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MORE AND MORE RIDERS nowadays are beginning to realise that
a good set of tyres, suited to their particular styles of riding,
are as much an effective motorcycle performance modification as
say a different carb or cam, if not more. The unenlightened are
often astounded by the difference in their own ride made by a set
of modern tyres as the motorcycle's feel can be quite radically
altered. With the right rubber, your familiar machine will have
better handling, safer stopping, will stick to the road surface
more securely under power or in adverse conditions, and they even
make it feel more stable in a straight line at higher speeds. After
all, what is the point of spending an awful lot of money turning
your machine into a fire-breathing road monster if it handles like
a full shopping trolley? And it's all well and good spending a fortune
on your suspension to keep the tyre in contact with the road more
efficiently, but it's also a good idea to make sure the tyre is
gripping the road to its best ability.
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American-V
was invited by Clive and Leo of Avon Cooper Tyre's motorcycle
division in Melksham to discover what actually went into the
construction of a motorcycle tyre. While I was aware that
any motorcycle tyre is expected to perform very differently
from, say, a car tyre and was certainly aware of the price
difference between the two, I knew very little of the manufacturing
process which brings one about and this seemed like an excellent
opportunity to find out.
What
follows is not an exhaustive account of the manufacturing
process, but hopefully will answer a few questions:
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| 1:
The process starts with massive solid blocks of raw material
cut into manageable strips ready to be blended with carbon based
compounds to form the separate elements of the tyre. |
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| 2:
Compounds are held in colour-coded hoppers. Tyre manufacturers
specialise in different parts of the manufacturing process and
I was surprised to discover that the different manufacturers
share their areas of expertise with each other. Avon's speciality
is compound technology, working closely with either their own
people or another manufacturer's brief, they develop different
types of 'rubber' with different characteristics. |
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| 3:
The control board of one of Avon's gigantic tread making and
bonding machines: machines that the company has developed and
built themselves. |
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| 4:
The molten tread compound pours onto massive rollers, where
it is squeezed flat and air bubbles are noisily forced out in
a series of loud pops and bangs - luckily the only bursting
I got to witness. |
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| 5:
Great skeins of coloured twine will be weaved into the different
compound elements of the tread
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| 6:
... partly to distinguish each element, but it will also perform
a vital task later in the process. |
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Tread compounds are heat bonded to the inner 'bladder' compounds
and then cut to length. It is here where the characteristics
of each type of motorcycle tyre are most crucially formed. A
harder, longer wearing tread will form the centre section of
the tyre, while stickier compounds are placed at the edges of
the tyre tread for greater traction when cornering. The tyre
walls will require very different characteristics again. |
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8:
How the two dimensional tread (on the top), bladder (underneath)
and walls (at the edges) you see here will react when forced
first into a hoop and then 'persuaded' to create walls and
gently curved tread is not an exact science. No computer can
synthesise the behaviour of the new tyre elements through
the complicated three dimensional twisting, very human judgement,
experience and yes, a deal of trial, error and luck develops
a successful tread.
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9:
The construction of the vital steel 'bead', these hoops when
bonded to the tyre wall edge will lock up into the rim of
your wheel, forming the air tight seal.
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The Final Build is the time consuming and most expensive part
of the manufacturing process of a motorcycle tyre. Whereas car
tyres are built entirely by machine, only the care and experience
of a trained individual - like this bloke here - is trusted
to properly build a motorcycle tyre. He first anneals the tread
into a hoop
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| 11:
and bonds the beads to the tyre walls creating, at last,
something that is becoming recognisable as a tyre (note the
coloured threads running diagonally across the tyre). |
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| 12:
Now the complete tyres are forced close to their final shape
by hugely powerful presses. |
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And then the 'slicks' you see here are mounted into the massively
hot tread moulds
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| 14:
to emerge a few minutes later as one of Avon's distinctively
huge new Venom 280s. Here you can see those new tyre 'whiskers'
- not Avon's name for them I must add, but what I've always
called them - I never knew what or indeed why they were
until now. The 'whiskers' are what remain of the coloured threads,
burnt away in the super intense heat of the final moulding.
