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Well, let’s see if I can help a bit. I have a couple of KD-15’s, which are the post-war version of the KA’s.
1. Rinse it out the best you can with soap and water. This will get out the big pieces and the loose pieces. Next, plug up the lower outlet with a pipe fitting plug available at your local hardware store. Then, fill the tank about 1/2 way with ammonia, drop in a couple dozen nuts (also available at your local hardware store), put the gas cap on. Proceed to shake and rotate the nut/ammonia mixture. This may take several days depending on how crudded up your tank is. When done, empty the tank, rinse with water again, then rinse with denatured alcohol which prevents rusting by, I believe, absorbing the water you used to rinse the tank.
2. I mean, the motor is almost 80 years old and if the water pump parts are original, you probably do want to replace them. That being said, I haven’t gotten in to my lower unit yet, so I don’t know what type it is. Couldn’t find the information in any of my old manuals either. Weird. I will look harder.
3. Manual says 9 oz. of GREASE.
4. Standard replacement wire, available at vintage outboard parts suppliers, should suffice.
5. Manual says 1 pint per gallon of SAE #40, so that’s 8:1 (thick!)
Anything that I’ve said wrong above will be corrected shortly.
Good Luck!!!