56 PLATINUM STREET LADINE - P.O. BOX 2884, POLOKWANE 0700 TEL: (015) 293-0736/7 FAX: 086 664 9201 E-MAIL: [email protected] Reg. No. 1989/027609/23 VAT Reg. No: 4920107051 !!! ! ! ! !! 4x4 Traction BeadLocker™ Internal Beadlock Installation Instructions:

HOW DOES IT WORK?

Your 4x4 Traction BeadLocker™ Internal Beadlock is basically a low-profile tire located inside the existing tire. An inner tube is located inside the beadlock casing, which is kept inflated to 3.5 bar. The beadlock casing holds the inner and outer tire beads against the rim, preventing bead separation. The standard tire can then be deflated and inflated to any pressure below 3.5 bar, via the beadlock air channel.

SAFETY

Read the instructions thoroughly. Work safely! Let common sense prevail throughout the entire installation process. Wear hand & eye protection. Be cautious with compressed air. Use tire chocks before jacking the vehicle up and safety stands after it is up. Work sober! Keep these instructions in the vehicle for future reference, as others may need them to repair your tire.

TOOLS REQUIRED

You must have: 1) Tire Levers, or machine. 2) A valve puller to remove the old valve. 3) A knife or deburring tool to smooth the tire bead. 4) A valve-core removing tool. 5) A hand operated drill to drill and deburr the new valve stem hole. 6) 4 & 8mm drill bits. 7) Deburring bit, or 10mm drill. 8) NB!! A ¼” or 7mm spanner to hold the tube valve stem, while tightening the nut. 9) A 12mm spanner to fasten the tube- and air channel valve stem nuts.

! 1! MOUNTING SUMMARY

The only modification required to install the 4x4 Traction BeadLocker™ Internal Beadlock, is to drill one hole in your rim (wheel) for the beadlock inner tube, which must be done correctly. 4x4 Traction cannot be held responsible for damaged rims due to drilling errors. The balance of the installation process involves mounting and centering the inner tube within the beadlock casing on the rim, seating the beadlock beads, fitting the special air channel and LOCATING THE BEAD LOCK TUBE VALVE STEM HOLE TIPS then setting the tire beads on the rim. By Harry Lewellyn 080709

This tip covers locating the bead lock tube valve stem hole.

The first step in installing your bead locks is to select where to drill the hole for the bead lock tube valve stem. It should be located within 6 to 8 inches, left or right, of the standard valve stem hole and inboard as shown. LOCATING THE BEADLOCK TUBE VALVE STEM HOLE TIPS A) To determine the “perfect” tube valve stem hole location, A put the tube on the flat lying wheel, valve stem up (toward the outside), about 6 to 8 This tip covers locating the beadlock tube valve stem hole.inches left or right of the standard valve stem hole, then 1) The first step in installing your beadlocks is to selectinflate t hewhere tube to take shape , but do not over inflate. Valve stem distortion is expected. to drill the hole for the beadlock tube valve stem. ItCen teshouldr the tube on the w heel, then mark the valve stem location. Finally, “optimize” the be located within 20cm, left or right, of the standardlocation tvalveo accommoda te your wheels as described in the next stem hole and inboard as close to the wheel centerparagraph .as

possible, to minimize stress on the beadlock tube valve. 2) To determine the “perfect” tube valve stem hole location, put the tube on the flat lying wheel, valve stem up (toward the outside), about 20cm left or right of the standard valve

stem hole, then inflate the tube to take shape, but do not B) The valve stem hole requires that both the outer and inner (air side) wheel surfaces be over inflate. Valve stem distortion is expected.parallel an d not too curved as shown in this drawing. Also, the wheel should be no thicker than 0.4375 inches. 3) Center the tube on the wheel, and then mark the projected IMPORTANT: Before considering drilling a hole on the inside (brake side) of the wheel, valve stem location. Finally, “optimize” the locationbe completely stoure t haaccommodatet there will be no interference b eyourtween the bwheelsrake caliper, disk as or drum and the bead lock tube valve stem. With a 1 inch piece of regular wood pencil or described in the next paragraph. similar dowel, stick it with chewing gum to the potential hole location on the wheel. Rotate the wheel to make sure that it does not interfere with the brakes of other inboard components and that you can get a standard air chuck and gauge on the stem. Try all four positions.