Their sacrifice creates a vital escape route for any air bubbles
still in the compound - air bubbles which could otherwise massively
upset the integrity of a tyre. |
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15:
Finally this gentleman trims off the excess rubber, checks
and finishes the tyre ready for shipping.
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| Having
seen the process, start to finish and realising what goes into
the making of such a vital element of any motorcycle, I was
able to chuckle when Leo recounted the exclamations of riders
who'd done the tour before. Before the tour started the riders
had wanted to know why motorcycle tyres were so expensive, once
they had witnessed the labour intensive manufacturing process
however, many began to wonder why motorcycle tyres were so cheap.
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There's
no better time than when buying a second-hand bike to question the
state of your rubber, and it isn't just a matter of whether the
tread is deep enough to pass an MoT.
Is
the rubber cracking with age? Replace it.
Is
the surface intact? Replace it.
How
and where is it wearing? If the tread in the centre has been worn
flat, either the bike has done a lot of motorway miles or has been
running over-inflated: does the owner know what the tyre pressures
should be? If the tread is good in the centre and worn at the edges,
the tyre has been under-inflated or has an aversion to the straight
and narrow. And that's the easy stuff.
So,
you're going to start from scratch: keep it safe. What do you get?
Do you fit a set of OE fitments or do you refit a pair like the
ones that came off? Do you buy on price or by tread pattern?
It's
only a pair of tyres, after all: how much difference can there be?
In
our ongoing attempt to demystify technology, American-V struck out
to Cooper/Avon tyres production facility in Melksham to find out
the facts.
Tyre
Specification:
You'd
expect sizing to be the simplest possible thing, you'd expect, but
as soon as you want to talk tyres, the first thing you need to know
is what size the tyre is. You really should stick to manufacturers
recommendations for sizes - in some places you are legally obliged
to - but if you don't, it helps to know what the rules are, and
how tyres are identified.
There
are many ways to express the dimensions, and these are most commonly
now determined using a standard which defines the width of the tyre,
followed by the aspect ratio, speed rating, wheel height and finally
load. Expressed as something like 150/90-16 58H, you would expect
a tyre that is 150mm wide, tall (90% of the width) for a 16-inch
wheel: 58H at the back means it will cope with 236kg according to
its load index, and is safe to 130mph.
Speed
ratings show the speeds of which a correctly inflated tyre in good
condition is capable, not the speed at which it is normally ridden
- and it's easy to equate higher speeds with increased heat to explain
why. Most of the alphabet is used but we've listed the common ones
because there's no point going much further. A good example of why
is seen in the ZR rating, because above 150mph it is all rather
arbitrary. Of course, you are unlikely to ride a Harley on the road
in speeds in excess of the current base level of "S",
but if the recommendation is for a V-rated tyre, you should stick
to it because weight is another heat generator, and American V-twins
tend to be on the heavy side. "
The
weights shown above are the maximum loads that the tyres can carry,
but you will be aware that a back wheel will not be supporting the
entire weight of the motorcycle and rider(s), but although it does
take the heavier load, it will share it with the front - hence the
differential. Straightforward stuff
except
what's
that MT90B16 all about?
Harley-Davidson use an American standard size of an MT90B16 74H
which has nearest metric equivalent of 130/90-16 73H. Easily sorted,
you'd think: stick a 130/90-16 in and have done with it? But it's
not that simple. The MT90 has a higher load index - an increment
of only "1", but that corresponds to 10kg - and in many
countries it is illegal to fit a lower load index tyre than the
manufacturer's OE, so we have to accommodate that for now.
And
before we leave that area, there is a nice little addition that
is often overlooked, but is realistically only going to apply to
Buell riders: as you go above 130mph / 210kmh on V-rated tyres,
the load carrying capacity decreases by 5% per 6mph / 10kmh,and
the same applies to ZR-rated tyres above 150mph / 240kmh. That's
reference more than anything else, and nice way to scare the pants
off your overweight Hayabusa-riding buddies over the bar of an evening.
