Smaller than 1" headset bearing help!

[utahdog2003]

Just buy the same size and balls and re-use the old cage or even better, buy the same size balls and fit them loose (and get more in)

Ditto that. Dump the cage and free-ball it.

 

[was8v]

thought it might be a nightmare. Might have to have the bike upside down to do the top race so I don't loose the bearings.

Plenty of grease in the cup will hold them in while you assemble!

 

[WD Pro]

Even headsets from the same spec (i.e. campy or jis) can vary from headsets from different makes e.g. they could have different ball PCD's (and sizes) which would equal different cages.

Externally my 1" M900 looks noticeably larger than the DX that came off and the tange that is on the old spez I have.

I even removed the cages from the NOS M900 before it was fitted

The cages on the right are crap anyway and deserve to be skipped (sorry ! ) - look at the gap between the balls and think of the effect on ball contact area / load bearing ability etc

WD

 

[EarlofBarnet]

Think the 'loose ball' route is the way to go then. Plenty of grease and fingers crossed I won't be chasing bearings around the shed with an unside down Stumpy in hand! Wish me luck!

 

[keitht]

Hmmmm..the different standards may explaim why I had difficulty with my 95 S-works and it new aheadset.

A certain amount of filing to the fork was required to enable the fitting ( read hammering ) of the crown race.....

:twisted:

Hope you sort your issue in less than the 4 hrs it took me to remove and fit a new headset.

 

[Dead Rats]

Hmmmm..the different standards may explaim why I had difficulty with my 95 S-works and it new aheadset.

A certain amount of filing to the fork was required to enable the fitting ( read hammering ) of the crown race.....

:twisted:

Hope you sort your issue in less than the 4 hrs it took me to remove and fit a new headset.

that's the problem I've had before too... didn't mind when it was on my steel hack but it made me very nervous when fitting a Campy crown race that's super tight on a Vitus... if I take it to LBS do you think they will resort to filing down crown race, or fork - or both?

 

[keitht]

I was very cautious whilst filing the flange.. ( great word )..but it should now at least be future proof for a while...

I f I had filed the inside of the race, I woul have to repeat this every time I fitted a new headset...not a regular occurance admittedly....

It was still a tight fit, and will now doubt have to be cut or ( carefully ) bolstered off with a certain amount of brute force when the time comes.

As to the LBS.. i am reasonably certain they would not have employed the methods I did to fit the headse..whos cups were a tight fit also.

Nothing that several peices of 4by2, a workbench, lumphammer, and a stubborn determination couldn't overcome..

 

[EarlofBarnet]

Removed the bearings from the (shiny) race in the picture and fitted them in to the top cup until it had a set with no gaps between the bearings. Popped everything back together and nipped up the headset nuts and it knocks. Think the bearings are too small a diameter when used on their own.

So, either need larger diameter bearings or...might try and fit a normal 1" headset top cup assembly. I've got one good set of the weird size bearings, so I could leave the bottom cup set-up as it is (although when the bearings have had it I'm back to square one). Arghhh!

 

[WD Pro]

Hmmmm..the different standards may explaim why I had difficulty with my 95 S-works and it new aheadset.

A certain amount of filing to the fork was required to enable the fitting ( read hammering ) of the crown race.....

:twisted:

Hope you sort your issue in less than the 4 hrs it took me to remove and fit a new headset.

that's the problem I've had before too... didn't mind when it was on my steel hack but it made me very nervous when fitting a Campy crown race that's super tight on a Vitus... if I take it to LBS do you think they will resort to filing down crown race, or fork - or both?

They will have a reamer / cutting tool (for the crown race seat on the fork). The park one I borrowed to do the marin had both sizes. It's a sub 5 min job with the correct tools.

I will get a picture when I face up the replacement forks

 

[WD Pro]

Removed the bearings from the (shiny) race in the picture and fitted them in to the top cup until it had a set with no gaps between the bearings. Popped everything back together and nipped up the headset nuts and it knocks. Think the bearings are too small a diameter when used on their own.

So, either need larger diameter bearings or...might try and fit a normal 1" headset top cup assembly. I've got one good set of the weird size bearings, so I could leave the bottom cup set-up as it is (although when the bearings have had it I'm back to square one). Arghhh!

A) don't mix headset parts unless from the same make / model - chances are the seals etc won't line up properly.

B) assemble one cup and race dry to find the max amount of loose balls you can get in - then remove one before greasing / assembly. It's not always easy to get the balls to sit in the right place first time round i.e. If you stuck then in grease around a slightly smaller diameter than the race is ground for, once assembled they would find their naturel position, space out a bit and potetnialy give you a 'rocky' headset

C) the cage has no effect on the headset working correctly - it is there to help assembly only and to keep the balls correctly spaced (which isn't important with the correct number of loose balls).

D) check the top and bottom cups actualy have the same size balls - some don't.

E) did it work correctly before hand or has it had a mish mash of parts making it harder to suss out what's actually correct ?

F) take one of the oe balls to someone who can mesure it acuratley to ensure your replacement balls are the same. To small and it will bind, to big and it won't close down / seal properly. Either big or small 'could' cause the ball to take a different position than the cups are ground for.

Don't give up the arkward jobs are always the most rewarding

WD