Progress - removing the flywheel.

At last, things have started to move on the bike.  Well, slightly - I've been taking it apart and cleaning the odd part.

The corrosion under the generator cover was quite intense.  I had a puller for the flywheel but it wasn't even going to attempt to start on the rusted thread!  Time for a Dremel  with a tiny wire brush - it worked a treat.

A puller is a wise investment.  I've damaged flywheels before when thinking a lever and a sharp tap to break the taper is enough to remove it.  It doesn't always work and one damaged flywheel is worth a lot more than a puller.

So, with thread nicely cleaned, it was time to see if it would screw on.  Plenty of WD40 and slight persuasion and it was soon screwing on easily. 

 

Ideally you need it to screw on all the way.  It's very tempting to get it on a couple of threads and try to remove the flywheel, but very often this will strip the vital first threads.  Persevere until you get it on properly, then tighten the bolt in the middle before applying a sharp tap with a hammer.  This is how you "break" the taper.

Tighten the bolt in the middle again if the flywheel hasn't dropped off.  Then apply another sharp tap.  Repeat the process, always tightening the bolt, until it releases.

And there we have one undamaged flywheel.