You
could be forgiven for thinking that the sizes and profiles would
be very similar once the sizing was agreed upon, and you would be
close, but there is enough flexibility within the standards for
a little artistic license to change shapes and even widths. The
one thing you will tend to notice is that touring tyres tend to
be less triangular than their Sports tyres, but aside from that
each manufacturer's production processes determine their final shape.
There
is a last number that you will find stamped onto your tyre sidewall,
and that is the maximum pressure the tyre will take. It will be
so far ahead of the range you're playing with that you shouldn't
have to worry about it - just as long as you know that it is the
maximum pressure.
Profiles
It
doesn't take a detective to see that the tyrewalls on traditional
motorcycles are higher than their more modern contemporaries. Harley
have joined in with this game, tentatively, with the Deuce and the
difference in handling characteristics between that model and its
plainer Night Train and Standard siblings are remarkable. Low profile
tyres have the advantage of less flexibility in the sidewall giving
greater stability at speed, and sharper handling. It's not all good
news, however, and it offers it at the expense of comfort and load-carrying
ability.
In
terms of rolling radius alone - determined by the circumference
of the tyre - a lower-profile tyre requires a larger diameter wheel
to maintain overall gearing, and the seventeen-inch wheel of the
Deuce goes half-way towards the more radical eighteens on the fattest
250-section tyres available at the moment. To get an indication
of the rolling radius, a 250/40-R18 rotates the same number of times
per mile as a 170/80-B15 or a 180/70-R16 - actually fewer times
than the stock, tall MT90-B16 and so represents a marginal increase
in gearing.
Wider
tyres are easier to sustain on lower profiles and it isn't hard
to see why: if you have a sidewall that is nearly as high as the
tyre is wide, the potential for the sidewall to flex, or slew would
be phenomenal, but it would be a very comfortable ride - you'd barely
need shock absorbers, but then you'd be wobbling round potholed
corners in a way that would make a hardtail look precise. So the
widest tyres live on the widest, tallest rims, and have the shallowest
sidewalls - as in the example of the 250/40-R18, which is 250mm
wide, should be 100mm high and is destined for an 18-inch rim.
Something
else that low-profile tyres do - especially when combined with a
lot of width - and that is to give a bigger contact patch, spreading
the load of the bike. That creates a problem of its own, too, because
it means that the fattest tyres will need a stickier compound to
provide the same grip as the same bike on skinnier tyres. It's the
same principle as wearing snowshoes. On a light bike that might
be a bad thing, on a heavy bike it's a good thing - especially when
leaving the boggy ground of sodden campsites. It's an odd truth,
but the thin wheels of a racing pushbike will leave a deeper rut
than a 250-section tyre on a Fat Boy giving the impression that
the pushbike weighs more: it obviously doesn't but what little weight
it has is concentrated over a smaller area.
Radial
vs Crossply
You'll
have noticed a few additional letters sneaking in before the rim
size, namely B and R: Belted and Radial.
They
all have a carcass in common, which is the actual bladder of the
tyre with beads at the edges, but they differ in terms of the way
in which that is reinforced.
Crossply
tyres are the most basic form, and while featuring the strongest
sidewalls, they are looked down upon for modern sports use, and
almost all car use these days. Belted plys of cords are laid diagonally
across each other at about forty-degrees to the centreline, from
bead to bead, providing strong radial and lateral strength across
the entire tyre. The downside is weight and heat generation. They
do still have their uses primarily on cruisers and off-road bikes
where the cushioning effect of the taller sidewall is beneficial.
Belted tyres are crossply in design, but have a layer of additional
reinforcing belts - typically Kevlar these days - angled at between
twenty and forty-five degrees which helps handling at higher speeds
and increased loads. The angles help provide some degree of lateral
stiffness when compared to the less compromising radials. They tend
to come out thinner than crossplys because the reinforced sidewall
doesn't bulk out so readily.
Radials
have a simpler construction altogether, with little sidewall strength
but with belts running round the circumference of the tyre at zero
degrees, with the advantage of extraordinary radial strength that
suits any situation where the speed of the bike puts greater forces
on the tyre than the lateral forces can exert. They are great for
high-speed handling dynamics - it's what they were designed for.
