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FIXED!!! Just did the JB weld fix and it's holding up amazing. I made a video on how I did it I'm going to edit and upload to YouTube for anyone needing help
10104
 

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The seals failed from the rust on the crankshaft. I fixed the rusty crank. Since no one wants to tear the motor apart to replace the crank this is a easy fix. Luckily my splines were in good shape
 

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Count me in for a class action.
Mine happened after warranty but was caused by the dealer not aligning the motor in the ski properly after replacing the hull (that's another story). Long story-short if you own a Spark you better learn how to work on them.
I have two 2015 Sparks; one striped the splines and both rusted at the seal area causing leaks. The crank shaft is now almost half the price it use to be (+/- $800) so I'm doing mine myself now.

Word to the wise...if your skiing in salt water change the output sleeve seals every two years. Check your motor alignment during this time if you a do lot of wave jumping or your motor gets removed for some reason. Sea Doom engineers allowed for to much linear travel on these drive shafts. I'm guessing that hulls flex more than fiberglass.
One more. Don't mix your antifreeze; I'm finding out now during this tear down that the same dealer above top mine off mixing variants of antifreeze. I'm glad I caught it now.
 

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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. View attachment 10018 View attachment 10019
Pedro, gostei da sua idéia, também sou do Brasil. Poderia fornecer mais detalhes para eu fazer o mesmo? Obrigado!
 
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