The valve stem hole requires that both the outer and inner (air side) wheel surfaces be B parallel and not too curved as shown in this drawing. In addition, the wheel should be no thicker than 13mm.

IMPORTANT: Before considering drilling a hole on the inside (brake side) of the wheel, be completely sure that there will be no interference between the brake caliper, disk or drum and the beadlock tube valve stem. Also, consider that you will have to get to the beadlock valve with a tire inflator or gauge. With a 25mm piece of regular wood pencil or similar dowel, stick it with chewing gum to the potential hole location on the wheel. Rotate the wheel to make sure that it does not interfere with the brakes or other inboard components and that you can get a standard air chuck and gauge on the stem. Check all four wheel-positions.

! 2! installation 1 DRILL AREA PREPARATION

The beadlock inner tube valve stem hole should be located about 20cm circumferentially from the standard valve stem hole in either direction. Although directly across from the standard valve stem hole seems proper, with this, it is more difficult to mount the final outside tire bead. installation * Double check your measurements and positioning, before drilling the hole! * 1 2 1) Locate position for the tube valve 3) Prepare the rims: The rims should be Check exactly where you plan to drill the beadlock valve stem hole while checking for: stem hole: The beadlock tube valve stem clean and free from all rough edges to 1) A flat spot to receive the O-ring, and hole should be 150 to 200 mm (5.905 to ensure that the tube is not damaged during 2) For rim thickness. The 8mm valve stem will accommodate any thickness of rim up 7.874”) clockwise from the standard valve installation. All rust and labels, and their to 13mm and requires a 16mm diameter flat surface to receive the O-ring, washer stem hole and as near to the center of the adhesive should be removed from the rims. and nut. rim as practical without interfering with the 4) Prepare the tyres: The inside edge of We recommend 6mm or more of valve stem-to-inside- rim clearance and more may be brakes and associated components if the the tyre bead should be checked for sharp required to use your style air pressure gauge. With most rims, this is easily determined by tube valve stem is located inboard/brake edges and buffed smooth as necessary. looking at the rim as normally mounted on the lugs. Again, check twice and drill once! side of the rim. Ensure that the proposed This is particularly true of tyres 36 inches 2 1)inside Locate and position outside for rim the tube tube valve valve stem 3) Prepare the rims: The rims should be 4 and larger. This is mandatory for all tyres DRILLING PROCEDURE stemhole hole: surfaces The beadlockare flat, parallel tube valve (to stem clean and free from all rough edges to with beads greater than 16 mm (0.629”) holeaccommodate should be 150 both to 200 tube mm valve (5.905 stem to ensure that the tube is not damaged during regardless of diameter. 1) Use a center punch mark the hole. 7.874”)O-rings) clockwise and less from than the 13mm standard (0.519”) valve installation. All rust and labels, and their stem hole and as near to the center of the adhesive should be removed from the rims. 2) Drill at a right angle to the center-punched surface. thick. (If your new Staun Internal Beadlocks 5) Powder all components: Powder rim as practical without interfering with the 3) Drill in stages, first 4mm, then 8mm. are being fitted to Staun manufactured 4) Preparethe beadlock the tyres: cap, The tube, inside air edgechannel of and brakes and associated components if the 4) Deburr both the outside and inside of the hole. the tyrethe beadrims’ shoulddrop center. be checked Pay particular for sharp tuberims, valve the stem tube is valve located stem inboard/brake hole has been 5) Remove all chips from within the tire with a cloth, if you drill edgesattention and buffed to the smooth inside as and necessary. outside of both sidepredrilled. of the rim. Proceed Ensure tothat step the 3).proposed with the