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Yeah 2 people would be nice just as long as they are versed on the parts of the engine that will rip them to shreds at the slightest contact
If it were my engine Smelly anytime the horn sounded I would instantly shut down, take an anchor and some fishing gear for the wait to cool... he he.. make a day of it
Do the highspeed run only on an engine that is just warm enough to stop the cold engine spluttering - 45 to a minute?
You sure it's not a short causing the horn? in all the times you touched the engine you got a good relative idea of where it was temp wise??
I started my engine downstairs and ran it at idle for 15 minutes just then, couldn't get any heat into it about 35 degC I guess was about the most, your Johnson runs hotter than my Yam but at no stage should you not be able to touch it after 30 minutes of idle.
Smelly
The VRO and over temp both use the same horn.
The VRO is 1/2 second on and 1/2 second off
A continious alarm is an over temp alarm. (99 degrees C +- 3 degrees)
There should be a temp sender for each bank of cylinders.
You could test each one separetly to confirm proper operation (test light or ohm meter) and the temp that they actually make contact at.
Station-rat