The lesser height of these low-profile tyre forms reduces the leverage
between the road contact patch and the fixed wheelrim to counteract
the reduced sidewall strength.
You
may recall the public information campaigns as radials became increasingly
common on cars, relating to the perils of mixing the two types of
tyre. Didn't mention bikes, though, did they, but they should have.
It is illegal to fit a crossply, or a bias belted rear tyre with
a radial front in the UK at least, and that is not just for fun:
it is dangerous!
It
is not illegal to mix a radial rear with a crossply front, but it
worth bearing in mind that all tyres are tested as matched pairs
and no account is made for people operating outside that environment.
You might get away with it, but the responsibility is yours. I am
aware of an example of a Buell-based chop that retained its original
rear wheel and tyre but matched them to a 21-inch front. It looked
stunning, but it shook its head at speed
well, at high speed.
Okay, when accelerating very hard at highly illegal speeds. It was
the last thing that was suspected and lots of steering geometry
work was done in tracking it down.
Compounds
Rubber
is rubber, is rubber surely? Forget it: we're talking rubber as
a generic form here: the stuff that forms your tyre has a high rubber
content, but owes more to the chemist's art than the man with a
drill and a rubber tree.
At
the tyre's initial design stage, the manufacturer's chemists are
told what the compound should be able to do, and a number of variants
are produced and tested with the best one being selected for the
final tyre. Compound testing isn't something that is done on a computer
simulation, but on the road because nothing else can give the cross-section
of conditions that a tyres has to survive.
It
is the success of the chemist that makes one tyre grip when another
will be heading for the ditch, and I remember all-too well the reactions
of an Asian-built tyre that looked remarkably similar to a Dunlop
TT100 in tread pattern when confronted with wet tarmac in my youth.
I was working at a British bike specialist at the time, and we referred
to them "Kamikaze Ditchfinders", and explained to potential
customers looking for a bargain that they may be cheap, but not
to expect much from them.
That
was more than twenty years ago, and the tyremakers' art has moved
on greatly since then - but then, so have motorcycles. A single
manufacturer will now produce a range of tyres for specific applications
with massively different grip and wear rates according to what their
purpose will be.
Tyres
grip better when they are hot, and hot tyres leave some of their
rubber behind as they grip hard on the bends. Sportsbike tyres reach
their operating temperature quickly and are particularly good at
keeping a lightweight motorcycle on the road at impossible lean
angles, but they don't last long in relative terms. Casting size
and load indices aside for the moment - but purely for the purposes
of example - put the same tyres on a heavy American-built V-twin
and they would be gone in no time, because they're not designed
with a heavyweight in mind: they'd overheat and leave a lot of rubber
on the road unnecessarily.
We
need harder compounds to cope with the weight, and can get away
with them because we won't be testing their grip anywhere near as
much. We go round corners too, sure, but not as quickly, and with
gravity pushing the tyre harder onto tarmac. Go the other way, and
put a set of tyres from a cruiser onto a Sportsbike and they'd probably
last forever - if only because no-one would want to ride it, and
certainly they wouldn't want to ride it fast because it would slide
all over the place being neither heavy enough to get enough heat
into the tyres, nor sticky enough to keep the lighter machine from
sliding.
So
there's really no point in going for the really sticky compounds
that your mate's R1 uses because your bike won't get the benefit
- it might even make it worse, and it'll certainly hurt your wallet.
Experiment,
by all means, but within parameters. Tyre compounds are developed
for sports, sport touring, touring, heavy touring and utility. Custom
tyres generally use sport touring and touring compounds for the
right amount of grip but allow you to use the radical profiles of
sports tyres without suffering an inappropriate compound.
Finally, anyone who's travelled abroad, or even interstate, will
be aware that road surfaces can change quite markedly from one jurisdiction
to another, and they might wonder whether there is - as there often
is with beer - a different type of tyre for different road conditions,
albeit one that is not spoken about. The answer, we are told, is
no. So while road surfaces vary, and even road conditions in terms
of ambient temperatures, tyres don't. They are tested in as broad
an operating range as is feasible, but after that you're on your
own. On the bright side, tyre manufacturers provide, on request,
special slick tyres to the highway agencies, and they use them to
check for grip and abrasion levels on many roads.