tire half on the rim. This is particularly true of tyres 36 inches inside and outside rim tube valve stem beadlock beads (the black webbing at the 6) Do not use compressed air to blow the chips out, but rather 4 2) Drill and chamfer the tube valve and larger. This is mandatory for all tyres hole surfaces are flat, parallel (to ID of the cap). vacuum or wipe them out. Left inside the tire, these chips stem hole: Drill an 8 mm (0.315”) hole at with beads greater than 16 mm (0.629”) accommodate both tube valve stem can eventually chafe and wear through the beadlock casing, the chosen position. Chamfer the drop regardless6) Contour of diameter. the air channel: Select the inner tube or both. 4x4 Traction is not responsible for this O-rings)center andside less of this than hole 13mm to receive (0.519”) the proper size rubber grommet for your rims’ 5) Powder all components: Powder type of failure or product replacement. Keep everything thick.inner (If O-ring.your new The Staun chamfer Internal face Beadlocks should tyre valve stem holes and discard the other. very clean and smooth. are being fitted to Staun manufactured the beadlockTemporarily, cap, andtube, without air channel force, and hold an air be 2 to 3 mm (0.079 to 0.118”) wide. A the rims’ drop center. Pay particular rims, the tube valve stem hole has been channel up to the existing valve stem hole screw countersinking tool at slow rotating attention to the inside and outside of both RIM PREPARATION predrilled. Proceed to step 3). noting the shape necessary to fit to the speed is best to make the chamfer. Clean beadlock beads (the black webbing at the Drill and chamfer the tube valve 2)all, metal chips off the rims, all beadlock ID ofinside the cap). of the rim assuming the tyre bead is 1) Remove all dirt, flaking paint, rust, burrs and corrosion from the entire inside 5 stemcomponents hole: Drill andan 8 frommm (0.315”)within the hole tyres. at in position. Without using the metal portion, surface and edge of the rim. Pay particular attention to the tire-bead-seating theChips chosen can position. cause tubeChamfer failure. the drop 6) Contourbend/pre-contour the air channel: the air Select channels the to the surface. The condition of this surface sets the air seal integrity and rim-to-tire center side of this hole to receive the propershape size ifrubber necessary. grommet Set for these your aside rims’ for anti-spin adhesion. We recommend wire brushing this entire surface along with the inner O-ring. The chamfer face should tyre valvestep 12.stem holes and discard the other. rim’s bead bumps. be 2 to 3 mm (0.079 to 0.118”) wide. A Temporarily, and without force, hold an air 2) Next, remove the standard valve stem. Mark or remember this hole is for the screw countersinking tool at slow rotating channel7) Mount up to the the existing first tyre valve bead: stem Mount hole the special air channel, which feeds the main tire. speed is best to make the chamfer. Clean notingfirst the tyre shape bead necessary as normal. to fitA toWindex-like the all, metal chips off the rims, all beadlock insideproduct of the rim is recommended assuming the tyre in placebead isof BEADLOCK PREPARATION 5 components and from within the tyres. in position.conventional Without tyre using lubricants. the metal This portion, ensures Chips can cause tube failure. bend/pre-contourthat if rewetted the in air actual channels use, to the the rim will not Using the powder supplied, generously “lubricate” 100% of the tube, shapespin if necessary. within the Settyre. these aside for inside the casing and the inside of the rim. Both the inside and step 12. outside of each beadlock bead must be dusted completely. The 7) Mount the first tyre bead:7 Mount the lubricating powder makes it easier to move the tube within the 6 first tyre bead as normal. A Windex-like casing and for the beads to migrate to the correct position when product is recommended in place of finally inflated. conventional tyre lubricants. This ensures that if rewetted in actual use, the rim will not spin within the tyre. ! 3! 7 6 TIRE PREPARATION

