Tried to clean up cylinders from stuck powerhead with hone...top of cylinder shined up but hone could not break thru corrosion at lower end of cylinders. No great surprise. Sprayed pistons with PB Blaster rings still stuck. No great loss there either.

After a few days of lawn and leaf duty I got in an hour or so of basement
shop time. Honed the cylinders of spare powerhead...they cleaned up nicely.
The clamp assembly had a weld repair and the screws were rusted and one
was bent. An excellent clamp casting available lacking screws. Used Dremel tool
and abrasive disc to cut slots in aluminum then used hammer and chisel to
split out an opening to work the screws out. Some careful work with press
may make screw close enough to straight to work. Discs will be removed and
reinstlled using the Mercury Service Tool for that job. There are several
work around techniques if that does not work as advertised.

Although the spare powerhead appears good to go it will be taken apart to
check bearings, seals, crankshaft and reeds. No point in finding out later
that it should have been done while the doing was easy. Hopefully no
unexpected bad news.

Louis

The bearing stuck in KF7 crankcase came out after making a close fitting plug
on lathe to catch the very narrow edge of bearing....into the press and
cautiously pump up pressure...a little bit beyond what I thought was
wise...BANG!!! Both bearing and plug came out leaving a corroded spot where
bearing had been. I do not know if crankcase is reusable but experience
was instructive.