Water in Oil

Sounds like you have on all accounts above. One thing I would insure in addition to the new OEM risers and correct spacers if needed. Install new flappers in the Y exhaust pipe. This is an additional measure against water running back up though the exhaust. But yes, I think the root cause of your engine problems is an incorrect exhaust installation that was hidden with the boat being stored on a lift.
 
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Don't know how I missed this, but found this broken water jacket in the head on the starboard side! Painted it blue to make it easier to see. Mystery solved. I wonder how in the world this happened? This was a fairly fresh motor.
 
Rethinking the riser height again. Every Sea Ray Sundancer I look at doesn't require the riser extension. I was wondering why mine would.
 
Just about ready to set her back in. Waiting on the new exhaust gaskets, much easier to install on the stand.
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Looking good, been following the thread. It's awesome to see someone take the time to diagnose what actually happened, so it doesn't happen again after the new motor has been installed.
 
I believe that I was on the wrong track for a bit? I could not figure out how the water was getting into the engine and exhaust, specifically on the starboard side. I speculated that the risers weren't high enough at first. However, after looking at hundreds of pictures of similar Sea Ray models as mine, NONE had a higher riser set up and I was wondering what would make mine different?
Well, I found the culprit. There was severe head damage to the head on the starboard side. The casting was broken into the cylinder between the water port and the compression area. Apparently the leak filled the exhaust and engine when the engine was off and one or the other valves were caught in the open position.
Not sure how this type of damage happened? But I know it was done during assy. (rebuilt motor) Looks like the head was dropped or fell over and the builder didn't catch the damage.
Anyway, I know what I have now and was able to stroke it with a 400 crank and rods. Running a .030 bore now so should be much easier on the temp situation than the .060.
Should be able to set her back in this weekend with any luck. This boat has never run right since I bought it in March. Super nice boat overall, so I am looking forward to some better performance.
Going to leave the risers alone and closely monitor the situation once it's back in the water. I sincerely believe that the broken head was the issue.
 

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