With very large tires, typically 36 inches in diameter and greater, the beadlock tubes may become damaged and fail. The failure can range from small holes, to slits 180° around the tube right at the tire-beadlock bead intersection. The problem appears to be caused by the inner edge of the tire bead.

The standard 16mm tire beads will seat completely behind the bead bump, but for wider tire beads, a portion of the sharp inside tire bead edge will be outside the bead bump area. This causes two problems:

1) It may prevent the beadlock case from moving to seat properly. 2) The sharp edge may cause tube failure.

The solution is to smooth out the wide, sharp tire bead edge using either a tire buffer, or a knife.

MOUNTING THE TIRE BEAD

Mount the inside tire bead on the rim, but do NOT set this bead. If you don’t know the trick to make this easy, use the rim “Well” as follows: 1) Place the first part of the bead in the rim well, allowing the opposite side of the bead to easily slip over the final part of the rim. 2) Now, elevate the tire with an improvised hoist or blocks beneath. You want to create a 100mm working space between the outside tire bead and rim: Fist to mid forearm size is best. Your objective is to make it easy to move your hand around inside the tire to properly align and check the dusted tube and casing for proper position.

MOUNT THE 4X4 TRACTION BEADLOCKER™ INTERNAL BEADLOCK CASING AND TUBE

For sake of illustration, picture that the casing is just like another tire, only it’s inflated by an inner tube. It has inside and outside beads, sidewalls (the orange material) and tread, the big, flat webbing between the sidewalls. The mounting process is identical to mounting a tire; only this “tire” is a little easier to work with.

! 4! 1) First, ensuring that all beadlock components are well lubricated with the powder before you start, mount the casing’s inside bead on the rim. 2) Roughly position the stitched overlap in the beadlock casing 180° across from the valve stem holes. 3) Now, gently force the tube over the rim so it nests within the casing. Put the tube valve stem through the newly drilled hole, install the O-Ring and washer, snug the tube up against the rim, then finger tighten the nut. (To be fully fastened later) 4) Remove the tube valve core and slightly inflate the tube to ensure it is not twisted. Deflate the tube. 5) Next, pull the casing’s outside bead over the rim.

CAREFULLY POSITION THE BEADLOCK & TUBE!

This is the important part of the installationCAREFU. LYouLY PmustOSIT ION ensure that both the inside and outside beadlock beads are THE BEAD LOCK & TUBE ! properly positioned and the tube is neitherThis is t hpinchede step tha tnor mak eins yaou r position that it will become pinched wheninstall afullytion p inflaterfect. ed. Yo u must ensure that both the Inside and Since you cannot see the inside bead,O useutsid eyour bea dfingers lock Be toads are feel inside the tire. properly positioned and the tube is neither pinched nor in a 1) The objective is to ensure that theposi ttubeion th isat notit w outsideill becom e either the bead lock casing, or thepinc htireed w hasen shownfully infla inted .A. 2) The beadlock beads must be properlySince posyou itionedcannot sasee the inside Bead, think like a rac- shown in B. The beadlock beadsco muston. Pa tnotientl ybe us ef oldedyour fin gers up against the beadlock sidewallto “inta keithere a look direction.” Your obje asctiv e is to ensure that the Air Channel shown in C and D. Walls and Floor are under the 3) To make the beadlock mountingtu bprocesse, and th aeasier,t the tu be is not gently inflate the tube to 0.1 too 0.15utside ebarithe rand the b ead lock Cap or the tire as shown in A. This is position. most likely to occur on the out- 4) Finally, take your time and feel s100%ide of ofthe bothrim s ithence the rim Well is very close to the rim’s inside and outside beadlock beadsbead tobu mensurep makin gthat a la rge gap they are positioned as shown inp oBs sandible. thatThe b theead ltubeock B eisad s must be properly positioned as centrally located and is not pinched,shown trappedin B. Th eoutside bead lo ck the casing, or in a position to becomeBeads m utrapped.st not be folded up 5) Once you are satisfied that the abeadgainstl ockthe bassemblyead lock Si disew all in either direction as shown in C properly positioned, deflate thea ntubed D. to “limp.” Give it a little body, but not so much as toTo interferemake th ewith bea d lock mounting process easier, gently mounting the outside tire beadi,n whichflate the maytube tforceo 1 or 2a PSI (7 fully inflated tube outside the casingto 14kP ina) aannd unseenposition t he Air area within the tire. That will undesirablyChannel so it ipinchs cente rtheed o n the new valve stem remembering tube! that the replacement valve stem 6) You are now ready to fit the specialnotch airmu schannelt point a. t the Air Channel Walls. Finally, with your hand, patiently, carefully and meticulously feel 100% of both the Inside and Outside bead lock Beads to ensure that they are positioned as shown in B and that the tube is centrally located and is not pinched, trapped outside the CAP or in a position to become trapped. 5

! 5! MOUNTING THE SPECIAL AIR CHANNEL

1) Remove the nut, domed washer and thick o-ring from the air channel valve stem. 2) Ensure only the thin o-ring remains on the valve stem. 3) Locate the original valve hole in the wheel. 4) Pushing your fingers between the beadlock casing and tube, create some space to fit the air channel valve stem through the original valve hole. The rounded end of the air channel flap face towards the center of the wheel. 5) Ensure that the air channel flap is completely smooth under the inner tube, against the wheel. 6) Fit the thick o-ring, domed washer and nut to the air channel valve stem, ensuring that the air channel hole is facing up and into the tire cavity, and tighten the nut with a spanner. 7) Some wheels have recessed original valve holes, which neccesitates the use of more than one thick o-ring under the domed washer; these are supplied separately. 8) Bend the air channel inwards to the center of the wheel and inside the tire bead. 9) You are now ready to fit the outer tire bead.

