2023 F3L SES Front Sprocket BUSTED! Has anyone else with a "newer" Spyder had a sprocket issue?

[PURPLE ON THREE]

Cannot believe this is an issue after the recall on the older models! I had my front sprocket replaced three times on my 2018 F3 and then BRP did the recall. My dealer/mechanic was always ahead of the game and I never broke down with a bad sprocket... until yesterday on I-485 Charlotte!

What a TERRIBLE sound, no warning, nothing! I was cruising along and tried to give it throttle to pass and got nothing but a terrible grinding sound!

This is my 2023 F3L with 27,500 miles. Luckily, it is under warranty until the end of this month, as I purchased it April 30, 2024. Guess who bought their extended warranty today???

BRP Roadside Assist contacted a tow truck and my Spyder was towed to Ride Now Powersports in Concord, NC. Got there at closing time but they knew we were coming. Of course they don't have a front sprocket or bolt in stock so TommyG went off on his Harley to Iron Horse Motorcycles in Monroe, NC this afternoon to get the parts and deliver them to Ride Now so we can get it fixed and get back on the road.

We live in western PA and are riding to Florida... at least that is the plan. Has anyone else with a "newer" Spyder had a sprocket issue? The dealer said they could get us back on the road in a jiffy because they have new Spyders for sale, lol. No thank you... do you know how long it takes to put swarovski crystals on a Spyder one small crystal at a time? lol

 

[bikerchris1270]

I’m thinking the last tech that installed the failed pulley did not use the specified Loctite on the splines of the output shaft.

 

[PURPLE ON THREE]

I’m thinking the last tech that installed the failed pulley did not use the specified Loctite on the splines of the output shaft.

The sprocket on my 2023 was never replaced - there was no recall on that model year. It's OEM. It should not be an issue. BRP put it together at the factory. I was referring to the older model Spyders (like my 2018 that had so many sprocket issues). I'm disappointed to have to deal with this issue at all on the 2023.

 

[Snowbelt Spyder]

The sprocket on my 2023 was never replaced - there was no recall on that model year. It's OEM. It should not be an issue. BRP put it together at the factory. I was referring to the older model Spyders (like my 2018 that had so many sprocket issues). I'm disappointed to have to deal with this issue at all on the 2023.

Since the recall period, I can't remember a single case that has been reported on here, of a catastrophic sprocket failure on a new machine... until now. So, I'm feeling that this is one of those manufacturing or assembly defects that just come along once in a while. Not a fleet problem. The very reason that we have warranties, I suppose. At this point, what I would be concerned about is that this "emergency" repair is performed properly at this shop. To Chris's point, even though this was a factory installed sprocket, the 2023 F3 shop manual specifies Loctite 609 to be used. it doesn't say, "or equivalent" (what-ever that might be, anyway). Loctite 609 has a full cure time specified as 24 hours. A conversation that I think you would want to have with the maintenance folks at this shop. Don't rush things. Hope that the rest of your trip is uneventful as you were hoping.

 

[Woodaddict]

This Ridenow is my dealership go to. I only go there for NC inspections. 2 yrs ago while there for inspection, they said sprocket recall came up to do. So I stayed extra to have done. They never said anything about a 24 hr cure. Maybe they didn't know or didn't care. I knew about it, but had to get back home to go to work, so I didn't get on the power band at all, just more easy on way home for 25 miles. So in the 2 yrs after, no problems with my 2015 RTL

 

[PURPLE ON THREE]

Since the recall period, I can't remember a single case that has been reported on here, of a catastrophic sprocket failure on a new machine... until now. So, I'm feeling that this is one of those manufacturing or assembly defects that just come along once in a while. Not a fleet problem. The very reason that we have warranties, I suppose. At this point, what I would be concerned about is that this "emergency" repair is performed properly at this shop. To Chris's point, even though this was a factory installed sprocket, the 2023 F3 shop manual specifies Loctite 609 to be used. it doesn't say, "or equivalent" (what-ever that might be, anyway). Loctite 609 has a full cure time specified as 24 hours. A conversation that I think you would want to have with the maintenance folks at this shop. Don't rush things. Hope that the rest of your trip is uneventful as you were hoping.

Thank you for sharing that... Gosh, I hate to be the guinea pig sometimes. Thank you for sharing your knowledge. So here's a question, could it be possible that there was an "old style" sprocket installed? I hope I get to see the sprocket and I know my dealer/mechanic in Hanover, PA would like to see it as well...

