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I think replacing the rod cap screws is very necessary. I did not do it after a rebuild of my Merc 1500, and she threw a rod. Although I did not open her up to see what failed, I suspect it was a rod screw. If you hone some of the cylinders, and they are within spec, you could install new...

Gee, the water jacket cover bolts are grade 5 or 7 steel in 1/4-20 or 5/16-18. Pretty common stuff at any HW store. Most of the trouble comes when the 1/4-20 water jacket screws break, when you try to remove them. I would skip replacing the cylinder heat water jacket gasket, unless you really...

CW is the correct direction. That is either an old Merc impeller or aftermarket. New Merc inpellers have resin instead of brass as the core of the impeller. Both work fine. It looks like your picture was of both the top and bottom of the impeller. The photos I saw did not show wear on the...

Gee, I had an '88 SeaRay Sorrento 19'bowrider. The deck was plywood with polyester resin and chopped glass sprayed with a chop gun. Some areas of the deck were fine, and others had only resin, w/o chopped glass, and were rotting in 2010 or earlier. Check the floor of the ski well. Mine...

OK, that cuts it down to internal engine issues. One of the experts on your engine will be along to advise on what portions of the engine to check. The last Johnnyrude V4 I had was from 1959.

If you are running the oil injection system, you might want to check the oil reservoir for water. If that is not the source of the water, perhaps a gasket in the exhaust system is leaking a bit. BTW- water in injection oil tank is very bad for motor lubrication.

A service manual will answer those questions accurately. Also, check the sealing area on the yoke for a groove worn by the seal. If the groove exists, usually replacement of the yoke is warranted.

This is a bit off topic, but I had a fuel pickup on my SeaRay sterndrive where the fuel pickup in the fuel tank had a filter under the pickup tube. It partially clogged one day when I took my son fishing. The clog would allow minimal planning, and got worst as the day progressed. We...

Don't feel bad. I replaced my Johnson 150HPV6 OMS pump because of a crack and leak. It turned out to be a casting mark and a leaking Oring, and $500 for the new pump. Now the orig OMS pump was from '98, so replacing it was not stupid, IMO. My motto is Better to replace it too early, than...

I logged onto WM the other day. There was some stuff on sale, which was more than I expected, but no mention of chap 11 The PCA premium a-f paint said it had an anti slime component. I did not check it out for effectiveness. The PCA GOLD PTFE anti slime stuff seemed pretty good.

Gee, if you are sure the wood is dry, it makes sense to treat it with epoxy or poly resin. Either works well with dry wood. Epoxy works better with not so dry wood.

Can you stick an exacto knife blade tip or other razor into the casting mark? That might tell you if it is a crack or not.

Is it possible water got into the bracket and froze, cracking it? I had that happen on a Merc 850 triple clamp. It was over the steering shaft part of the component. I had it welded and made sure no more water got into it. In your case, the crack suggests a design defect, if not cracked from...

Replace transom and other rotten parts from the inside, if you can. This preserves the original fiberglass of the transom, which is obviously structural. A lot of times you will need to remove the cap from the hull to have ready access to the inside of the transom and the stringers, deck...

KBB will usually have that kind of info. If it counts, my 1998 21 foot SeaSwirl dual console cites 200HP as max. My opinion is that it could take more HP, but 200HP is the spec for max.

Gee an 1-1/4 ID copper pipe or thereabouts should fit. It is not important to get it exactly right, as I think the one-way valve is an acute problem. You do not have much pitch on the filler tube, that with a sticky one-way valve can restrict the fuel flow I would think. Is that one-way valve...

Have you trued up the manifold to elbow joint? Rust and warped joints can cause all sorts of leaking, even with good gaskets. A good way to true it up is to use emery cloth on a piece of glass, and "sand" the joints in a figure 8 movement.

Check your head bolts for proper torque. If they are loose, exhaust gasses can leak into the cooling jacket and cause overheat.

Yellow fuel is not always bad. Some gas used to be dyed. Anyone remember blue SUNOCO? Put an oz of 2 cycle oil into the gasoline. It will color the gasoline and alcohol, but not the water. If it is separating, you should see it. Check the bottom of the fuel tank for water.

Gee, a piece of copper or PVC plumbing pipe can easily substitute for the one way valve, for testing purposes. If that doesn't fix it, temporarily disconnect the charcoal canister inlet to take that out of the equation. Is the fuel tank vent clear?