Tyre
pressures:
Tyre
pressures are extremely important, but are possibly the most overlooked
part of daily maintenance - especially on the rear wheels of dressers
because you can't find them very easily. We've all ignored them
until they are actually noticeable either visually or by the change
in handling characteristics, but it is worth being aware of the
implications of getting them wrong.
Over-inflation
will wear out the tread in the centre on your tyre quicker than
your wallet would like, and prevent the tyre from spreading out
on the road as it was designed to do to give you the maximum grip.
It is easily done because you put more air in your tyres when taking
passengers, or when running loaded, but you seldom take it out again
when running empty or solo.
Under-inflation
is potentially worse, because the tyre will spread out on the road
further than it was designed to do. It is sometimes done deliberately
to increase grip on soft surfaces, but in those circumstances it
would be combined with low speeds - don't think about trying the
same trick under any other conditions. Under-inflation makes areas
of the tyre flex more than they are designed to do, and can lead
to premature failure, as the rolling tyre deforms when the weight
is placed upon it, and returns to its original shape a moment later:
this constant flexing builds up a lot more heat than is desirable,
and can even lead to the separation of the composite layers. Quite
apart from that, it will tend to wear out the shoulders of the tyre
more than the centre which are designed to take a different sort
of loading.
Recommended
tyre pressures are usually shown on a sticker somewhere sensible,
but these refer to the stock OE tyres: if you change your tyres,
check the pressures recommended by the tyre manufacturer - you may
be surprised by the variation.
Always
check tyre pressures on cold tyres - as the tyre heats up, so does
the air inside it by as much as 5psi.
Tube
and tubeless tyres
The
traditional inner tube has largely had its day on modern motorcycles,
but still makes a useful temporary repair on tubeless tyres unless
they are stamped TLO - or tubeless only - in which case the internal
dimensions of the tyre are not suited to the use of a tube, and
can be dangerous.
Inner
tubes were essential in the old days when spoked wheels were much
more common, because no matter how good a bead you got on the rim,
the air would leak through the spoke drillings. The same is true
of a lot of spoked wheels today, but there are now tubeless spoked
wheels available.
Inner
tubes can be repaired, but will never be as strong as they were
originally: they are relatively cheap to buy new, and a damn sight
easier than discovering that the fix wasn't as good as you thought
it was when you put the bike back on the road again.
Tyre
manufacturers recommend that you replace tubes when you replace
tyres, and on tubeless tyres, you should replace the valve. It's
a relatively inexpensive exercise and a sensible thing to do. Get
a virgin balloon, inflate it and then let all the air out of it
again - that's very much thinner than an inner tube, but they adhere
to the same basic principles.
Balancing
Regardless
of how much care is taken in their manufacture, tyres are never
going to be perfectly balanced, and so weights are attached to the
rim of an alloy wheel, or the spoke nipple of a laced wheel. Less
critical on a rear wheel than a front, an out-of-balance wheel can
lead to anything from "pattering" sensation at the front
end to uneven tyre wear at either end. It takes next to no time,
and makes life a lot better.
Aesthetics
Tyres
are black because that's how we like them. They don't have to be
black, and are only made black by adding carbon to the mix. They'd
far rather be buff, which is the colour of the mix before it's messed
about with, but no-one wants buff tyres, and motorcyclists of all
types are typically too conservative to contemplate blue, red, green
or purple - any of which is achievable, but none are available.
And if you think about it, it would always be the wrong shade anyway.
So black it is.
We
can and do experiment with whitewalls to conjure up an image of
days gone by, but these have a legacy that we prefer not to think
about: grip. It is an age-old thing, and something that a lot of
people will never come to terms with, but there is no reason whatsoever
why whitewall tyres should have any less grip than the plainer offerings.
