One of the posts from 8/2011
Something Is Rotten in the Spyder engine
RS2008 SM5 with 129K miles under BRP Best Warranty:
Original Rotax 990 engine quit suddenly September 2010 with 87K mileson the Salt Flats during the 130 miles/hour attempt (front and back pistons melted) tacking out the turbine from the Aerocharge Turbo; all maintenance done in the service including valve check 6, 12, 24, 36, 48, 60, 72 and 84K, shimmed at 48K. See BOSSWeb.
Second Rotax 990 2010 engine stalls unexpectedly at 42K miles during the 2011 Spyder Triangle Event 20 miles NE from Reno, NV on the highway (previous oil change done under 2,800 mile in NY state). All maintenance done in the service including valve check 12 (99), 24 (111) and 36K (123K). See BOSSWeb.
If the first incident was an accident, the second was a coincidence and I do not believe it. So I called Rotax (Austria), Aerocharge and Aprilia (Germany and US):
1. The Aerocharge Turbo: dial in at 12-14 fuel/air ratio; no other turborized engines melt down.
2. Rotax 990 OEM non-forged (cast) pistons: unanimously they need to get replace from any Spyder that supposed to run long time under full throttle; already they are many other owners with the non-turbo engine failure.
3. Fuel management- fuel pump and injectors: according to Aprilia engineers, the Spyder have the tendency to lean in long full throttle instances due to lack of fuel (fuel pump and/or injectors).
BRP did not cover the warranty on the first engine; paid cash for the second engine (full list price) and engine installation (swap 3 times, still full list price). According to BRP: because the second engine was cash purchased, carry no warranty, despite the purchase and installation in a BRP authorized dealer. Spyder transportation, rental cars or plane tickets were not covered either.
The Bosses reply:
"Well Doc I would agree with you if I didn't know the rest of the story and hadn't seen how you drive. I think you got exceptional mileage out of your first motor seeing you rode it as hard as you do and then put a turbo on it with stock pistons at 80K or so. I told you that was not going last long and to be honest it lasted way longer than I thought it would. How many miles did you drive it at first with no air filter on it because it kept falling off? Not only that but the air filter is now outside of the bike where the tire throws up dirt right into it.
So the second motor you ran 3 quarts low on oil on a 4 quart motor when it blew and you want to blame Rotax on that? When you ride that hard for that long with a turbo with stock pistons you're going to get some blow-by, that's why they have a catch can that comes with the turbo. You should have been checking you oil every 500 miles or so to see how much you are blowing by to figure out when you need to add oil, and you will need to add oil.
There is a reserve built into the injectors but anytime you're going to hold any motor full throttle for miles and miles you need to put it on the dyno and make sure your air/fuel is correct for the abuse you plan on putting it through. In your case when you put the turbo on all bets were off. This is a classic case of if you want to play you're going to pay.
Sorry Bro I love you man but there's over 30,000 Spyders out there and most of them are holding up just fine. If you want to race cross country wide open throttle you better build that motor like we talked along time ago. I've been there done that and was trying to help you save some money by doing it right. You keep throwing stock motors on a turboed bike and run it balls to the walls like you do it will blow again. "
From 2/2011
RE: Multiple engines
"I might be on engine 3
I just called today to get my oil leak fixed again, (the water pump shaft gasket) and on the way back (it was 49 degrees up here, beautiful day for sure) I noticed some black smoke in the exhaust which sucks cause to was pulling great today.
so I listened to the engine and for the last two miles home it felt light on the throttle, my buddy put it in the trailer and it sounded fine (NOT LIKE LAST TIME) but you could smell oil more than usual.
I am hoping that it just needs a valve and cam adjustment and it was not smoking in the garage, the unknown issue is that I got some "we are almost out of gas" gas in AZ and it was popping when I was low on gas which I was not today.
I have to work till 6am get home hook up the trailer and get up at 11am drive to st cloud,dump the spyder and trailer at my main dealership that does NOT have the best wrench in MN anymore and come back to work tonight. "
I cannot find the red line comments--so will retract them.
