Could also be a bent valve. The compression test should reveal that.

 

flywheel key looks fine, but I can't get the flywheel off....any tricks? I've got a wheel puller on it and I've been bagging the crap out of it, but it won't budge. I've got it cranked down really hard, but I don't want to crack the flywheel. I think it's going to be something with the stator, because it feels like something behing the flywheel is rubbing when I move it....if i could just get it off!!

 

It's easiest to get it off with an impact gun. If you have access to one, just use it on the puller. Don't worry, you won't damage the flywheel.

 

OK...got the flywheel off....does this look like a problem?? :-) haha...so my question now is this...is this broken magetic material part of the stator or part of the flywheel? I'm looking at the parts diagram and the stator doesn't appear to have anything around it, so I'm guessing this was a lining on the flywheel?
http://img.villagephotos.com/p...8-2/1300546/stator.JPG

 

YEP!! Replacement flywheels have superceded to inclosed magnets eliminating this problem!! I've done several along with the damage stators. HOPE you can salvage your stator,but everyone I've done ended up replacing the whole mess. Sorry about problem. opt

 

MK looks like you get your cookie
lmao

 

Sweet!![img]i/expressions/face-icon-small-happy.gif[/img]

 

OK, I got the new flywheel on, but still no spark. If the stator was damaged by the flywheel's self-destruction, would that cause it to have no spark, even with a fully charged battery?

 

Just did one on a 1999 Sportsman 500..check your pulsar gap..mine was knocked out of alignment..

 

I have a 98 500 sportsman flywheel in my shed with detached magnets as well. After replacing the flywheel I had some wiring issues. One of wires going to the stator were damaged where they come through the side cover. My bike would still start but would not charge. The wires were stretched and one cracked right in the rubber grommet. They looked perfect, but it took a volt meter to find the broken wire. It took a few evenings and a few beer before I found the wire. I was driving my bike through deep water when my bike backfired and died. Mine also seemed to be seized. I used the winch to pull it out but it would not start with the electric starter. After some fumbling in the dark with the pull cord it freed up and started. I drove home with lights that would barely light up. Hope this helps. Good luck!