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  1. #61
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    Merc swore me to secrecy on how this was resolved

    Having said that, this makes me want to open up my new one and have a look.
    13' Biel tunnel AKA "Flight Risk"
    13" Modified Yamaha V4 - 101 mph

    21' Paramount
    Mercury 300 Promax

  2. #62
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    Quote Originally Posted by Liberator*21 View Post
    Let me throw something else into the pot:

    One further thing that must be considered in this evaluation, there is "NO" evidence to support it as a scored journal vs cast surface. As a rotating mass it would display smearing to some extent in the direction of rotation, that does not exist in the photo. Since the bearings are of a needle type, hammering would be displayed the length of the journal/needle bearing surface as the journal and needle bearings are directly parallel to each other and therefore would impact the entire surface (had it been there to begin with) and not a local area.
    I,ve seen cranks with a million hours on them and they looked like that. The hard casing has just been worn off. You would think you would get spalling following the rotation but no.
    If it was new you would say it was a manufacturing fault.

  3. #63
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    Quote Originally Posted by half fast View Post
    He said it lasted 200 hrs.If in fact it was like that from the begining it would have made it maybe 20 minutes.When the heat treated outer surface goes that is exactly what it looks like on any outboard crank. hf... Don't really care if he is fortune 500 or not .How many outboards or optis has he worked on ?
    yebbut remember, this is a compressor, not a motor. it's only loaded on the intake stroke and at that, only by the force of compression. i can't imagine that it has anywhere nearly the hammering forces applied to it that it would if it was undergoing a power/combustion stroke like a motor does. I'm with the guys that say "defect".

    -Peter
    "padded wonder"
    __________
    the wet:
    Hydrostream Viper, 140 v4 crossflow, some Raker props
    16' Baja/Tahiti/Sidewinder clone, 135 v4 crossflow
    17' boston whaler alert, 90 merc fourstroke
    13' boston whaler, 40hp yamaha

    the dry:
    2003 bmw ///M5
    1993 mustang/griggs racing road race car
    and a handful of clunkers

  4. #64
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    It is about time to open up a new compressor and verify design changes or improvements to the original. To me it SHOULD have 2 bearings supporting the crank, one on each end, but I think it is impossible to assemble unless both bearings are in the top cap.

  5. #65
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    The moral to the story is that if the motor is out of warranty, you are out of luck on the compressors. We lost one in our first 250 XS with about 175 hours, Mercury did not care. No help. We replaced the compressor and sold the motor. The real answer is where the compressor was assembled, "Mexico". You don't think they care about us, do ya. The latest compressor is supposed to be the final fix for the issue, we hope, since we have 3 300XS's in our current possession. However, the cost of the replacement compressor is not really too bad if you think about how much fuel you have saved running an Opti. over non direct injected motors. And when we replaced a 250 offshore with a 250 XS, the fuel savings was a staggering 40%. Just our 2 cents!!!!

  6. #66
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    Whats the price for a new compressor? I have a 2007 300xs.
    Checkmate 2002 Convincor 270 496 MAG-HO

    2003 Cougar 22MTR w/300xs SOLD
    90 21Skater w/300xs - sold
    98 STV Euroski w/280 - sold


    2006 Trailblazer SS 6.0l 395hp

  7. #67
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    Quote Originally Posted by Euroski View Post
    Whats the price for a new compressor? I have a 2007 300xs.
    750ish, depending on how bad your dealer does you.
    > Stainless steel Merc cowling plates - $110 shipped TYD - LINK <

    1979 16' Action Marine/2.5L Merc S3000 - Metalflake Maniac
    1984 18' Contender Tunnel/2.4 Merc Bridgeport

    "Where does the love of God go, when the waves turn the minutes to hours?"

  8. #68
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    list is 792.00.. plus the injector cleaning/replacement.

  9. #69
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    how sure are we that the new design compressor is supported at BOTH ends of the crankshaft? i've got folks climing my azz on another forum for proof of this. anyone got pics?

