06' 225XS compressor pulley sheared off

[Beast96Z]

Was running across the lake to weigh in tonight and my motor gradually started loosing speed, then ultimately died. Volt gauge was dead and lights were going dim. Thought I lost the cranking battery, so I swapped in a troller, and it did nothing, but they were run hard. Had someone pull me in. Got home to find the 6 bolts on top of the compressor had sheared off and the pulley and belt fell off. I never heard a thing or noticed much difference except for a small loss of speed. Looks like there is no damage other than the broken bolts, but I'm wondering if I should go ahead and replace the pulley along with the bolts, or just put it back on. It doesn't seem to be the tightest fit, tolerance wise, so maybe that was the reason? Do these bolts normally come loose? Anything else I should look for before repairing? Common problem? Didn't see anything in the search.

[EuropeanAM]

Check the pulley for any damaged (or "wollered out") holes. If all is ok there, reinstall it, utilizing RED LOCTITE on the bolts. Recommend the OEM bolts be used... and regardless of any "thread paste" on the bolts- USE RED LIQUID LOCTITE ALSO.

Torque spec is printed on the top of the pulley, in most cases.

Inspect belt carefully for any signs of wear- replace if AT ALL IN QUESTION (you don't want any additional vibration here).

Once the pulley is installed, check for any "up and down, or side to side" play in the crankshaft (endcap) bearings of the compressor. This is usually easiest to note with the compressor at the "bottom of it's stroke".

Bolts do sheer occassionally.....

[Beast96Z]

What's the cost of the pulley, bolts, and belt? If it is fair enough, I may just go ahead and replace them for piece of mind. Is there any I'll effects to running the motor without the belt other than the dead battery? We got it to limp for about 1/4 mile and then it wouldn't do anything because of the battery.

[Beast96Z]

Also, what's the best method for removing the sheared bolts. I tried cutting a thin groove with my dremel, then used a flat head screw driver, but it just broke off more of the bolt. It would be nice if I could take the plate off, but it doesn't seem to be removeable.

[ducttape]

This happened to me not to long ago. Ended up having to replace the compressor head because the broken bolts would not come out and there was too much play in the compressor shaft. I tried to start mine without it to get back to the dock and the motor over-revved and shut off. Took me 3 hours to get back to the dock then I had to load the boat standing waist deep in water with a cross wind.

If there is enough of the bolt below the mounting flange, you can try to get it started with pliers. Otherwise you can drill it out and retap the holes, but I do not recommend this unless you have a steady hand and a helper.

Maybe someone else can recommend a better way...

[EuropeanAM]

You won't get your Optimax to start without the belt.... because the fuel pressure is regulated to "air pressure plus 15 psi".

If you have no air pressure... (I think you get the picture).

The bolts and belt are not very expensive. Drop me an email with your serial number and I'll price them for you.

The pulley on the other hand.... costly!

[Beast96Z]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ducttape &raquo;</TD></TR><TR><TD CLASS="quote">This happened to me not to long ago. Ended up having to replace the compressor head because the broken bolts would not come out and there was too much play in the compressor shaft. I tried to start mine without it to get back to the dock and the motor over-revved and shut off. Took me 3 hours to get back to the dock then I had to load the boat standing waist deep in water with a cross wind.

If there is enough of the bolt below the mounting flange, you can try to get it started with pliers. Otherwise you can drill it out and retap the holes, but I do not recommend this unless you have a steady hand and a helper.

Maybe someone else can recommend a better way...</TD></TR></TABLE>Do you remember how much the head was? These bolts are stuck. Not sure that I am going to get them out. I have a decent amount sticking above and below the mounting plate, but not sure that anything will be strong enough to hold on to them. Size of the bolt seems to be the problem.

[gambler4]

your compressor is probably shot that is what happened to mine. it should be un der warranty

[EuropeanAM]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Beast96Z &raquo;</TD></TR><TR><TD CLASS="quote">Do you remember how much the head was? These bolts are stuck. Not sure that I am going to get them out. I have a decent amount sticking above and below the mounting plate, but not sure that anything will be strong enough to hold on to them. Size of the bolt seems to be the problem.</TD></TR></TABLE>

Check your serial number again.... the one you sent was not for an Opti....

[Beast96Z]

No warranty that I know of. Think it was out in Feb. 09'.

[ducttape]

I believe it was around $200-$250. Not sure though. It was on a 1999 Optimax 200. My receipt is in my truck, which is in the shop getting the motor replaced at the moment.

[FISH TICK]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Beast96Z &raquo;</TD></TR><TR><TD CLASS="quote">No warranty that I know of. Think it was out in Feb. 09'.</TD></TR></TABLE>

Did you not get the extended warranty?? I have an 06' and my warranty goes to 2011.

[Beast96Z]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by FISH TICK &raquo;</TD></TR><TR><TD CLASS="quote">

Did you not get the extended warranty?? I have an 06' and my warranty goes to 2011. </TD></TR></TABLE>I didn't buy the boat new. I got it from a guy who gets a new one every 2 years, so no need for him to buy the extended warranty. On a side note, the compressor seems to be fine. The boat was running great until the pulley flew off. There is no run out or play in the shaft, so as long as I can get the last 3 bolts out, I should be good. First 3 came out with a big pair of channel locks, no problem. The last 3 are broke off clean with the plate. Trying to drill them out as I speak.

[Beast96Z]

Just an update, the compressor was not bad. I still haven't got the last 3 bolts out, but I put the pulley back on with the 3 good bolts. The battery was shot after being drained, so I bought the Die Hard Platinum 1150 cca battery. Installed it and it fired up on the first shot.

[EuropeanAM]

BTW.... just wondering if PERHAPS there is enough clearance BELOW the flange to turn the bolts DOWN (and remove beneath the flange), rather than UP (towards the pulley mounting surface)?

I've done this before......

[Zimmer250XS]

I replaced my compressor last year on a 250proxs. It was $900 CAN. Covered by warranty under 2012 though.

[Beast96Z]

I haven't tried it yet, but we'll see what happens. Not a lot of the bolt sticking out, but I'll try that before I remove the head and take it to a machinist. I'm pretty sure some of the bolt vibrated loose and that is what caused this whole situation.

[Beast96Z]

Dropped it in the water today and I am still in guardian. I have to floor it to get it to fire off, then it just smokes and runs rough. Have to maintain at least 1500 rpm's to keep it running. Any thing else I can check before I have to carry it to the dealer?

[Beast96Z]

Just checked spark at all cylinders and they are all firing, however, 2 cylinders showed very weak spark. I also checked compression on the top 4 cylinders. 1,2,and 3, all bumped around 145ish, but 4 was around 120. I couldn't get the gauge to the bottom cylinders without getting an adapter. The part that worries me the most is the fact that I only found 2 of the 6 bolt heads that sheared off. I'm worried they may have been sucked into the motor since the plastic cowling somewhat directs air straight from that location.

[gambler4]

you will have to confirm this but if your compressor isnt pumping air (as in when the pully sheared) you either have to doubleoil or the computer doubles oil for a while after it starts running again , you will have oil and fuel in lines that arenot supposed to have it. after my compressor was replaced it took about2 miles of full throttle to clear the engine of ??? but it wouldnt plane out and it wouldnt get over 3000 rpm's at the start of a tournament we were boat 6 and dang near got run over by the othe 100+ boats. it finally quit blowing smoke and coughed a few times and took off i passed about 30 boats after that .