posted 06-19-2015 10:58 AM ET (US)        

Not a whaler question per se, but my whaler came with a 1971 Mercury 800 s/n 3053476. Does anybody have any suggestions for an appropriate forum to get advice on this motor? Sources for parts? Maybe I'm in the right place already?

I've got the seloc manual; I'd like to get an FSM if I can find a place selling it, seems to be hard to come by.

Spark plugs and wires are good. Fuel lines look new.

I did a compression test; 155 155 155 150. Leakdown test is coming.

I fired it up and it ran fine for a couple of seconds but then I had to shut it down immediately b/c there was no telltale; pulled the waterpump, it was completely clogged with ANTS. They'd built a nest in the lower unit water manifold and got sucked into the pump when I fired it up. Yuck :P I identified Sierra 18-3317 as the appropriate pump kit; on order.

The wiring is rotten; I ordered a new internal harness from CDI and I'm repairing the remaining wiring.

When I pulled the lower unit I found the splines on the drive shaft were covered with rusty grease. After cleaning the grease off I discovered the splines are worn about 40% of the way through. I wonder how much longer that will last? New drive shaft is $500. I wonder if there are any other motors that used the same drive shaft? I know it's possible to repair the splines but dunno how much that would cost. $200 maybe? Seems like a good machinist should be able to do it in a couple of hours.

I tried to pull the prop but it's seized on. AFAICT the previous owner's mechanic didn't use anti-seize anywhere and this boat's been in and out of saltwater over the years. I whaled on it with a 2x4 to no avail. Seloc says to melt out the rubber bushing with a torch and then cut the sleeve, ugh. It's got a couple of chips in the blades but I guess I'll just run it for now.