    -peter
    "padded wonder"
    __________
    the wet:
    Hydrostream Viper, 140 v4 crossflow, some Raker props
    16' Baja/Tahiti/Sidewinder clone, 135 v4 crossflow
    17' boston whaler alert, 90 merc fourstroke
    13' boston whaler, 40hp yamaha

    the dry:
    2003 bmw ///M5
    1993 mustang/griggs racing road race car
    and a handful of clunkers

  10. #70
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    Does not sound like it is much different. Just sounds like they have added an extra bearing in the end cap to support the crankshaft better. Do not know anyway they would be able to get it together unless it was built this way, without a major rework

  11. #71
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    Quote Originally Posted by Wayne Cammidge View Post
    Do not know anyway they would be able to get it together unless it was built this way, without a major rework
    oh. I was hoping they DID do a major re-work.

    ninja edit in italics, sorry

    -peter
    Last edited by pcrussell50; 09-03-2013 at 01:48 PM.
    "padded wonder"
    __________
    the wet:
    Hydrostream Viper, 140 v4 crossflow, some Raker props
    16' Baja/Tahiti/Sidewinder clone, 135 v4 crossflow
    17' boston whaler alert, 90 merc fourstroke
    13' boston whaler, 40hp yamaha

    the dry:
    2003 bmw ///M5
    1993 mustang/griggs racing road race car
    and a handful of clunkers

  12. #72
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    My last outing at the end of last year I noticed what I thought was a momentary rod knock after firing up on a cold morning. Thinking I might be developing a compressor problem, I replaced it with a new one before running the motor this year. What I was hearing wasn't related to the compressor, some piston skirt slap as they round up from a cold start. The old new style compressor is sitting on my work bench. I expect to find it in good condition internally when I open it up, hot up here in the north country for a couple more days so I will update after some more serious hours/days of boating /skiing. I'll still go out on a limb and say it can't be assembled with bearings at both ends.

  13. #73
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    Quote Originally Posted by Liberator*21 View Post
    Being a Manufacturing Engineer, I know what I see here. I totally agree with Stitch King, factory defect. That area is a raw casting, no material there from the beginning to machine.........

    i have seen several wheel bearings that the rollers in the cage look like new. but the race that the rollers ride on have damage that looks about the same as that compressor does.

  14. #74
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    I've seen this exact issue on HP snowmobile cranks, the technical term is "flaking" and is due to the thin nitrided/hardened layer flexing under high pressure in a localized area which eventually fatigues the harder surface which comes off in flakes creating "casting like" craters etc.

    The type of failure shown here is typical of a needle roller bearing flaking failure, in the link below you can see how it looks on a ball roller bearing;

    Click image for larger version. 

Name:	tt-flaking.jpg 
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    I don't want to get into an argument of how/why/who is at fault or why it happens but I can relate how we fixed the issue to repair cranks that had these issues...had a similar issue with needle roller bearing on Muncie M22 transmission input shafts as well.

    You can hardface weld the shaft and regrind so the hardened layer is thicker or you can grind undersize and chrome oversize and then grind to size. Since this part is so tiny welding would have to be done via TIG and thin 1/16 chrome facing rod or the part undercut and radiused so the chrome could be ground flush with the mounting face/flywheel.

    My educated guess is Merc nitrided this surface or laser hardened the surface (which I doubt because I dont see the typical discoloration) and its too thin to handle the vibration/load.

    Ideally the bearing surface area needs to be longer to handle the load, you could press fit a die pin custom ground to size and install a longer needle roller bearing if there is room. None of this is easy to do and obviously Merc thinks that increasing the rigidity of the crank will reduce failures to tolerable levels.

    Its too bad these tiny engineering flaws are ignored during the design phase where they are easily fixed, the occillatory nature of the load on this little crank would be easily handled with a plain bearing if there was enough oil to keep it lubricated but that would require a seal and an oil supply to accomplish.

    Seen it many times, chroming and regrind was the cheapest fix but hard facing rod was the most durable...nitriding is just too thin for this application.

  15. #75
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    Subscribed to thread. What year did this newly designed compressor get installed in the motors? Just purchased a 2012 250 sport XS that was manufactured in Dec. 2012 I assume due to the # 12 being inside a large square on the engine ID sticker.

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