Crank Shaft Spline Failure.

[XbWolf]

well, i'm not quite for sure how this happened...

the other day when i got home from work, i was pulling the bike in through the front door, and it died. i didn't think much about it, until about 30 minutes later when i was going to leave to see my dad. the bike wouldn't start... the starter was going, but not turning the engine over...

SOOO.... after further investigation, here is what i found..

http://www.buellxb.com/buell_images/8059_20110326100446_L.jpg

the crank shaft splines stripped off....
i'm now at a loss here, i'm not quite sure exactly what options i have....
i need help.

[XbWolf]

http://www.buellxb.com/buell_images/8059_20110326102233_L.jpg

just my luck.

[Livers]

How tight was the nut on removal?

[XbWolf]

it was almost finger tight. so... loose.

[Sirius815]

Wow - interesting break. How many miles do you have on your bike - just for reference?

[rusty2004xb]

Bummer...:(

[redrider]

If the bolt that holds the primary drive gear to the output shaft was loose i could see this happening.It also looks to me that it could of been done over time and engine braking. sorry man it looks expensive. what is the milage on your bike and have you ever had your output drive gear off?

[Livers]

it was almost finger tight. so... loose.
That was the cause, then. You need a crank repair or replacement.

[seatonii]

I had a similar issue with my X1. The nut backed off and the engine started to make a mild knocking noise. I rode the bike home and took it apart and found the nut loose. It put some wear marks on the splines but nothing like yours. I replaced the nut with a new nut and backed off again within 50 miles. I tired another new nut with Loctite 620, stud and bearing mount, on the nut and it backed off within 50 miles. Finally I used Loctite 620 on the splines of the crank and the nut. That was about 5000 miles ago. So if the wear is not real bad it will work. From the looks of your pics I doubt it will work on your application but I would try it before replacing the crank. I think they stopped making Loctite 620 but I am not sure. I think i saw a similar product called 630. Check with someone that can research Loctite products. What you are looking for is a product that is designed to repair damaged or worn shafts and bearing mounts. If you needing else about this please let me know, I understand what you are going through.

Dwight
Nashville IL

[redrider]

Did something change with the newer motors cause mine is a bolt my bike is a 2010 this is giving me the creeps! I changed my output drive sprocket to a xb9. I used a new bolt w/red locktite torqued to 150 foot lbs.

[XbWolf]

there is 4100 miles on my bike.

i talked to a service technician at my local harley/buell dealer and he said it should have made a noise before it went out... i had no noise. the bike ran and sounded fantastic until this happened.

so my options are, Replace the crank shaft, or repair the crank shaft. right?

so, the best fix would be to replace it right?

[XbWolf]

i'm sad... i won't be able to ride for the rest of the year..

http://www.buellxb.com/buell_images/8059_20110326100652_L.jpg

[XbWolf]

and have you ever had your output drive gear off?

no RedRider, i have never had the drive gear off before now.

[Loki]

. i won't be able to ride for the rest of the year..Â*
If you dont get it fixed you wont... Riding season hasnt even really started yet. Just replace it and youll be on you way in no time. [up][up]

[buelladdicted]

this has been going on since the first evo sportster motor,sorry two hear it. I have a friend w/ an 04 crank in his 94 sportster for that same reason.

[jimijeans]

A really talented Welder could zap that . This would require some serious patience to file it close to perfect.Plus a good rinsing for the tiny debree. If it was me I would [replace] it. That I know really SUCKS and please put the orignal parts back in so that won't happen again. I realize the XB9 parts(use) advantage you wanted,but unless you spot weld the end area AFTER you install all the needed parts,it Will happen again.Of course the Stator goes bad you have a hard job on your hands. It's always best (my opinion) to replace the broken parts.See if Buellister parts has something as well.Just a thought.~Jimi

[chrispudd]

Doh! sorry to hear the bad news. New crankshaft is approx $1000 too. Maybe faster to buy used engine from Buellster so you can ride sooner and keep original engine on backburner for a sweet rebuild someday. Hope it all works out.

[jstfkndi]

I say buy a whole used motor. Rebuild the other in your spare time (I realize easier said than done) but at least your bike would be together and you could really dig down int he one you have to see how it all works. I hate trying to put a bike together that I don't really know that much about when I want to ride it. The tendency to hurry and take short cuts is more enticing than when you have the extra time.

For what it's worth, I had the same problem on one of mine and if you do get a used crank with a good half, you might find someone to split the crank and put it together. I lucked out with and extra from a previous buy that had the opposite side shot, but good output splines. Guy did a good job and it was relatively cheap ($190 or so). Sorry to see this man and hope you get your bike up again soon. Redlocktite and stand on that torque wrench!

;)

Also, I engine brake quite a bit. Has there been an association with the shaft stripping from that? Always have done it on my bikes, as I though they were equipped to handle.

[gater]

This sounds like this might the problem my brother might have with his Ulysses. We won't know until he takes the motor apart.

[XbWolf]

i like the idea of getting a whole new motor to swap out.

that would make me feel a little better about spending 2000 dollars to remedy my problem....

i just can't justify paying this much money and having a completely stock motor still, you guys know what i mean?

i would enjoy having MORE power... i think all of us would. LOL

[XbWolf]

does anyone know of any GOOD upgrades i can do to this motor once i tear it down to gain some HP?

[anrkizm95]

engine kits,cams,heads,big bore link (http://www.revperf.com/XB9-XB12/XBHome.html)

[Sirius815]

If you have a 12, put in 9 pistons for increased compression. If you have a 9, put in 12 pistons for decreased compression and add a turbo :D !!

Also lighten up any rotating parts - much like point_doc did. (I think that was his user name) He's got some pretty good write-ups on another buell site - can't rememeber at the moment.

[jstfkndi]

I would go 1250 kit, port and polish and cams. Of course have never done those things, so can't give any ideas of daily driveability, but was my plan before selling. Also wanted to lighten the crank, but that can get really expensive and from what I've heard, if you're not racing it, it shouldn't make that much difference. I would've done it though :)

[Ranger3987]

so not to hijack the thread but I had the exact same thing happen to my xb12s and im curious if i have to split the case to replace the shaft and if anyone knows parts wise what it will end up costing me

[jstfkndi]

I think except for the gaskets and parts that have failed (assuming you buy a crank new and replace the bearing on the case)about $800-$1000. The crank is uber expensive and you are better off buying one from someone parting out their motor. Try to get the connecting rods on it already if you can. usually, that is the way they come as I don't see many people having the ability to split them. takes a major press!

I apologize if I am off on the quote, but I think i remember the crank being around $800, gasket kit about $130, bearing (at least on lunched side) ~$35 Haven't looked up part prices in some time though.