My old 96 sportsman (2300 miles) has been losing the motor oil from the balance shaft dip stick. I've been trying to make a point of toping it up b4 using it the last couple years. (though its alway off the stick)
Now this hunting season I shut it off and and it would not restart. Only has 1 spark when you first hit the starter and then just as the motor stops spinning one more spark.

Local dealer says stator, (270.00 new) likely cause of spark problem (he has used, not sure on $$ yet) Balance shafts are @$400 from what I see online and it will need that. Says he never seen a good used one. And if i do all this he is also recomending a new piston as some of these 2 strokers drop a intake skirt and bust the case.
Waiting for his quote, but I'm thinking I'm into this for at least 1k.

Now on here I'm reading just press the balance shaft apart and re bearing it. No special tools needed just a press. (which I have in my shop, so does dealer, he is a engine rebuilder machine shop) Is that the common problem the bearing? I'm asuming the seal that keeps the motor oil in is in this area too. Sould like water pump being and seals are also in order while in the balancer area.

I have a 05 Sportman also. Wife ocasionally rides this 96 and my 4 year old son will be ready for it soon when he outgrows his 50 kazuma I don't need a second bike too bad just now.
I hate to dump 1000 + into my old bike, high book is 2100 for it.

Dealer has offered 1300 against 6150 for a 08 500 x2 demo with 400 miles. or on a New 08 500 efi .
Which would be great in a few years when my 3 sons (also twin 19 months) are bigger.
What do you think is resonable to fix the old bike? It in good shape otherwise with original tires and rear chain, which still does not need changed. (had a spare chain/sprockets on the shelf since 1500 miles
And on the spread of the new versus old. Though I'm still leaning towards keeping it for Cole and maybe getting a X2 when the twins get bigger.
Ken

 

If you can get a shop to do it for a grand you will be lucky.You may get by with a bearing and seals on the counter balance but a the other stuff is a must.Yuo could save a few $$$$$ doing the work yourself