today's jigsaw puzzle... Headset replacement

[SatNavSaysStraightOn]

so far found 2 sets of instructions and neither of them make it any clearer...

http://www.fullspeedahead.com/wp-content/uploads/2014/04/Headset-Installation-Instructions5.pdf
http://img87.imageshack.us/img87/5164/fsaorbitxliidiagram.jpg

guess I am just going to have to take the plunge and dismantle the old one and note down what comes from where...
And I am useless at getting the wheel realigned with the frame and then the bars perpendicular... any tips?

 

[Scoosh]

Well, I can tell that there are separate parts for different sized tubes.
The black thing (with Orbit) takes the bottom RH cover and the bolt goes through both ... and the cup-shaped thingy must go at the bottom, as the bolt threads into that.

Arrange others in any order you want .. then PM @mickle ...

 

[SatNavSaysStraightOn]

@User14044
new headset for the Nomad. picked up some issues back in Finland with it which were resolved (minus English) by a random cycle shop... Unfortunately now the issue has returned and on top of that it now creaks something chronic when the weather is warm... can't actually loosen things off any further and have found some rust streaks on the double crown forks... time to quit and have new bearings but couldn't locate just the bearings alone...

@Scoosh I had worked out that the words/letters most likely went the UK way up not the ∀nsʇɹɐlᴉɐu way or is it uɐᴉlɐɹʇsn∀ way, either way its the wrong way (probably)!

I know the rubber seal goes at the bottom - that is missing from my OH's bike, came out whilst we were on tour and was never replaced...

as for an LBS... I don't really have any of sorts...
the closest is dedicated mtb and has let me down badly in the past (at Delamere Forest)...
the next local one is in Northwich (great guy, friendly but with odd opening times, no website, does what he wants (not mtbs or hub gears).
One of the local CC'ers uses one over the otherside of Frodsham but that also leaves me with a transport issue - mind you they all do. the car and my OH are away from home... so I have to be able to ride the bike there, them fix it whilst I wait and then ride home again... guess its back to the DIY and DGIW approach!

 

[SatNavSaysStraightOn]

found the source of the rust... does this look OK on a 3 1/2 year old bike? OK it is high mileage all under a heavy load but, that blacker area is 'narrower' than the rest of the forks (and that is after I have cleaned it up with a wet rag) will also email the photos to SJSC technical support as well.

 

[Scoosh]

This vid is for a road bike ....

This one is for an Utah MTB.

HTH and it works !!!

 

[SatNavSaysStraightOn]

thanks - MTB one seems closest. As far as I can tell, I may not have put enough lube back on.. but otherwise I currently only have 4 spare parts ... 3 of which I can ID and had decided I was not fighting with - they don't look worn on bike and were the frame top & tail (and that is going to be a hell of a fight to remove them if they really do need doing) and the part that the top nut bolts down into...
the other part the silver thing on the LHS I have only just realised where it goes and again the original looked fine after I had cleaned it up. It was covered in rust from is actually in the left picture above.

So, bike assembled and back together. May take it and an allen key for a ride later on to test it out before next weekend's mini-tour.

I was only really aiming at replacing the 2 cartridge bearings ( ) to deal with the creaking when hot and the 'Auto straight on/self centering' that happens when you even marginally try to tighten the top nut. The good news is that whilst the top bearing was fine, that one pictured is unbelievably gritty and unsmooth when I move it by hand, so correct decision and we will find out in time if my first headset replacement has gone smoothly!

 

[Scoosh]

'SNSSO Bike Mechanics' is now open for business !

 

[derrick]

found the source of the rust... does this look OK on a 3 1/2 year old bike? OK it is high mileage all under a heavy load but, that blacker area is 'narrower' than the rest of the forks (and that is after I have cleaned it up with a wet rag) will also email the photos to SJSC technical support as well.

View attachment 52609 View attachment 52610

That does not look good, could just be the pic, i would get that checked out properly.

 

[winjim]

1-9 bottom to top.

 

[SatNavSaysStraightOn]

View attachment 52656
1-9 bottom to top.

9b goes in before 9a though and 9a after 9c...

 

[SatNavSaysStraightOn]

How's it going with the repair,@SatNavSaysStraightOn ?

How bad was the rust on the tube? Dave Whittle at Thorn is always v good with advice - he usually responds on the Thorn forum.

the bike was reassembled last night though I didn't go for a ride, but it feels smoother. I didn't have chance to email sjsc and am out all day today, but will tonight hopefully... either way I suspect I will be undoing it again at some point soon because I don't think I put enough grease over the bearings. But the fields should be good for the mini tour coming up and for the 2 week tour at the end on the month.

 

[Profpointy]

Just a hint, when re-assembling, don't put the forks in upside down !

(guess why I say this)