Alan - I had the EXACT same thing happen to my Surpass .40, including the bearing issue.
The performance just kept degrading and becoming more and more inconsistant. I tried different fuels, plugs, tanks and prop combinations but nothing worked. Also, the fuel consumption was getting rediculous - over 5 ounces for the pattern.
I decided to try it for one more flight before relegating it to the junk heap. Started it up, was running perfectly and while I was walking out to the handle, it blew up.
The crankpin broke off and was rammed downward, splitting the case.
As you may know, I have many 4S engines but the Surpass .40 gave me more problems than all of the others put together. Yet, I know of many people who use them in RC and love them - go figure.
I should also add that the .40 was he only Surpass that ever gave me a problem - all the others are fine. The Surpass .26 on the Cardinete gives absolutely perfect runs.
Bob Z.