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So that is a no on getting a service manual? Just curious.

A service manual is in order. It will explain exactly how to do it, what adhesives, greases and permatex products will substitute for the OMC products cited. Also, you may need to do other repairs, and most shops will not want to work on that old an engine.

Gee, fix the few blisters you already have, and then apply an epoxy barrier coat to prevent more blisters. If you launch it now, you could have blisters all over the wet area. That fix will cost $$.

Does the ign click when you turn the key, or is there silence?

I would not think the VR would do the stuff you desribe. Since the charging and ign coils share an iron core on the stator, I thought a shorted VR might affect the ign coils, hence my recommendation to disconnect it. A lot of Mercs have an idle stabilzer. This device often malfunctions...

Overton's has black marine carpet. Regular indoor-outdoor carpet has lots of colors. Not sure if they have orange or not.

That is standard on some trailers. Maybe the PO put the bearing buddies on 'cause he couldn't see the hub-mounted zerks or they were inconvenient.

At this point, I think you need to look at the ign system. A lot of Mercs use high and low speed windings on the stator. The transition between the two may be causing your issue, but it is a guess. That electrical device from your post 17 is a voltage regulator. You might disconnect it from...

Seems hard shifting. Does it have the correct gear oil?

Normally the battery is connected to the one of the starter solenoid secondary windings posts. The other secondary winding post is connected to the starter. The primary winding is connected to the start switch which is a momentary push button. Based on the picture, I will guess the starter...

Gee, The start switch should momentarily provide power to the starter solenoid. When you release the start switch, the solenoid will stop power to the starter. Sounds like a wiring problem.

After you rebuilt the carbs, did you set the idle mixture on all six carb throats for a smooth idle? If so, the idle mixtures maybe set too lean to accelerate. Most Mercury carbs do not have accelerator pumps. Therefore the carb idle mixtures need to be a bit richer to compensate. You might...

Does that motor have an ECM? I see CDM ignition, but no ECM on the parts list. Do you have an idle stabilizer? If so, you might disconnect it, as they can alter the ign timing in bad ways.

All I can think of at this moment is water infiltration. Water can get into the cylinders and foul some spark plugs, causing them to misfire until high speed can overcome the water. If some of your spark plugs are real clean compared to others, that is a good bet.

Gee, a 19 footer could easily have a 35G fuel tank, or more. My 19 foot sterndrive had a 35G fuel tank, which was pretty standard, and my 21 foot outboard boat has a 63G fuel tank. If there is a hatch that exposes the fuel tank, it may have a capacity plate. Alternatively, carry a full...

I used to run some marvel mystery oil in my carbed Merc 4.3LX. When that ran out, I ran 2 cycle oil at the same ratio. Whether it did anything for the valves, I do not know. I thought it might keep the rust down in the intake manifold, though.

If the shift rod moves hard or binds, you need to drop the gearcase and find out why. If it moves freely, look at the other linkage, under the carbs for the binding issue. Also, look at the alignment of the triple clamp that the shift rod goes thru. If the lower motor mounts have play in them...

gee i always used whatever cheap ones were avail. water spraying is pretty normal. when you first start the motor, most of the water will be pulled into the drive, until the block fills, then it will start to spray a bit. that means it is working.

don't fill the tank as much. remember, fuel is stored underground at 55-60*f. when you fill the tank, the fuel warms up and expands.

the shift rod needs to go down into the shift pocket cover to engage reverse. sometimes dirt or corrosion can build up on the shift rod or cover oring, binding the shift rod. also, I have had the shift pocket cover swell a bit, grabbing the shift rod. drop the gearcase and try to shift by...