HAND MOUNTING THE OUTSIDE TIRE BEAD

1) For hand tools, start mounting the outside tire bead directly across from the valve stems. 2) Continue mounting the bead, in both directions, toward the valve stems. POP THE TIRE BEADS 3) Finish mounting the outsideWe bead recom atm ethend uvalvesing n ostems.thing ot her than water for a bead lubricant, and only if absolutely necessary. We suspect that soapy lubricants may again become wet and thus slippery, allowing the tire to spin on the rim under extreme conditions. The use of gasoline, oil, grease or MACHINE MOUNTING THE OUTSIDEsimilar TIREprodu cBEADts of a ny sort is foolhardy. Remove the bead lock tube’s valve core. A flat tube keeps the 1) Know how the tire-mountingtub emachine from bein gmounts forced o theutsid outsidee the CAP bead. (tube p inch) in the tire bead 2) Ensure that the tire is not movedpopping onpro ctheess .rim by the machine. Using the notched replacement valve stem, safely use the tire to 3) Ensure that the machine disturbspop the tnoneire bea ofds btheack components on the rim. Do installed. not exceed the tire manufac- 4) Independent movement of tuanythingrer’s MAX Imay/willMUM LOAD break rated ptheress tubeure. Rvalveemem stember to andkeep thisall b oisdy not covered by our warranty.par tRegardlesss (primarily fi nofge rmethods) out of th(machinee bead are ora. hand), this is the Using the tire’s concentricity rings, ensure that the tire is centered time to pay close attentiono, nso th eyou rim .don’ An itm pinchproper lythe ce ncasing,tered tir eor m otube.st like ly indicates that an Air Channel Wall (*) is trapped between the tire (B) and the rim (A) as POPPING THE TIRE BEADS pictured (C, tyrepliers and D, tire spoon, previous picture). This is unacceptable. To remedy, break the tire bead at the mis- 1) Only use water to aid in poppingalignme nthet an beads,d free/re nopos ition soapy or oily solutions! Thesethe A canir Ch leadanne l toW athells. tireWhe n spinning on the rim under rextremeemedied, sconditions.tart again a t the “POP THE TIRE BEADS” para- 2) Slightly inflate the beadlockgr atoph bring above .the Aft emainr the btireead s bead close to the rim. are properly seated, deflate 3) Using the special air channelthe valvetire co mstem,pletel ysafely. Next, reinstall the bead use the main tire to pop theloc tirek va lvbeadse core abacknd in fonlate the the rim. Do not exceed the tireb emanufacad lock iturer’snner tub e slowly. maximum load rated pressure.Inflate Remember a little (up to to 3 PkeepSI/ 21 kPa), then, with your ear right on the tire, carefully listen for an internal hiss. If OK, inflate a little ! more, then listen again. We have learned that if you hear what6! appears to be a “leak” inside the tire, it is actually a pinched tube slowly passing air from the bulk of the tube to the pinched portion. IF YOU HEAR AIR, immediately deflate and check for a pinched tube. It is absolutely necessary to remedy this, otherwise, it will blow the tube. Now, start again at the first of this paragraph. Do not exceed 48 PSI (331 kPa) in the bead lock tube. Now, inflate the tire to your desired pressure. Remember to keep the bead lock pressure at least 2 PSI (14 kPa) higher than the tire chamber pressure.

