I found my problem. First I'll say I made some wrong observations. I was correct on the motor not getting hot but wrong on the exhaust not getting hot. I removed the thermo switch from it's housing and ran it for about 25 seconds and the tail of exhaust was hot but the water out the pisser just warm, head warm. Earlier I made the assumption the sensor was bad but it wasn't. As soon as I hit the gas the pipe heated up tripping the limp mode because of overheat. I figured I better tear down the exhaust and from initial inspection it appeared fine, from a rookies perspective, ha ha ha.
I tore deeper and removed the head and cap. I did find a bit of sea weed and a fair amount of shells and and but not enough to see it overheat. I saw the water inlet on the underside of the exhaust manifold and seen the ports where it comes up into the cylinders. There are no cooling ports on the reed side. Water just comes in the exhaust side and fills the cylinder jackets and up through the heads, into the exhaust. Since I didn't see anything that was alarming on the motor I took a close look at the exhaust and disassembled it completely. The beaches we rode at in Fl was crushed shells as the sand, (hard on the feet) and I found the the very end of the exhaust with a load in it and the bypass hose clogged completely. There was also a hole in the exhaust where the sand was sitting. There was no flushing this out, this was also in close proximity to the thermo switch thus the reason of excessive heat and no circulation ion that particular area of the exhaust. Actually there were 3 small holes in that area totaling roughly a 1/4". I am glad I did tear deeper so I could see the bore, things look okay there. I have learned a bunch now ands the thing I learned the most was to never assume. I need to take my time and think practically, than things make sense. I found a complete exhaust on eBay for 88 bucks shipped and it looks clean.
If other guys are having similar issues, I would look at the exhaust because that tail section is far away from the flow and could easily be a place to deposit debris. Pull off the bypass hose that seems like a loop at the end of the exhaust where it ties into the large rubber elbow just before passing through the hull into the rear hull area, after that there is not more water in the exhaust, it goes right into the big silver muffler that out the machine. Does the exhaust get circulation to keep the motor area of the hull cool. Anyways, It cool to find the obvious instead of throwing parts and money just to accomplish nothing.
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