There are tales concerning their original manufacture that suggest
that white rubber was bonded to black rubber using a galvanising
process, and that galvanising process affected the rubber's grip
in some way, but we are given to understand - by our friends at
Cooper/Avon - that it isn't done that way any more. I have vague
recollections about a new process that Avon started using nearly
ten years ago with their "Gangster Whites" which was supposed
to resolve all such problems, but no-one's letting on any more so
we're going to have to leave it at that. I will note, however, that
Rich is absolutely convinced that the whitewalls on the Road King
Classic are nowhere near as good as the white pins on the stock
model which is, as much as anything, the reason why I'm running
the narrow white stripes on my 'Glide - watch this space.
Then
we get tread patterns and love them or hate them, this is the fashion
end of the tyre.
We
don't need tread to grip because the rubber compound does that for
us, as you'll know if you watch any sort of motorsport. We need
tread to get rid of the water beneath our tyres when roads are wet,
and it is little more than a channel for the water displaced by
the rubber to escape through, and the reason why there are laws
relating to how deep the tread needs to be is to make sure the pathways
are capable of transferring enough water.
If
the water can't escape, you get a thin film of water between your
tyre and the road, and that means you're a boat. The expression
is "aquaplaning" but that is more applicable to cars:
on a bike your bike is sliding out from beneath you at a rate of
knots, with no friction between the rubber and road to reduce the
speed at which it does it - and it's touch and go as to whether
finding a dry spot of tarmac is a good thing or a bad one: at best
you'll regain control if you've not gone too far, but at worst you
will high-side the whole plot and do significantly more damage to
both yourself and the bike.
If
anything, the tread reduces the grip of the tyre on dry roads because
it reduces the amount of the rubber compound that is on the road,
but it is to a minor extent. It also affects the stability, and
the current generation of tread patterns go a long way to resolving
this with irregular patterns breaking up the natural tendency for
a tyre to create its own track. In principle it's not dissimilar
to "white-lining" - when you cross overbanding or road
markings and notice a tendency for the bike to follow the direction
of the ridges - except the ridges are on the tyre not the road and
it makes the bike marginally harder to break off its line. It also
reduces that annoying road hum that haunts riders of quiet stock
bikes. But for all that, there is an element of making a good-looking
tyre to compliment the bike that it's fitted to.
It's
also worth noting that treads are the perfect hiding places for
stones: if you see them, get them out before they start worrying
at the tyre's carcass: nothing is more soul-destroying than throwing
away a set of tyres with loads of tread because they've been damaged
in other ways.
In
Conclusion:
- Don't
take tyres for granted: bad ones, worn ones, damaged ones or old
ones will affect your bike's safety.
- Good
tyres will add another dimension to your machine.
- Different
tyres - and especially compounds - will suit different riders,
but there are a few things that are worth looking into.
- Cheap
tyres are in the same bracket as cheap helmets: how much is your
bike worth?
- Be
aware of the load index and don't undercut it if you want to keep
within the law - and the safety margin determined by the developers.
- If
you want to play with custom tyre profiles but are not sure what
is suitable, talk to the tyre companies. They have people who
know more than we'll ever find out about their products, and are
committed to making sure you are safe.
- Don't
mix crossply rears with radial fronts: it is illegal and dangerous.
- If
you want a high profile tyre for the back of your American-built
V-twin, consider belted construction in preference to a straight
crossply.
- Streetbikes
generally only have a belted rear tyre, because the front is doing
a lot
less work.
- Heavy
tourers benefit from a belted front tyre too to handle the braking
and steering loads.
- Don't
waste money on flash tyres with compounds ill-suited to your application:
every tyre manufacturer will make recommendations as to the suitability
of a tyre's range for a given model.
- Cheap
tyres are often a false economy.
- Riders
of Dyna Super Glide Sports and T-Sports will be interested to
know that they're running the same Dunlop D401 rubber as the Super
Glide but the K591, as fitted to the XL1200S, is the sportier
compound of the two.
- Check
tyre pressures and adjust them according to your loading.
- Take
as much care of inner tubes as you do of tyres. You can repair
some tubeless tyres when punctured with inner tubes, but don't
try to repair TLO tyres.
- Make
sure your wheels and tyres are balanced to prevent uneven tyre
wear.
- Tread
doesn't grip, rubber compounds do.
- Don't
judge a tyre by its tread pattern.
- Keep
your tread clear of stones, and at a good depth to allow the passage
of water.
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