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[smithy]

Hi All,

There was a service bulletin released in July of '23 which noted specific VIN#'s early on in the Experia production run, Service Bulletin # 22-SI-2723, dated July 4th 2023...my Experia was on that VIN list.

The service bulletin gave instructions on how to check for oil leaking from the little reduction gear case into the motor on the Experias. When I first did this inspection not long after the service bulletin was released, I found no evidence of oil in the motor, but now I do..! The little gear case only holds 50ml of oil, so it doesn't take much of a leak to lose most of the oil....I've been keeping an eye on the level and topping up as necessary... and draining the oil out of the motor as required, there is a drain/inspection plug on the motor for this.

I believe Energica replaced complete motors under warranty for this issue if it was found oil was leaking into the motor and they were one of the VIN's listed, there were about 70 VIN's listed in the service bulletin ranging from 006 through to 079. Mine is #029.

The bike is running fine and has no mechanical problems other than this oil loss issue. The bike now has just over 34,000km and has been essentially faultless. The only things I have replaced are wear and tear items, tyres, chain & sprockets, brake pads etc.

There is a lip seal which runs on the motor rotor inboard of the left side rotor roller bearing and seals the gear case from the motor, I suspected it may have been this seal leaking, so I replaced the seal. Unfortunately this is not the case, I'm still losing oil into the motor, not as much as previously, but it is still happening.

I now suspect the oil is leaking along the rotor gear splines and under the roller bearing inner race and seal runner. This part of the motor is accessible without removing the entire motor from the bike, it's difficult but doable.

My issue now is the fact that since Energica has gone into liqudation and we basically no longer have an Energica dealer in Australia, (the dealer is still around but they have no external support from Energica any longer), getting it sorted is not going to happen....I'm at a bit of a loss as to what I can do..??

I have some photos of the offending bits. If anyone is interested, I'll post them.

Any thoughts.??

Smithy.

 

[PWM]

If motor casing is sealed, can you pressurize the housing a few psi to counteract the leak?

[most]

Smithy, I have VIN#47 and nether checked the oil level. For this afternoon, I now have a task.
Please post all you have on this issue, like the service bulletin itself and supporting pictures. It will certainly help about 70 owners…
Thanks
Mat

[smithy]

Smithy, I have VIN#47 and nether checked the oil level. For this afternoon, I now have a task.
Please post all you have on this issue, like the service bulletin itself and supporting pictures. It will certainly help about 70 owners…
Thanks
Mat

No dramas....I've attached the offending service bulletin....and will plonk some photos in other posts.

Smithy.

[smithy]

The next couple of posts will have photos of my Experia with the gear case removed etc.

This first pic is prior to taking the gearcase cover off.

Smithy.

[most]

… so you are in bed with the enemy. I see BMW bolts

[smithy]

Now with the gear case cover removed.

Note the drive gear....driven gear is in the bottom of the pic.

Smithy.

[smithy]

… so you are in bed with the enemy. I see BMW bolts

Yes, there are a few BMW bolts/screws there...the originals are a bit on the "soft" side and tend to damage the heads of the bolts when removed etc.

Smithy.

[svelectric]

Interesting, VIN 080-083 are not included in this service bulletin.  Mine is 082.  I'll still keep an eye on it.  1st and 2nd oil changes were fine (picking up from dealer today, got a new sprocket and chain installed).

[electrictwowheeler]

Is it possible that the seal was installed backwards from the factory? I don't see how else oil could migrate between the gear drive and motor. The side with the spring should face out, the flat side in, toward the motor.

[Commodore]

Thanks, Smithy

Changed my oil at 1130 miles, now at 4664 miles.  All seems to be OK, oil level at 2/3 height of window.  Experia serial no.  xxx095.

Good luck with your issue.

[smithy]

Is it possible that the seal was installed backwards from the factory? I don't see how else oil could migrate between the gear drive and motor. The side with the spring should face out, the flat side in, toward the motor.

You are correct...and yes, the original seal was installed correctly...with the rear "spring side" facing out towards the gear case. I installed the new seal the same way.

Smithy.

[smithy]

Another pic....this time with the drive gear removed showing the rotor left side support roller beaing.

Smithy.

[smithy]

Now with the outer rotor roller bearing removed to reveal the inner rotor seal.

Smithy.

[smithy]

Drive and driven reduction gears.

Smithy.