Loose steerer tube in frame's headtube?!

[DIYer]

Bike: 2023 Boardman HYB 8.9 - here's the 2020 model spec which seems almost identical: https://www.tredz.co.uk/.Boardman-HYB-8-9-2023-Hybrid-Sports-Bike_228762.htm

But the link above has a different headset (Boardman ships with two different headsets depending on supply). My one is a one-piece FSA Orbit C-40 ACB, 1 1/8” - 1.5” tapered, Integrated. This looks like:

There has always been play in the headset, but I've only just realised that's what it is. When I have the brakes applied, and push the bike forward I can feel it, and now I know what it is, I can't ignore it anymore! I did have the bike assembled by Halfords so... (and is now out of warranty).

The top cap bolt doesn't seem to pull the stem down (maybe because it's a one-piece), it just tightens the headset to the steerer tube, as do the side bolts. It doesn't matter how much I tighten the top cap bolt, the play remains the same. I've attached a 2 photos below with and without the sealed ballbearing ring, which shows the gap (indicated by the red triangle) between the steerer tube and the frame's headtube. This is what I believe is causing the play.

Does anyone have any advice solution to this or an idea why there's this gap? On principle and economics, I'd love to fix this myself.

 

[Pat "5mph"]

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[Pblakeney]

First impression is that there should be an insert in the top of the head tube for the bearing.
If not, then it is an incorrectly sized bearing.

 

[Yellow Saddle]

You don't say whether you understand the mechanics of an Aheadset or not. Nevertheless, the top cap can only adjust the bearing play if the stem bolts (side bolts as you say are loose). Loosen the stem bolts, then adjust the headset according to this recipe:

https://www.cyclechat.net/threads/rocking-headset.176021/#post-3578370

Then tighten the stem bolts again. If this doesn't work, you've runm out of gap underneath the top cap and need to insert another small spacer lor, you need to push the plug in futher.

 

[raleighnut]

^^^^^ wot e sed

 

[DIYer]

You don't say whether you understand the mechanics of an Aheadset or not. Nevertheless, the top cap can only adjust the bearing play if the stem bolts (side bolts as you say are loose). Loosen the stem bolts, then adjust the headset according to this recipe:

https://www.cyclechat.net/threads/rocking-headset.176021/#post-3578370

Then tighten the stem bolts again. If this doesn't work, you've runm out of gap underneath the top cap and need to insert another small spacer lor, you need to push the plug in futher.

Thanks for this input everyone!

Between the YouTube videos and taking it all apart and putting it back together again, I've got a hold of the mechanics of it, incl. tightening the top cap before the side bolts. But whereas a topcap pulls down a conventional handbar for a snug fit and no play, this handlebar is a one piece construction and the topcap simply creates pressure inside the steerer tube (and the side bolts apply pressure outside the steerer tube). The issue doesn't seem to be the vertical tightness but the gap between the ballbearing ring and the frame head tube...

Which makes me think perhaps Pblakeney is right that the ballbearing ring that was fitted by Halfords on bike assembly is not the right size?

 

[Pblakeney]

Which makes me think perhaps Pblakeney is right that the ballbearing ring that was fitted by Halfords on bike assembly is not the right size?

That gap at the red arrow in the top photo is certainly not doing you any favours. Something is wrong.

 

[fossyant]

That gap is there deliberately - it's on the preload adjuster, which should be pushed down on by the top cap. Have you popped the bearings out to see if there is any play in the cartridge. I've had this on cartridge hubs - bought some new bearings, but they were poor quality and had play in them from new - no adjustment would take it out. Replaced with quality ones, no movement.

 

[Way-Out-West]

Since I can't see a bung in the top of the steerer tube, maybe the bung has pulled up and is inside the one piece handlebar/stem. If so remove and fit to the inside of the steerer tube, then it'll compress correctly. Don't over-tighten the top cap bolt. It only needs to be tightened just enough to remove play. No more than 5NM on the pinch bolts too.

 

[Pblakeney]

That gap is there deliberately - it's on the preload adjuster, which should be pushed down on by the top cap. Have you popped the bearings out to see if there is any play in the cartridge. I've had this on cartridge hubs - bought some new bearings, but they were poor quality and had play in them from new - no adjustment would take it out. Replaced with quality ones, no movement.

No amount of preload on the internal diameter is going to make that bearing fit that head tube on the external diameter.
Isn't the bung the green part?