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For the past couple of years, every now and then my temp alarm would sound for a bit and then shut off and stay off. I figured it was a loose connection.

This year, I had a new water pump kit put in at the beginning of the summer. It looks like it works well, stream comes out strong. No issues for about a month.

But for the past couple of weeks, I can only go about 5 minutes at 3/4 throttle or higher before the alarm comes on. I can idle around for hours on end without problem.

Once the overheat alarm comes on, the telltale still feels cool to touch. But the alarm won't stop unless I sit for a while -- sometimes as long as 5-10 minutes. Even then, it doesn't go off until I run it at low RPM to get cool water cranking through. I tried running it in reverse a bit to flush the system but the problem returned anyway.

So I don't know if it's a bad sensor/false alarm/loose connection -- or is it possible that water flow could get restricted somehow at high RPM but move fine at low RPM? (The boat is always in saltwater.)

Could it be the thermostats even if there's no issue at all when putting around with no wake?

I read the alarm could also start buzzing for low fuel pressure, but the engine doesn't sputter or anything when this happens. It runs fine.

Would the alarm sound for another reason?

Any knowledge is appreciated. Thanks.

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See this article and tell us more about the "Sound" you refer to.
http://www.whalercentral.com/articles...ticle_id=9

If you have never changed the thermostats, now would be a good time to do so no matter what this outcome is.

You hav a 1982 Johnson 90 with 20 inch Long Shaft and Trim and Tilt according to your model number.

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Hi Joe, thanks for the link and the reply.

The sound is a high-pitched, constant buzzing coming from the horn inside the console.

It looked like it was wired to the gauges. My temperature gauge doesn't move ever. I'm not sure if it's broken, or if the water temp is just very consistent. But it's been that way for years without this problem.

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Use the article to test your Warning Horn System.

Very simple to do.

Maybe it is just the Horn which is another simple and inexpensive fix and replacement just like replacing the Thermostats.

I would start with a newer Warning Horn and new Thermostats.

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Thanks, I'll start with those and see if it returns.

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Could also be the temp sensor going bad - you can test with a kitchen thermometer in a pot of water on the stove. I don't think the sensors are terribly expensive so you could also just replace it.

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Update - When I took the cover off to get at the thermostats and temp switches, I noticed a tan wire just hanging out. It runs from the wiring harness to the starboard side of the motor and was just sitting there.

I'm not sure what it's supposed to connect to. The temp switches both also have tan wires, but they are connected properly.

Any thoughts?


Attaching a pic