Drive Unit, Spare Parts, and Tips

Glad I took a closer look at the new pedal drive unit. The new pedal sail mast isn't connected to the sprocket by a cotter key (pin) like the old one, it is attached by a set-screw. Does that mean the spare masts I have with a cotter pin hole won't work in the new drive unit? If not, where can I get spare masts (set-screw kind)? I don't see them in the parts catalog. I really, really don't like the idea of kayaking without a spare because I've already bent three masts on hidden submerged objects.

Does the new Mirage Drive unit have sprocket bushings? If it helps, the SN on the old drive is 25394 and the SN on the new drive is 34769.

My worst nightmare happened as the Drive Sail stopped working after riding a wave. The failure occurred 10 miles away from the launch site, while in 3 foot seas, and with an area of current to go through to get back. Wisely, I had a spare drive sail from an old drive unit with me, but to my horror, it would not fit because my old drive unit is different from the new drive unit. It took a long time to paddle the tub, but I managed to get back to the launch site.

I can't trust the Hobie Outback anymore on long trips. Important components like steering are held together by cheap plastic ties which were not meant to be used in swivel connections. Now it looks like someone has compromised production parts in order to save money. Whoever it was, just ruined my long 4th of July weekend.

Now I have $750 of drive units (2), neither of which are working, and the new one we can't get parts for yet.

I'm ticked off! Time for me to go back to regular paddle kayaking and search for other pedal boat alternatives.

Do you have a new Mirage kayak or drive unit? You might want to take off your drive sail to see if it has been butchered so you don't have a nightmare.

Bye

I am shocked, disappointed and VERY CONCERNED. I'll be interested to read what Hobie's response is to this posting.

I don't expect to read much. The more Hobie responds, the more liable they are. Heck, Hobie hasn't responded to my June 11th post when I talked about concern for drive parts not matching those available in the catalog and asked if the new drive has a plastic bushing.

What if someone's drive breaks and they fall in the water because their kayak suddenly became unstable (which it will trying to pedal with only one flipper working), and drowns? What happens if someone is fishing a few miles off shore and a sudden storm comes up, and during their mad dash for shore, their drive unit breaks and they get blown dozens of miles out to sea? Yeah, Hobie can be liable if their manipulated parts contributed to the cause.

Can you say, "Damage Control" and "Product Recall?"

Hey Hobie - is my new Pedal Drive Unit still under Warantee? Who do I need to call about getting my two broken drive units fixed and getting replacement parts?

Have you tried to contact Hobie directly? I had some issues with a Quest that I have, when I contacted them, they seemed pretty interested in getting the problems fixed. If the boat is still under warranty, I'd check with the dealer you bought it from.

4925 Oceanside Blvd.
Oceanside, CA 92056
[email protected]

1-800-HOBIE-49

Yes. Hobie has said the failure of the drive sail had nothing to do with the drive sail being cut in half at the supporting ring and that they will replace the drive sails (rubber fins). I've ordered parts for my old drive and await to hear from my hobie dealer about obtaining new parts for my new drive unit.

I hope you can get your problems figured out. Since the Mirage system is new technology, I would imagine that Hobie would address any problems now before they produce more.
I design and manufacture some unusual stuff that is used in severe ocean conditions. Maybe I can help you with some of your issues.

Hobie has been in contact and has assured me that cutting the Clevis Pin rubber support ring from 9/32" to 4/32" (cutting the support by more than half) had nothing to do with the breakage of the rubber. There is a manufacturing seam that runs diagnonal from the Clevis Pin hole. Upon close scrutiny with a magnifying glass, I see the seam in both old and new rubber sails, and noticed a slight crack forming in my other "cut" sail. In other words, that one will eventually break, too. It is a production problem and Hobie said they would replace my rubber drive sails.

I understand that the Mirage is a work in progress and that it has and will continue to be adjusted to improve it. Far as I'm concerned, the Mirage Drive system is leaps and bounds ahead of the old energy deficient propeller system. The best thing we as consumers can do is to continue to provide feedback to Hobie.

It is obvious that Hobie is listening to feedback and implementing design changes based on feedback. I applaud Hobie's support and will continue promote the Outback. When necessary, I will point out potential problems that could affect production, and other Mirage owners, too.

Thanks for your offer to help, but I think Hobie is taking care of it. I'm just waiting on some parts now.

With some stuff, like surfboards and sailboats for example, user feedback is what drives innovation. Being from this school of thought, I'm always interested in making things a little better, it's an ongoing process. I'm pretty sure Hobie is the same way and will always try to keep their boat owners satisfied and in the water.
Good luck with your repairs.

