Replacing the front tire

Removing the wheel

Remove the ignition key from the switch to avoid injury to you or damage to your Pukka.

Loosen the axle nuts and remove the front wheel assembly from the front fork.

Dismantling the wheel assembly

Once the front wheel assembly is removed from the forks, remove the axle, washers, and axle nuts. The bearing cups are held together with four bolts. Remove the bolts and the bearing cups.

The wheel halves are held together by eight bolts. Remove the eight bolts and pull the wheel halves apart. Each side will have a metal ring.

Inside the wheel is a metal tube spacer and a rubber O-ring.

Assembling the wheel assembly

To re-assemble the wheel with the new tire, place the wheel half without the air valve stem on a flat surface. This half has a groove for the O-ring. Place the O-ring in the groove.

Place the new tire over the wheel half so that the shape of the treads point in a clockwise direction.

Place the wheel half with the air valve stem in the center of the tire, making sure that the four inner holes are aligned.

Place the metal ring with the air valve stem notch on the wheel half.

Insert the eight bolts into the wheel. Start by putting two bolts at opposite sides of the circle.

Place the metal ring on the other side of the wheel and tighten the nuts. Insert the remaining six bolts and tighten them to hold the wheel halves together.

Place the two bearing cups in the center of the wheel on each half. Align the holes. Insert the four bolts and washers, and tighten the nuts.

Mounting the wheel assembly

Slide a spacer, washer, and safety washer onto the axle. Position the safety washer so that the angled insert is pointing toward the center as shown below. Tighten an axle nut to the end.

Insert the axle into the center wheel hole and place a spacer, washer, safety washer, and axle nut on the opposite end of the axle.

With the axle inserted into the wheel you are ready to mount the wheel assembly onto the front forks. Position the front wheel assembly so that the tire treads point forward.

Slide the axle into the drop outs of the front fork so that the drop outs are positioned between the washer and safety washers.

Insert the safety washer into the hole in the front fork and tighten the axle nuts with a wrench until they are tight against the safety washers.

The finished assembly should look like the pictures below.