This Ridenow is my dealership go to. I only go there for NC inspections. 2 yrs ago while there for inspection, they said sprocket recall came up to do. So I stayed extra to have done. They never said anything about a 24 hr cure. Maybe they didn't know or didn't care. I knew about it, but had to get back home to go to work, so I didn't get on the power band at all, just more easy on way home for 25 miles. So in the 2 yrs after, no problems with my 2015 RTL

Thank you and glad you have not had any problems with you 2015 RTL since the recall!

 

[Deanna777]

I have the same Spyder year and model as you @PURPLE ON THREE, and I haven't had any problems with the sprocket. I have not had any recalls on mine either.

Deanna

 

[Snowbelt Spyder]

Hey Purple. I’m sure that the old, defective sprockets have been thoroughly purged from the system. Besides, they were a completely different color - black. Pretty obvious if one got loose at the factory. Under the circumstances, I believe that the BRP Mothership will want the dealer to send that sprocket back. But it would never hurt to ask if you can keep it, or at least take some pictures of the damage. Your home dealer would love to see them, and so would we.

I didn’t mean to imply you should wait 24 hours on that Loctite to cure before you left. Don’t want to stress you out any more. “Functional strength” is reached after 1 hour, according to their information. So, if possible, that would be a good wait time as a minimum… if it was me, anyway, and as said, just go easy and cruise for a bit. Good luck.

 

[blacklightning]

This post was a wake up call for me. I used to keep an eye on my 2016 F3T and my 2016 F3L. But since the last recall on my 2016 F3L I haven't looked at it at all. I have about a 3,500 mile trip coming up starting June 1. I think I will add that front sprocket check to my pre trip check list.

 

[Mikey]

This post was a wake up call for me. I used to keep an eye on my 2016 F3T and my 2016 F3L. But since the last recall on my 2016 F3L I haven't looked at it at all. I have about a 3,500 mile trip coming up starting June 1. I think I will add that front sprocket check to my pre trip check list.

It really should be done no matter what year or model just because! Every time I do an oil change or have that side cover off, I look at the pulley, just one thing to inspect while there.

 

[blacklightning]

It really should be done no matter what year or model just because! Every time I do an oil change or have that side cover off, I look at the pulley, just one thing to inspect while there.d

You are right. I have a tendency of not checking that too often. I am actually having a tech day at my house locally for spyders and rykers in my area. I have a place with the tools, and a buddy of mine has the knowledge. So it is more of an instruction day for simple things like oil changes, tire pressure checks, etc. But it is something that some in our group had expressed interest in. We will add sprocket check to the list.

 

[Knizar]

It really should be done no matter what year or model just because! Every time I do an oil change or have that side cover off, I look at the pulley, just one thing to inspect while there.

Hmm? When I service (oil change), I don't remove any left side plastic that would allow getting a look at the drive sprocket!
In my near 60K miles, I've never had the left side black plastic removed on my 2020RTL.

 

[Snowbelt Spyder]

Pretty much all you can do is look for the red dust. If you try to re-torque the bolt, you will break the bonds of the thread locker. I can’t recall cases of red dust still happening with the new sprockets. This looked more like a case of sudden, catastrophic failure. They get service at Hanover PA, and we know that they stay on top of things.

 

[PURPLE ON THREE]

I have the same Spyder year and model as you @PURPLE ON THREE, and I haven't had any problems with the sprocket. I have not had any recalls on mine either.

Deanna

Deanna, I'm glad you have had no issues! How many miles do you have on yours now?

 

[PURPLE ON THREE]

Hey Purple. I’m sure that the old, defective sprockets have been thoroughly purged from the system. Besides, they were a completely different color - black. Pretty obvious if one got loose at the factory. Under the circumstances, I believe that the BRP Mothership will want the dealer to send that sprocket back. But it would never hurt to ask if you can keep it, or at least take some pictures of the damage. Your home dealer would love to see them, and so would we.

I didn’t mean to imply you should wait 24 hours on that Loctite to cure before you left. Don’t want to stress you out any more. “Functional strength” is reached after 1 hour, according to their information. So, if possible, that would be a good wait time as a minimum… if it was me, anyway, and as said, just go easy and cruise for a bit. Good luck.

Thank you so much! TommyG is talking to our #1 dealer/mechanic from Hanover right now and he is saying the same thing as you about the Loctite. He says once it gets hot, it's going to cure. And we have a picture of the sprocket...it is not one of the old black ones. And we have pictures of it. Ride Now is discussing the possibility of replacing the output shaft as they have concerns about it. Our dealer at home wants to see pictures of that as well. Thankyou for your knowledge and good wishes!