Re: Safe cruising rpm and WOT rpm the same or different
an outboard motor should run all day at WOT, especially a smaller motor.
I think stressing the "especially a smaller motor" part is important. The higher the power density, i.e. power output per unit of mass and displacement, the quicker temperatures can build above safe limits in critical components.
100% power duty cycle in any marine engine is a function of metal mass and cooling system performance to dissipate heat. The more metal mass you have in the engine components, the more heat it can take without distortion. For instance, in a gas MerCruiser stern drive operating at continuous 100% power, cylinder head, oil and exhaust temps will eventually rise to a point that overwhelms the cooling system and you'll get shortended valve seat and valve face life, and shortened bearing life, as compared to operating the engine at a lower continous power setting. However, a Cummins MerCruiser will run all day, around the clock, at 100% power without hurting it. This is due the iron mass in the Cummins diesel, as compared to the gas power unit that may have the same hp rating - the Cummins has enough iron mass to take extremely high operating temperatures without dimensional tolerances changing in the engine.
But like you say, the fuel penalty for continuous full throttle operation is huge. I really can think of few situations outside of racing where you'd want to run your engine at much above 85% power, continuous.
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Chris