While out in the rain yesterday, I noticed brown rusty gunk leaking out the bottom of my head tube (Specialized Tricross). A closer inspection today revealed what I suspected; the bottom set of ball bearings were rusty and had worn the races.
So today, bike into kitchen/workshop
and off with the bars, front wheel, mudguard, front brake, and forks. A long metal rod and a hammer, followed by half an hour of swearing, banging, and a few blows to my left hand with said hammer, and the races were out of the head tube.
Into the car and off to Dales bike shop (nearest competent helpful bike shop open on a Sunday) and they sold me 2 sealed bearing units to replace the loose bearings and races set up which had been fitted originally.
Back home and back to work in the kitchen. All re-assembled, but why was there a gap between forks and head tube? And, there was play in the forks, and it wasn't rotating smoothly? Took it apart again for investigation and found the problem. The sealed bearing is bevelled on one side, THAT is the side that mates with the head tube - doh! I hadn't even noticed that the 2 sides were shaped differently when I first put it together.
All now sorted and awaiting trial run tomorrow
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