Fast cats have always had a history of lower failures.
The simple fact is the mercury sportsmaster is the strongest (production... just in case there is someone making a bulletproof aftermarket lower) gear case on the market.
If your breaking sportsmasters then you will definatley break any other manufaturers gearcase!
Exactly where appsyscon's gearcase is cracking is where mercury beef up the sportsmaster compared to their standard gearcase to try and prevent breakage.
I definatley agree the casting could be improved though as you can see the air bubbles all through the cast, cant be good!

are the 250 xs motor's having as much problem's as the 300xs motor's ?

thank's
mike

I haven't really heard of too many 250's having the same issues, however there aren't many 250's on the performance boats either. 250's have very attractive prices and performance, but most opt for the 300's on performance style boats. Just saying- 250 may be pushing an 18 foot 1K LBS bass tracker where my 300's are pushing a 8K 30 foot hull.

Not saying the 250's do or don't have the same issues because I don't know, just don't pop up or as prevalent if they do.

I have the 250xs's on My Motion. Replaced a powerhead @ 35hours.

all I can say is thank God I still have warranty ,I just wish we could nail the problem

You just think you have a warranty.

When my lower units cracked the most recent time, I needed replacements 5 and 6, and I still had another year on my warranty left, Merc Racing told me that they would no longer honor the warranty, claiming either improper installation, improper use or abuse. I needed to get Peter and Chris from Skater involved, and then the Florida Attorney Generals office, and threat of litigation. MR finally replaced my units, after much fighting.

I do need to say, that the local MR guys treated me very will, but they do not get to make the decisions.

Warranty
 

I had a battle with Mercury Racing a few years ago with one of my lowers that was under warranty. It took some work and many phone calls, but in the end they replaced it.

I was surprised when Mercury Racing came through on my latest issue. One of my powerheads turned four out of six sleeves. The motor was not abused, but well out of warranty. Mercury replaced the powerhead. I give a lot of credit to my local dealer who went to bat for me.

I never saw anything like this before, nor had my dealer. He's seen a sleeve turned, but never four on one block.

http://i41.tinypic.com/o5s3gy.jpg
http://i41.tinypic.com/k2bsja.jpg
http://i39.tinypic.com/am850y.jpg

Blew a powerhead @ 26 hrs, blew port lower @ 56 hrs ( No water / overheating problems , possibly Maufature F- CK up, rod Bolt came lose :eek:)currently have 76 hrs. I will be upgrading to the mde EfI seal kit. Never once in 250 hrs on my 2.5`s did I ever blow a sportmaster.....Damn Miss my 2.5`s !!
My warranty is set to expire in May, anyone have an extended Warranty ??

I am on my second boat with a 300XS. Just keep up with changing my lower unit oil. 60 hrs so far on current boat.
there are a couple of hard core O/B guys on Performance Boating that run the crud out of thier boats, long hi speed runs. They have a company that they highly recommend and use, and have had many failures covered with 300+ hrs on thier motors. The motor has to be under the factory warranty in order to get the coverage. Their screen names are War Canoe and Bullhead Bully. Both have extensive O/B experience. They are on the West Coast. Here is the link to the secondary provider that they use and recommend:

Don Sullivan

Manager, Inside Sales & Marketing

Protective - Asset Protection Division

601 Carlson Parkway, Suite 990

Minnetonka, MN 55305

Office – 800.328.8690 X158

Fax – 847.572.3125

Email: [email protected]

The last time I checked a year or so ago I think the cost was roughly $3,000 for 3-4 years coverage?!?!? Don't quote me on that!! Good luck, JT

whats wrong with Merc extended warranty ???