Hi Deb, nice to hear from ya! If you need a Spyder fix, c'mon over and we'll let you take a ride. Sorry to hear of your wait, but I have a theory in the paragraphs below.
I can't explain a two month wait for gasket sets, but I do have an idea about the rest. There has been a sudden rash of bad output shafts and front sprocket problems. There are a few possible causes, at least two of which require a major step back on BRP's part. First, it could be a problem with moisture and corrosion. BRP can't do too much about that, but I doubt it is the case. The mild rust shown on Brian's output shaft is not severe enough to cause the splines to be destroyed. It was probably a result of loose fit that allowed moisture to seep in after the wear became evident, and opened a gap where moisture could easly creep in. BTW, corrosion on sline accelerates the wear. I'd recommend lubing the splines if you have the sprocket off.
Now, why the wear? One possibility is a weak alloy, poor heat treating, or poor machining in the front sprocket. Could be a combination of these. A loose spline problem gets worse fast, in a logarithmic fashion, as the parts wear. Another possibilty is poor heat treating, and brittle alloy, or poor machining on the output shaft. There could also easily be a combination of these. BMW has had spline wear and shaft failure problems on several of their modern machines.
BRP would certainly want to try to address these problems. Just like with the faulty Gear Position Sensors, they may have had to obtain a different vendor. Since the output shaft (and maybe the sprocket) is actually supplied by Rotax, that adds a third party. Things this complicated take time, especially with the testing involved to make sure the new part is better. It is always a disappointment when we have to wait, but there may be good reasons that are in our best interests.
One thing is for sure, if anybody will ride their Spyder when they get it back, even in the middle of a Michigan winter, it will be these two die-hards.
