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Thx for the info on the gearcase cover. Yes the plastic looks like poor quality. Only a small crack at one corner. I took out the bolt and sprayed the area good with carb cleaner to clean any salt out of the crack and bolt hole. The metal insert was not corroded. I cleaned the bolt good and put it back in with grease like you suggested. I took out and cleaned/greased the other two bolts and holes – no sign of salt or cracks by those. I did the bolts one at a time, so never disturbed the gasket, as it appears to be sealing well. Put the new pump housing and impeller in and got it running good in a tank. This motor hadn’t been run for 20 or 30 years. A small amount of water was in the gearcase, but the washers on the drain and vent screws were in bad shape – one was in two pieces, so that’s probably how the water got there.
I put an OEM kit and float in the carb – the float valve was badly stuck shut and some passageways were totally clogged with dried up gas/oil residue. This model has a self-contained fuel tank. I never saw one of these before with the small, fuel pump built into the manual fuel valve assembly. I assume that helps when the tank gets near empty, where it may have trouble gravity-feeding fuel to the carb.
Thx again for the help and tips! Dave