Crosbyman is the least condescending man on this site bar none.
Another example of internet reading being interpreted incorrectly.
Keep your story going.
Being freshly rebuilt I'm going to say 130 to 140 lbs but you wonder about things like the gearcase. Might want to have your own mechanic give in the "once-over"
Whoa, so many things to correct.
Let's start with the low voltage issue. Do you have an electrical meter? You need to trace your battery wire connectors and see if their maintaining voltage along the way. Do you have wing nuts on your battery? If so replace them with nuts. Might be your nutruel...
Pop off opens at high speed so yes that could be it otherwise clogged water passages on the starboard side.
Sound like the past owner knew there was something wrong and Mikey moused it.