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

[PURPLE ON THREE]

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 serviced at Hanover PA, and we know that they stay on top of things.

Snowbelt, on my 2018, Ryan at Hanover changed the previous sprockets when he spotted that "red dust of death"...one time I had only traveled another 8,000 miles and it was time to change it again...

 

[Snowbelt Spyder]

Snowbelt, on my 2018, Ryan at Hanover changed the previous sprockets when he spotted that "red dust of death"...one time I had only traveled another 8,000 miles and it was time to change it again...

Yeah, you've got an excellent support system there with Hanover. And it seems like the dealership where you are now is competent enough. Otherwise, they would have just slapped a new sprocket on there and sent you on your way. The 2018, of course, was part of that recall population. Those sprockets had a specific machining defect from the vendor, and for a while, replacement sprockets that were still in the supply system had the defect also. All that has been corrected. Your F3 came with the new, corrected sprocket. This failure has a root cause of course, just not the same one.

Just saw the picture. The sprocket and shaft did a pretty good job of grinding away on each other. Are you getting a new shaft also, or have they evaluated that already? Oh, just read your update in post 1.

Once you get it all buttoned up, I think that your biggest issue from then on will be traffic and sun screen. Off you go. Be safe.

 

[PURPLE ON THREE]

Yeah, you've got an excellent support system there with Hanover. And it seems like the dealership where you are now is competent enough. Otherwise, they would have just slapped a new sprocket on there and sent you on your way. The 2018, of course, was part of that recall population. Those sprockets had a specific machining defect from the vendor, and for a while, replacement sprockets that were still in the supply system had the defect also. All that has been corrected. Your F3 came with the new, corrected sprocket. This failure has a root cause of course, just not the same one.

Just saw the picture. The sprocket and shaft did a pretty good job of grinding away on each other. Are you getting a new shaft also, or have they evaluated that already? Oh, just read your update in post 1.

Once you get it all buttoned up, I think that your biggest issue from then on will be traffic and sun screen. Off you go. Be safe.

Lol, traffic and sun screen! Well, it's going to be warm here in Florida this week so we already need the sunscreen, but I'm not complaining! I was happy to not have to ride in heated gear on Saturday to get down here! I understand what you're saying about the root cause... I just wonder what that may have been... maybe Lenny can share more once he replaces that output shaft... Have a blessed day!

 

[PURPLE ON THREE]

What actually fails? The fit between the splines of the output shaft and the sprocket? Poor metal hardness of the sprocket? They require locktight to take up the slack? Is the output shaft damaged if the fit fails?

Well, I know the output shaft on my 2018 was fine, even though I had three sprockets replaced.

What we are finding out with the 2023 is poor metal hardness of the sprocket leading to poor fitness of the splines of the output shaft and the sprocket. With the poor metal hardness of the sprocket, sometimes just the sprocket fails, or in our case, there is damage to both the sprocket and the output shaft. The Loctite does not take up any "slack". It's just a safeguard I guess.

I want to see that output shaft... and I will, we saw the sprocket. I'll add photos of the output shaft once I get some pics of it. BRP wants the failed sprocket and output shaft back.

 

[Deanna777]

Deanna, wish you nothing but the best this summer with your riding season!!

Jody,

Thanks! I hope to have a great riding season

Deanna

 

[PURPLE ON THREE]

Altho admittedly, this one does sound very much like the previously encountered shaft issues, there's a chance that it might not be the sprockets actual mounting to the shaft bit that's at issue - we've seen a couple here where the guide flange on the edge/sides of the sprocket has broken off the sprocket proper - so the sprocket still functions and is properly connected to/mounted on the output shaft, but ring that was that flange can be trapped between the engine and the sprocket/belt, or if it's on the outside, come flying off as the sprocket spins, making a helluva noise as it does so, but in either case, the belt can (and does) then eventually wander off the sprocket during normal operation!

I think there's at least one pic of a sprocket that's failed like this posted here on the Forum, and there's a few more comments from owners over your way who've had the same experience; but IIRC, there have only been a few instances like this and they've all been fairly recently. I'll do a bit of a search around later, to see if I can bring anything up.

Thank you, Peter!

 

[tntnj]

WOW ! I always get a safety check from my dealer before I do a long ride (3K or more about every two years)
That must be a bad feeling giving the gas and nothing.
Glad you are safe, that is what matters most.

 

[PURPLE ON THREE]

WOW ! I always get a safety check from my dealer before I do a long ride (3K or more about every two years)
That must be a bad feeling giving the gas and nothing.
Glad you are safe, that is what matters most.

I think that's great you have a safety inspection! Well, my dealer felt bad about this for sure. This happened April 8 and he put on a new rear tire April 7, also new rear brakes. I did not ask him to check the whole Spyder because he squoze me in for the tire and brakes. We have inspections every year here in PA and I am at my dealer at least 2x per year for the rear tire replacement. He is the one who caught all of my bad sprockets on my 2018 before there was an issue. Anyways, yes, glad I was safe BUT this issue really needs addressed by BRP, it IS a safety issue. It was a VERY bad feeling being in the far left lane of I 485 doing 80 mph and had to make my way to the right with all the traffic. I could have easily been hit if the drivers around me were not paying attention. I am so very grateful and thankful for safety. We did around 2500 miles on this trip and are heading out to ride Rt 66 next week. I have a full inspection in June with my dealer as we are headed west for an even longer trip. Hope you have a great summer of riding!

 

[tntnj]

@PURPLE ON THREE, If I recall you have another F3. I know there were problems with the pulleys, but, I thought that was taken care of. I guess it is now going through both the RT's and the F3's. I hope this will be covered if someone is out of warranty.

Ps. Love tour videos.

 

[PURPLE ON THREE]

@PURPLE ON THREE, If I recall you have another F3. I know there were problems with the pulleys, but, I thought that was taken care of. I guess it is now going through both the RT's and the F3's. I hope this will be covered if someone is out of warranty.

Ps. Love tour videos.

Yes, I had a 2018 F3L and the sprocket was changed 3 different times and now on my 2023 F3L. I agree about covering it if out of warranty, it should NOT be an issue and it IS a safety issue. Maybe NHTSA needs involved, but better yet, BRP NEEDS TO FIX THIS! Thank you, it is harder for me to make videos when we are out on the road, but I try... lol. I'm not Itchy Boots.