Every outboard I have worked on has had a warp in the cylinder head !!!----Some more than others.----That is the nature of an aluminum casting over time and heating / cooling cycles.---So there.
Just one cylinder head.----Easy to refinish yourself if you have a flat surface.----Like a piece of hefty glass and valve grinding compound.-----A bit of elbow grease but good results with minimum material removed.
Compression test values ?---Post them here.----And does the tell tale hose come off the side of the block or the top "---Service bulletin came out in 1994 to move it to the top.
If spark is NOT CONSISTANT it needs to be addressed.-----Weak spark is a major reason for no start.----When ever a motor ( outboard or lawnmower ) came into the shop I used to ask folks ----" a little hard to start "---The usual answer was " yes " ----Trouble shooting and inspection is the path...
Hard to believe to believe you are having this much difficulty.-----The 92 model that I have ( when assembled ) will start easily.----I have about 10 or 12 of these 9.9 / 15 HP motors , various years..----They are easy to trouble shoot.
The belt driven generator was standard on the electric shift models.----Optional on electric start models.-----Your location ?---Used item may be easy to find in Canada.
No ---Modern factory does not use an entry level worker with a spray gun.-----Paint line / electrostatic charge / powder coating / ETC.-----I do not have enough fingers and toes to count how many times I have seen that !!!
