Just my 2 cents. I had similar problems with my 1995 Evinrude 150. Paid good money to have it return to me still with issues. My tach was bad. Not sayin your is but mine was. Unhook it from the back and try to run the engine, just try it see what happens. Good luck.
Did a quick re-read of this thread Sutor and the whole thing doesn't add up, I'm sure you'd agree.
It's not like you to leave any mysteries behind.![]()
I hooked up the old powerpack and LEFT THE TAN WIRES DISCONNECTED and the alarm was sounding with the key on!!! (Keep in mind the motor is NOT overheating, and is premix from the factory.) There was a short somewhere in the powerpack that grounded out the tan wire is my guess. When I put the new pack on, again with the tan wires completely disconnected, the buzzer buzzed for a few seconds intermittently, and then stopped. At this point, if the diode is not bad, maybe there is a short in the harness.
... yet finding & fixing a short from the tan wire to the block fixed it.I also ran the motor with the tan wire disconnected from the powerpack, same issue.