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Oopsss. So what the help!

Yes.... I am one of those do-it-yourselfers!

Started a tire replacement on the rear end of my 07 Suzuki Boulevard. Everything smooth until "axle removal time". Everything is loose, managed to turn the axle bolt..... But the axle won't come out?

What exactly does this mean... and what can I do to get the axle out.
Hint: The OEM manual, with instructions, does NOT supply any skillful direction. Short of "reassembly and letting the tire wear off"...Any takers?

Shadetree, knowledgable mechanics.... please help!

Harley Owners, exempted.... I already know what you will tell me... "Should have bought a HOG : )



I just sold my hog and went back to Honda. Did you take the weight off the axle. I assume the tire is off the ground, but are you lifting the tire as you pull the axle. And the obvious, is everything that needs to be removed or loose.

Ok, I'm assuming you tried tapping it out with a rubber hammer so,as not to damage it.Suzuki do not grease the axle very well and that is what causes this to happen,You also need to have a look at the splines on the drive shaft as they often dont grease them either.I have heard of a bully that had to have the rear end removed and the axle pressed out .dont be afaid to give it a good whack to remove it and grease it when you put it back, I sold mine and bought a hog!

Tillydog comment about getting the weight off the back wheel is the difference between success and failure. A gentle but firm strike with a drift should remove it. I sold my Boulevard and bout a Mean Streak!!!

What tyre are you putting on?,my rear is due for replacement and so is the back tyre ha-ha,
I hear good things about the Michelin Commander, any feed back?

I cant help with any of this but you do need to get cracking if you want to get riding, so give it a wacking with some wood and you will see it just might come clear. Good luck

Lucky, are you talking dirty again...

Wacking? off?

Hey.... hope you guys have checked back on this commentary...

Yes, I did finish the rear wheel removal and tire change on my Boulevard. I found some interesting facts about the original instructions and wish to pass them on. How best may I do this so anyone who chooses to go this route will be well advised?

Just post them here, see ya Lowie.

Hey fellas.... and gals for those female commenters!

Anyways... had a little trouble trying to post my final comment about the front and rear wheel axle removals. Yes, I did do both. Here are my comments, excuse any "longwindedness...." a word?

The front axle and wheel removal was the easiest. This is a first time removal for both. I compliment "Tillydog" on comments about the lack of axle greasing... as this played a very important role in the removal difficulty. Here are some forward-thinking tips before beginning... and as always, "hind sight is 20-20"!:

1- You will need plenty of time and the proper tooling.... some will be a retrofit, as I will explain later.
2- I have found "WD-20" a chemical problem solver where Lock-tite has been applied. Either this or brute force. I have found the chemical solution more suitable.
3- The general directions provided in the Suzuki owner's manual is just that..... "general".
4- Always "safety" yourself and your bike.... YOU first. You can always get another bike or have one repaired due to lack of safety protocols.

Front axle and wheel:

Removal is easy after all associated attachments, IE: fender, brake assembly, and length of cables are removed and out of the way. Sometimes in a haste, you may forget where/how something attached. Take pictures.... they are worth a thousand words when reassembling.

There is a lack of axle grease on my removal. WD-40 or a like lubricant, will break down the resistant matter and allow you to remove the part easier. This will certainly be the case with the rear wheel. Use it!

Along the way, you will see other parts that may need servicing. In my case it is my brake pads. Rather than make this a "Boulevard Project". I did take pics and will service this at a later time. Sooner than later. However the goal is to be focused on the job you "intended" to do, this is the axle removal.

I checked all bearings and seals, the axle itself and associated hardware. You will undoubtedly bruise some of this metallurgy. If nuts or the like are damaged, replace them or the next repair should be done at a shop. As they will undoubtedly have to machine away the damage you left behind.

Once the axle is removed, I cleaned it up with a good solvent, AND "greased it". Not over the top grease but a general application, hi-heat grease. If someone can explain to me why this is not the case at the factory..... I certainly would like to know.

Rear axle and wheel:

This was undoubtedly the most difficult of the two. You will find the axle resistant to removal. From my previous postings... I was hesistant to be agressive. I found the reason for the use of force to be in good order..... No axle grease present! Once removing the brake and rear wheel attachments, to include the upper pipe..? Yes, it was in the way! I was able to get the axle out by relieving as much weight as possible from the wheel, applying WD-40 to anything that met with friction, and tapping out the axle from the pipe side. Trust me, this was not easy. I used a impact wrench, modified axle tapper (rod with rubber blunt end), and again WD-40.
Once I did get the axle out, the rest of the wheel was easy. Although I did have one "moment" where my motorcycle stand and brace failed. This was safety by a 2 1/2 Ton hydraulic jack, underneath my bike rear chassis. Trust me.... some real grief was saved by this jack!
I did service the axle by cleaning it up with solvent, removing any surface contaminants and yes......
greasing it! Looked better and rethreaded quicker thereafter.

There was an earlier question about tires... the actual end goal was to replace both front and back. I purchased OEM, Dunlops at front= 130/90 16H and rear= 170/80 15H. I attended a MC show in Charlotte, spoke with a rep for Dunlop, he convinced me they do the "science" in tire engineering.

Thus far, I am satisfied with the results, the added greasing of the axles have smoothed the wheel action and I believe will reduce or impede axle abrasions. Eventually I will replace both axles but for now they seem to perform fine.

Along with my new tires.... I am "ready to ride"!

Thanks for your help everyone... I hope I can help one of you in the near future.

Newmotobiker aka "50Rider"

Great work mate ,dont forget to check the splines on your drive shaft as i'm betting they wont have been greased either, there is a suzuki grease for this but no one ever has any, honda does have it but I cant remember the name of it, Im old! see ya ,Lowie.

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