Replacing the inner tube

Problem, symptoms/identification:

Flat tire, the inner tube does not hold air.

This document is relevant for the following models:

Start, Hero, Challenger, Freerider, Ranger

Solution:

Installation procedure (see video instructions)

1. Remove the wheel from the motorcycle (disassembling the motorcycle wheel).
2. Using a wrench or valve cap, unscrew the valve from the inner tube and bleed the air.
3. On bikes with tire spin lock, loosen the nut and unscrew it all the way to the end of the bolt, do not remove completely.
4. Place the wheel on a firm pad using the other tire or wood blocks and use the inside edge of a sturdy shoe to push the tire off the rim towards the center of the rim.
   CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel, so the disc does not touch the ground.

5. Rotate the wheel so that the tire valve is towards you and insert the tire iron between the rim and the tire bead. Do the same on the other side of the valve about 10 cm from the first.
6. Push the tire iron towards you and fold the edge of the tire over the rim.
7. Gradually remove the bead from the rim in this way.
8. Push on the valve and push it through the rim and take the tube out.
9. Visually check that none of the spokes protrude into the inner rim space and that the protective inner rubber or wrapping is not damaged. If so, using a small grinder, grind it off at the same time as the spoke nut (nipple). Replace the new protective rubber or make a new wrap.
10. Check the inside of the rim for possible defects and clean it.
11. Insert the new or repaired tube by first pushing the valve through the rim and then inserting the tube into the casing. Screw in the valve and gently inflate the inner tube. Just enough to make it about ¾ of its volume.
12. Lubricate the tire bead with mounting paste or soap and water solution eventually.
13. Begin installing the tire opposite the valve by pulling a portion of the bead inward toward the rim and using the tire irons to pull the tire bead further around the circumference of the tire, gradually up to the valve. While doing so, take care not to catch the tube with the tire iron.
14. We finish about 10-15 cm apart and before we do the complete loading of the bead into the rim, we push the valve inwards towards the rim with our finger and at the same time we fully load the bead into the rim by moving the tire iron. This ensures that we cannot break the tube.
15. Inflate the tire to about 3 bars (44 psi) and check that the tire fits properly on the rim. We can check by putting the wheel on the axle and turning it. Observe the axial and radial run-out of the tire.
16. Set the correct tire pressure as specified in the specific model manual.
17. Mount the tire back on the motorcycle. Select the opposite procedure as for dismounting.