>> how to remove a flywheel

Removing the flywheel make take more skill or tools than you have available. Proceed with caution.

The flywheel on a Vespa serves two purposes. The motor turns the flywheel forcing air up and around the cylinder keeping it cool. Also the flywheel turns magnets around coils on the stator plate to power the lights and produce spark for the motor. If your Vespa is prior to 1978 (or so) your flywheel is self-extracting. If your Vespa is newer than 1978 (or thereabouts) you'll need a flywheel extractor tool. You will need to remove your flywheel if you need to change your condenser, reset your timing or access your transmission. Removing a flywheel requires special tools and mechanical ability, ask for help or take your bike to a shop if you are unsure about your abilities.

Early Vespas with Self-Extracting Flywheels

Step One

Remove the cowling and the fan shroud.

Step Two

Loosen the nut in the center of the flywheel carefully. Loosen the nut using your socket set and socket wrench. You may need a second person to hold the flywheel while you loosen the nut. If the nut does not loosen at this point you'll need to employ an impact wrench, which can provide more torque.

Step Three

Once the nut is loose, continue loosening it until it comes in contact with the retaining circlip. The circlip is held in a small groove in the center hub in the flywheel. You will need to turn it tight against the circlip. Loosening the nut further pulls the flywheel away from the motor. A few turns and the flywheel will pop off. Make sure you don't drop it.

Later Vespas with Flywheel Extractor Tools

Step One

Remove the cowling and the fan shroud.

Step Two

Remove the nut cap covering the nut in the center of the flywheel.

Step Three

Using a thin-walled socket, remove the center nut of the flywheel using your socket wrench. You may need a second person to hold the flywheel while you loosen the nut.

Step Four

Clean and examine the threads that line the inside wall of the flywheel center. These threads may need to be cleaned using carburetor cleaner and a clean cloth.

Step Five

Thread on the flywheel puller at least four or five full turns. Once you have the puller on securely, turn in the center nut on the puller so that it comes in contact with the crankshaft. Using a wrench turn the center of the puller so that pressure is being put on the crankshaft (If the flywheel is stubborn you may need to employ an impact wrench). This will pull the flywheel away from the motor.

Points to remember

Never try to hold the flywheel by inserting something into the point's access hole. This may seem like a good idea but if anything slips and it will, you can cause hundreds of dollars damage to your stator plate.

Don't try to wedge something into the flywheel fins to prevent it from moving. The fins break off very easily and this will make your flywheel unbalanced causing damage to bearings and unnecessary vibrations.

When reinstalling your flywheel make sure to check the condition off the crankshaft taper and the flywheel key, these items need to be in very good condition or the flywheel will come loose no matter how tight you think you have installed it.

>>If you have any questions about this or any other topic, please don't hesitate to contact us: 206.763.0160 or info@bigpeoplescooters.com