7 all body parts (primarily fingers) out of the bead area. 4) After the beads are properly seated, deflate the tire completely. 5) Next, inflate the beadlock inner tube slowly. Inflate a little (up to 0.2 bar), then, with your ear right on the tire, carefully listen for an internal hiss. If OK, inflate a little more, then listen again. We have learned that if you hear what appears to be a “leak” inside the tire, it is actually a pinched tube slowly passing air from the bulk of the tube to the pinched portion. IF YOU HEAR AIR, immediately deflate and check for a pinched tube. It is absolutely necessary to remedy this; otherwise, it will blow the tube. Now, start again at the first of this paragraph. 6) Inflate the beadlock to 3.5 bar. Do not exceed 4 bar in the beadlock tube. 7) Now, inflate the tire to your desired pressure. 8) NB!! With the beadlock fully inflated, hold the stem with a ¼” or 7mm spanner over the flats and securely tighten the tube valve stem nut. You want to compress the gasket/O-ring, but not damage, or over tighten it. If the thread of the tube valve stem turns while tightening, it is BAD, loosen, and re-tighten.

CHECK FOR LEAKS

Check for air leaks at both tire beads and both valve stems. A dilute solution of dish soap and water (1/2tsp/2ml soap per cup/240ml of water) will reveal even the slightest leak by building a “nest” of tiny bubbles. Leaks must be remedied. When satisfied there are no leaks, rinse the soap. NB!! The beadlock working pressure is 3.5 bar and should always be checked prior to inflating, or deflating the tire. We recommend that you run the beadlock at 3.5 bar all the time.

HOW LOW CAN YOU GO?

Although the 4X4 Traction BeadLocker™ Internal Beadlock can beLow usedest Tir eas P reass “urunre flat” for a Harry Lewellyn 090430 short distance, you cannot drive on flat or very low pressure 4x4 Traction BeadLocker™ Although the Staun beadlock can be used as a “limp flat” for a mile or less, you cannot drive on flat or Internal Beadlock equipped tires for extendedvery l odistances.w pressure Staun b ea dlock equipped tires for greater distances. This section describes how to determine the lowest pressure you can run in your application. This section describes how to determine the lowest pressure you can run in your With the bead locks installed and on your fully loaded vehicle on flat ground, completely deflate both application. front and rear tires (bead lock fully inflated) and measure the distance from the ground to the bottom of the rim.

1) With the beadlocks installed and your fully loaded vehicle standing on flat ground, completely deflate both front and rear tires (beadlock fully inflated) and measure the distance from the ground to the bottom of the rim. 2) Your objective is to ensure that the beadlock tread (brown OD) never touches or rubs the inside of the tire tread. Add air to the tire until the bottom of the rim is

25mm higher than with the tire Your objective is to ensure that the beadlock Tread (orange OD) never touches or rubs the inside of the flat. tire tread. Add air to the tire until the bottom of the rim is 1 inch higher than with the tire flat. Now 3) Now measure the tire pressure. This misea stheure th elowest tire pressure .tire This ispressure the lowest tire pyouressure ycanou can safelyrun. run,

at speed. 4) For slow off-road work, you can deflate right down to ultra low pressures.

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Staun USA Inc Harry Lewellyn (949) 645-7733 [email protected] UNINSTALLING THE BEADLOCK AND/OR TIRE

1) First, deflate the tire and then the beadlock. 2) You must deflate both the beadlock and tire to uninstall either. 3) Holding the valve stem with a ¼” or 7mm spanner, remove the beadlock tube valve stem nut, washer & o-ring and push the valve stem out of the rim and into the tire cavity. 4) Remove the special air channel valve stem nut, washer & o-ring (o-rings) and push the valve stem out of the rim and into the tire cavity. 5) Taking care not to place the bead breaker tool over either valve stem (preferably 180° across from them), break both tire beads. 6) Ensure that neither valve stem is stressed while removing the tire bead. 7) Re-install the tire & beadlock as per these instructions.

TECHNICAL ASSISTANCE

For clarification of these instructions or installation assistance, call or email 4x4 Traction.

WARRANTY

4X4 Traction BeadLocker™ Internal Beadlocks are guaranteed against defects in workmanship and materials for a period of two years from the date of original purchase by the original purchaser. The inner tube is guaranteed for a period of one year, excluding puncture or mounting damage.

DISCLAIMER

• 4x4 Traction cannot be held liable for 4x4 Traction BeadLocker™ Internal Beadlocks incorrectly installed and/or misused in a manner for which they were not intended. • Vehicles driven with low tire pressures may result in less predictable handling on or off highway, so drive accordingly. • Installation can be dangerous. • 4x4 Traction does not accept responsibility or liability for misdrilled rims and inner tubes pinched or damaged during installation.

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