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I just got back from the lake after installing a new impeller (with key) and I’m not very happy. I saw a little bit of smoke come out the indicator while the motor warmed up. I shut it off after running for a good 30 seconds. I saw ONE drop of water at the end of the indicator. That’s all.
I’m leaning towards a bad head gasket being the problem but can’t help but wonder if it could be a warped exhaust cover inner plate as suggested by Dan. Based on this theory, I figure the most logical path forward is to pull the head and then the exhaust cover and inspect the gaskets and plate before ordering any parts.
One other observation that might be noteworthy: I looked up into the exhaust cavity last night before replacing the lower unit. I was curious about the condition of the grommet the water tube slides in to. I don’t know what I was looking at on the other side of the grommet but it was light tan and appeared to be perpendicular to the opening.
All things considered, what would you (ie. anyone who has an idea) do if it were your motor?