In reply to noteviljoe:
> Ok so I think I am (as you say) mixing up two issues. Basically the main issue (for me) is that the freewheel is failing. But having listened to the sounds the wheels make when spinning I think that mechanic is right that the bearings are also in poor shape. I guess how I am cleaning them is stripping the grease out of both. I am doing what you say and spraying degreeser on the chain while it is on. I also spray it on the gears which I am now thinking it a big mistake? I asked whether I (or they) couldn't just add more grease but he (claimed) that the type of hub it is makes it hard to service like that and also something about something being 'pitted' which I didn't really understand.The most irritating thing about whole thing for me is that my cheap old sit up and beg bike, that I never clean, just works (or at least doesn't break like this it just cronks on)
"Pitting" is when the bearing surfaces get damaged and are no longer smooth, meaning the wheel feels "rough" when you spin it. Often caused by failed bearings, but can also be caused by rust spots if you've washed the grease out and they've stayed wet, or by over-tightening the cones and damaging the surfaces.
If it's on the cones, then they can be replaced. If it's on the race on the front hub or non-drive side of the rear hub, it usually means a new hub, although on some hubs you can (with the right tools) replace the races. On the drive side of the rear hub, the race is usually part of the freehub, so can be replaced.
Not sure why the mechanic thinks it's hard to service the hub to re-grease it, but I'm not familiar with that specific hub. For general cup and cone style bearings, it should just be a case of removing the cassette so you can get at the nuts (you'll need specific cone spanners), then un-screwing one side and pulling the spindle out. Bearings in hubs are usually loose and so cheap that it's worth replacing whenever you strip a hub. Once you've cleaned the old grease out, apply plenty of new, waterproof, grease and re-assemble - the bit I hate is adjusting the cones.
Sounds to me like there wasn't much grease in the hubs to start with and you're, perhaps, over-washing with too much degreasing.
He is right that cartridge bearings are easier to live with, as you just need to knock them out and put new ones in, but you'll need specific tools for doing it.
Either way, you shouldn't need to be replacing the freehub on a bike less than a year old, so keep plugging away at Evans until they sort it.