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If I understand you, the motor has been heavily used in salt water off and on since 1992. If so, unless it is FW/antifreeze cooled, I'd pitch it and start with something only used in fresh water for cooling. Just my 2 cents...

Not 100% proficient on EFIs in boats, but I suspect knock sensor is not doing its job. Clean and reconnect. Mechanic may have "bumped" loose. Or,, perhaps spark plug wire is leaking to it before going to ground???

Original salt water motor? RUN!

Excellent information but I can't enlarge diagram to fully view! I had an 86 SR Amberjack back in the 90s (v8S) that didn't have any shutters. My 1995 Proline (V8s) did. My recent 86 restoration did have them but one motor's was almost disintegrated. I also had to buy new Y pipes due to salt...

Or a loose nut on coil or gauge... Been there too!

No disrespect but "seems" may cost you a fortune and hard work, if there is rot. Trust me. I have been working on a restoration for over 4 years due to an incompetent marine surveyor. Take 1/4" drill bit and drill at least a half dozen holes around inside transom assembly and a couple near drain...

Inside battery lugs too where they make contact with battery posts???????

I stopped counting the times I have had to clean off terminal green crap. I started spraying Fluid Film on them , which just slows it down.

I had a helm faulty ignition switch on a MC that didn't allow enough current for the starter/Bendix. It ended up destroying the flywheel ring gear's teeth. You may want to directly jump starter and examine the difference in performance. If it was my boat, I'd paint starter teeth again and...

Depending on your easy access to it, there should be an oil pressure or sender near the factory oil filter location that you may consider relocating. Some motors have been retrofitted with remote and easy access filters. However, if there is a switch or sender near the oil filter, and it...

That's exactly what I would do!

But the bearings are still coated with contaminated lube?????

Perhaps you implied and I didn't catch it, but I would not let that contaminated lube stay on OD all winter. Just my 2 cents....

I am not 100% on Alphas, since mine all required grease fitting type hinge pins. But, my Bravos needed special performance hinge bushings, not requiring grease fittings. Is slop horizontal or vertical or both? R u the original boat owner? Is there a chance that you have a newer OD requiring...

Sounds like a plan!!!!!! External engine compartments are always in a fisherman's way, until the fisherman has to work on the motors. I have only owned one MC that had a box, and it was much easier to work on than the rest. Good luck!

Over the last 40 years, I must have installed or re-installed a dozen MCs. I have never been able to easily install a complete motor with exhausts and risers attached because of mount alignment issues (seeing) and at the same time getting the risers inside the riser/y-pipe bellows. The Y-pipe is...

If bias metal, I would have recommended at least painting, but it looks like you are doing fine!!!!!! Nice build!

Very Nice and clean!!! SS fuel tubing? Stat housing looks very similar or the same as mine. I removed my stat housing temporarily in order to fastened a HOMEMADE lug for the up and down adjustments required for the front motor mounts. Of course, my exhausts' manifolds were not installed on...

Read on Trailer or in water????

If accurate, time for a tear down! Sorry....