Wow! From the video it definitely appears as though something internal is NOT right. Looks like it's time to pull and crack it open. You might be able to pull just the jug and head with out removing the whole engine to inspect for pieces or broken parts. Now this is just a crazy theory because I've never seen this for myself,(maybe someone here knows) but would it be possible for a valve to be set so tightly that it won't seat and interfere with the piston completing it's revolution? If this was the case, just simply backing off the valves to proper spec would cure this but like I said it's just a crazy theory. Never seen it or heard of it.

 

Anyone have diagrams picture show what I need to take off

 

ok, maybe if someone replaced the cam or had the cam taken out, or maybe the sprocket on the cam broke, and if thats the case than u have a bent valve or two and probably a broken piston. just start at the top of the motor and work your way down, just keep everything lined up the way you took it apart and you should be fine. let us know what u find and we'll go from there

 

Pull the flywheel first. Everything looks bad in that area. The magnets in the flywheel could have come lose and got tangled up in the stator and locked everything up.

 

how do I go about pulling flywheel off. Do I need a puller.

 

I agree with Overdrive. I just got done with the same problem you are having. I pulled the motor apart thinking I had pieces of piston jambing the crank or even worse a broken crank and found everything was in beautiful condition. DO NOT open the jug until to look at all the simple things. First thing to do is pull the flywheel, on mine there was a broken magnet and it was jambing against the stator luckily there was no damage done to the stator. I have a 99 sportsman 500 and the magnets could be seen once the flywheel was removed. I ordered a new flywheel and thought I had the wrong one because there was a cover over the magnets. I asked why the difference and was told new teleology verses old. with the new one I`ll never have the problem reoccur. The new flywheel/ring-gear was near $500 from the steelership. Hope this helps.Randy

 

Yes you need a puller there are 3 threaded holes in the flywheel

 

Yes you need a puller. An automotive harmonic balancer puller works well.

 

+1 Hadn't even occurred to me but makes sence. Alot easier to check that first! I've been able to use a three jaw puller to remove the flywheel but I don't know if it's recommended as there is a chance of messing up the teeth on the flywheel.

 

Some early 500s were known for flywheel problems. Seen more than a few.