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Discussion Starter #1
The E-804 is the new front knobby from Shinko, similar to the Continental TKC 80. I'm trying to mount the tire on my 2004 DL-650.

I'm confounded. The problem is that the bead won't seat on the rim. The inner diameter of the tire (at the bead) is actually too small to come out of the dish of the rim. No amount of air will push the bead out of the dish. If you maneuver one side out of the dish, the opposite side drops into the dish.

Anybody ever had this problem? Ideas, solutions?
 

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Use quarts of tire lube, no wd40, or any spray, tire lube with a warm tire and take the guts out of the stem to seat the bead, must have a fair sized compressor with tank, no tankless jobbie.

This is no help for you. Just wanted to say that I've been mounting my own tires with irons for over forty years and about 7 years ago when I bought a KLR, I couldn't believe how hard DS tires mount/dismount, hence the No-Mar tire "holder" now in my shop, and they are still a wicked bit4h.
I have a friend that has owned a bike shop for about 33 years, he will not touch a dual-sport tire, knobby or not. And,he uses a regular commercial tire changer.
I've heard him tell customers to bring it to the dealer.
When I'm going to mount as new tire, it sits in the sun or over the wood stove for at least an hour beforehand, huge difference when warm.
The sidewalls are the culprit---- so stiff.
I've thrown things more than once mounting/dismounting tires, even cut a few off.
Stay cool.
Edit,,, And I buy tires months before I need them and block the tires open with pieces of pine wider than the wheel as soon as the tire arrives, helps a lot.
 

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Discussion Starter #3
This is the 6th front and 10th rear I have mounted on the DL650. Never had this problem before. I have also mounted tires on my KLR without a problem.

This Shinko is really flexible - not stiff at all. Getting it mounted was a breeze. The issue is that the inner diameter (measured at the bead) is actually smaller than the diameter of the dish.

A guy on advrider.com suggested a ratchet strap may help. Going to give that a try, along with removing the valve guts as you suggest. Thanks.
 

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Yup lots of lube and high pressure, and bounce the wheel hard up and down all around as well.
 

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Discussion Starter #5
Success

The combo of the ratchet strap and removing the valve core worked. Bead set no problem - 2 pops and I'm done.

Thanks for the tips, guys.
 

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There's more than one way to skin a cat and seat tires, go on YouTube, there's a ton of tricks for tires that won't seat easily.

 
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