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On another note, a friend of a friend mechanic said he thinks welding the crank to the driveshaft would solve the issue and last until the motor itself fails. Thoughts??
 

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On another note, a friend of a friend mechanic said he thinks welding the crank to the driveshaft would solve the issue and last until the motor itself fails. Thoughts??
First you need to center the engine. If you are going to weld the shaft, then in the subsequent repair you will have to change not only the crankshaft but also the jet shaft. Take a shank of a new sample, cut the old crankshaft, make a thread and screw a new shank. If you have companies that are engaged in turning, they will do it cheaper than buying a new crankshaft.
 

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guys, good night.

i'm from brazil and i managed to carry out a low cost and long lasting repair.

the first step was to sand the part that was oxidized to remove all the existing rust. After removed and sanded well, I measured the piece with a caliper.

the original piece is 32 millimeters in diameter.

after removing all the rust my piece was 31.40 mm.

it is also necessary to remove the dark part of the part that is not oxidized, so that it is uniform and the repair is reliable.

I went to a turner that made a stainless steel cover for the shaft with the measures of 31.40x34.85x44mm.

with the cape in hand, I expanded it with the torch and fitted it to the shaft. an iron adhesive was also used between the part and the cover to improve the fixation.

after the repair was completed, it was necessary to exchange the retainers for larger internal measures. in my case the measurement jumped from the original axis from 32mm to 35mm.

I am attaching the photo of the completed repair.
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Add me to the list.
Spark 900 HO ACE 2up - 2015 - 86hours

First, I had to change the wear ring. Discovered a misalignment with the motor... Image shows the new one after only 2 hours of usage.

Within like 5 minutes, I went from driving at full speed (80 km/h) to 5 km/h because the tooth of the shaft suddenly started grinding... what a noise!

Planning on repairing during winter...


Also, I had a problem with the gear of the oil pump. That gear is made of plastic and it was almost melted to the center!
That part cost 20$ but the time and gaskets and all... total bill was about 1100$CAD
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only option im aware of ( and ive researched a fair bit) is to replace the crankshaft. = complete engine strip and rebuild and not cheap in parts either. my local agent has priced this at $9k nzd. ( i bought the ski for $8.5k 2 years ago). i threw some nz consumer law at seadoo and they offered to supply the crank and pto at no cost. cant do a job like this myself so still leaves me $5.5k out of pocket which i think is still unreasonable when this is clearly a design flaw (this should be a recall on all 2014-15 sparks) so im still pushing them harder. recommend people do the same. contact seadoo support and dont take no for an answer.
 

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I have 2 2014 seadoo spark 3 Ups baught used two years ago with each having about 23 hours on them. The first crankshaft stripped 3 months ago and is currently at the shop for "appraisal". The second one stripped the splines an hour ago. This is very frustrating that BOTH of my skis are now majorly broken almost to the point of replacement. I was going about 40mph and it just suddenly out of nowhere lost all power. Checked the wear ring and it was good and then realized the issue was much larger than anticipated. Im going to see if there is any way to get two new crankshafts for free from someone. I am able to do the job just didnt have time or patience for the first one.
 

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Yip it sux alright. 23 hrs is BS for a chronic mechanical failure like this. dunno what your consumer law is like in USA but go to BRP first up. At the very least they should supply you replacement crank and PTO (x2) for free. I have heard of other spark owners receiving this resolution from BRP.
 

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I just finished a teardown of a 2014 to replace the crank. Just got it running again successfully. If anyone needs technical advice along the way while rebuilding theirs feel free to ask. I also have the service manual PDF
 
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