-03@rogers.com
 

klze

Cadet
Joined
Jul 22, 2009
Messages
20
Re: 2002 Mercury Bigfoot 60HP Complete Rebuild

Decided to update this thread.
I ended up buying shop manual off ebay 1998, they are the same from 98-03 I believe.

All went well with my rebuild ;)

cleaned all water jackets, replaced thermostat.
cleaned all three carbs along with fuel pump.
engine fired right up, everything getting cooled properly and 115 psi compression across all three cylinders.


Thanks guys for all the help!
 
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