New fork - Headset problems

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vbc

Guest
Location
Bristol
Thought I'd replace the original steel forks on my Kaffenback with a set of Easton EC70X carbon/aluminium steerer forks from Chainreaction.

Took off the old forks and salvaged the lower crown race to put on the new forks, no problems.
Cut the forks steerer on the new forks to the same length as the old forks, no problem.
Tried to assemble the new forks to the frame but I now seem to have a gap between the lower plastic spacer (below the lower bearings) and the shoulder of the forks. When I tighten the headset (lightly) with the star nut & bolt, the forks are tight in the frame but there is still a gap below the lower crown race bearings.

The steering is now too tight for the bike to be rideable.

Can I just fit some kind of spacer to take up the gap or have I done something stupid but elementary?
 

bonj2

Guest
Firstly i would make sure there is actually supposed to be a "lower plastic spacer" between the lower bearing and the crown race. There might well be, but on most (semi-)integrated headsets i've seen, the crown race nestles into the bottom bearing. There is no spacer between them.
Secondly make sure that what you think is the crown race, actually IS the crown race. It's an easy mistake to make.

If you're still unsure, post a picture or several - preferably one showing the forks with the crown race on, and another one showing how you're fitting it together and why it won't work. Then we can take it from there.
 
OP
OP
V

vbc

Guest
Location
Bristol
I had a look here;

http://www.parktool.com/repair/readhowto.asp?id=65

The bottom bearing retainer was in upside down so I corrected that. Also disconnected the front cantilever brakes and loosened the front cable hanger before tightening the star nut. Still a little too tight but I'll pack both top and bottom bearings with grease at work tomorrow so should hopefully be sorted.

Thanks.
 

02GF74

Über Member
dunno unless you post pictures. if the bearings are tight, then grease won't fix that.

mentioning star fangled nut makes it sounds like you have ahead forks; the nut is done up until all the play is taken up and no more - the ahead set clamped onto the stem is what keeps the fork in place so there is not need to put mega torque onto that nut.

in the past when fitting the race onto the fork, I found there are tight spots as you must get the lower race square onto the fork.
 
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