Werhoooooooooo!
After a bit more fettling with closing up the sleeve I was able to get it back into the steerer tube, tightened it some more once in their, reassembled stem etc and lo and behold as hard as I try I cant rotate the spacers/headset dust cap!!!
I suspect at some point I've tightened the top cap due to a loose feeling headset, this has pulled up the bung very slightly out of the steerer tube and hence it was not gripping it correctly.
Whether thats actually fixed the clicking when out of the saddle I'm highly doubtful but atleast its one thing removed from the list of possibilities.
I managed to also change the pedals today with some help, went for a quick test ride but unfortunately the same noise is still there, so I'm afraid this has beaten me. I will have to see if I can live with it, if not I'll be looking to sell it at some point for something else that doesnt have any kind of press fit bottom bracket!!!!!!!.
Hi, I've been reading this post with intrest as I've been having exactly the same issue. I've replaced the bottom bracket disassembled and rebuilt everything on the bike using lots of grease and it still didnt cure it. I had resigned myself to putting up with it.
It was only by chance when my chain fell off that I noticed the chain catcher was virtually touching the small chan ring, I moved it away a fraction and Hey Presto!! the noise had gone. The frame must have been flexing slightly when putting the power down and moving it away slightly cured it. I didn't notice in the post if you have a SRAM group set but if you have I hope this helps.
Thanks for letting me know but I have a Shimano Tiagra groupset and I'm not even sure what a chain catcher is? - If I'm right I think they are only used on 1x drivetrains to stop the chain coming off as there is no front derailleur?
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