Just a quick note to let everyone know that last Thursday I received a package from Hobie containing replacement parts to fix up both my drive units, at no cost to me.

Thank you Hobie and Greg Ketterman!

Hopefully I be able to start going Out Back to the swamps in the Outback (ooh, bad pun) and look forward to kayaking with a fairly confident feeling about the drive unit functionality.

Spent Saturday night rebuilding my old Outback Mirage Drive Unit. I replaced a sprocket shaft, sprocket, and sprocket bushings. Had to remove the sprocket guards from the old sprocket. Inserted them on the new sprocket and used some gorilla glue to lock them in place. It worked real well. I lubed everthing up with water repellent grease. Reconnected all the cables and tightened them up and set this unit aside to be a spare.

Went out Sunday and enjoyed a leisurely trip. It sure felt good to be back pedaling a kayak. When almost back to the launch site, I decided to test out the spare drive unit. I couldn't believe the difference in the drive units. The one I just rebuilt worked so easy compared to the new unit that had a new rubber sail on it.

Spent this evening taking apart the new drive unit, cleaning everything and lubed it up with water repellent grease. I noticed a couple of links in the chain not rotating properly - tight links. Tried to work some WD-40 into the links and hope this will make it easier to pedal.

Answers to my own questions posted about two months ago:

That is correct. If you have a pedal unit with a cotter pin holding in the rubber fin mast, you need a mast with a hole in it for a replacement. If you have a pedal unit with set screws holding in the fin mast, you'll need a mast with a notch in it.

Dealers here are not familiar with the differences of parts because they go by a parts catalog which does not reflect current design changes. I had two different parts, same part number - one noted as "old" and one noted as "new." I'm sure this parts confusion will eventually be resolved.

No the new Drive Units do not have sprocket bushings.

The old steel sprocket has been replaced with a composite sprocket that serves as it's own bushing. What is interesting is the gears are made from composite material. Metal chain against composite (plastic) gears? Only time will tell how these two different materials interact when in contact with each other in water that has grit and sand floating in it.

To those concerned, I am not trying to paint a negative image of the Outback or Mirage Drive Unit as one Hobie manufacturing rep insinuated to me in email.

I am relating my personal experiences with the Mirage Outback. These experiences can serve to provide Hobie with continuing feedback on their great invention and hopefully help others avoid some of the troubles I've had. Experiences will vary widely from person to person.

I am not encouraging anyone to grab wrench and vice grips to take apart their drive unit.

Sorry about the delays in responding to these forums. Myself (Chief Poster) our Warranty Manager and Our other poster who works in sales were all at the Hobie 16 North American Championships ( We provided 36 brand new Hobie 16 for the racing. We built, maintained and then disassembled and came home just Sunday) in Ventura for 15 days. Very busy period for us and little time to catch up on internet action. I had just 4 days in the office for July.... Yeah... tough work!

_________________
Matt Miller
Former - Director of Parts and Accessory Sales
Warranty and Technical Support
Hobie Cat USA
(Retired 11/7/2022)

No biggie - I was just clarifying some issues for the readers.

Yes, I did some web browsing and watched some excellent movies from those championships. What I was looking for was the Hobie Mirage Outback category and was disappointed.

You folks at Hobie don't realize what a potential gem you are sitting on with the Outback. It pedals, it sails, and it paddles. Where is the racing catagory for the Outback division? Open the door for Outback racing and people will begin to enter.

There could be local chapters and yearly nationals where only Outback kayakers race against each other. I don't say this under the hopes of winning races - for it won't be long before I can get a senior citizen's bank account.

After lubing up my new drive unit, it works better than new and was real quiet. For me, the Drive Unit is much like a bicycle drive unit. With lots of use, it needs regular maintenance. I'll just take apart the drive unit on a regular basis and keep it clean and well lubed. Hot Dog - I can get back to being hooked on endorphins again and drop those excess pounds.

Took the Outback out for a trip Sunday in some beautiful weather and about 7 miles into the trip, I heard the dreaded sound of "SNAP" and felt the drive unit die. Almost fell overboard from losing balance. My 5 month old drive unit chain assembly broke in two at the crimp point. This sure is bothersome, knowing from experience now, every few months, something is going to break on the Hobie. Thankfully, because of a backup drive unit I carry, in only a few seconds, the trip was resumed and successfully finished. I highly recommend to anyone pedaling a Mirage Kayak to carry spare parts or a spare drive unit and carry the necessary tools to fix it.