Headset Maintenance

The rust coloured stain which would come out the bottom of my headset after riding in the rain and the fact that sometimes it would seize up and need a few twists to loosen off properly should have been a warning sign, but after last week's trip to Glentress and a ride back from work in the rain the day before, my headset was sounding even worse. There was a distinct grinding feeling when moving the handlebars and on my commute, the bike sometimes wanted to keep going straight on and required a bit more effort than normal to turn.

So I had a go at removing the forks to see if I could improve the problem. Step one is to undo the cap at the top and remove the stem by undoing the two bolts on the side, then you just have to remove the spacers and you're ready to take the forks off. Most of the websites I read said the forks should just drop out, or a sharp knock with a mallet would loosen things, but this didn't seem to be happening for me, even after hitting the steerer tube as hard as I was willing to. I later discovered that there is a rubber wedge in the top of the headset which keeps everything down, prying it up a bit with a screwdriver meant that the forks could drop out easily.

A little too easily it turned out, I ended up holding the forks in one hand and the frame in the other, a situation which could have been remedied if I had a workstand, or if I had taken the wheel off first. There's not really anywhere you can stand a set of forks with a wheel on the bottom and I couldn't but either part down to sort things out. To make matters worse, the bottom bearings had fallen out and a few were now rolling about on the floor. After a quick call to Rosie I managed to sort myself out and take the wheel off. Then I just needed to find the bearings.

Problem was, there was one missing ... after a good bit of searching I realised that the bearing retainer had been bent and there wasn't one missing at all, there was just one jammed somewhere it shouldn't be, I assume that's what the grinding noise was!

Changing the who headset sounded like a bit of a worrying task and buying individual bearings doesn't seem to be possible (added to the fact that the headset on my bike doesn't seem to be available for sale anywhere) I resorted to trying to bend the retainer back into place. This was quite easily accomplished by getting Rosie to bend the retainer back into place with a pair of small pliers. I then degreased the bearings to remove most of the rust, put it all back together with a liberal amount of grease and took it out for a spin.

Everything seemed to work fine (after I tightened up some loose parts) and it's still working now. Definitely needs replacing sometime soon, but for the moment it's doing the job. I hope everything is ok for tomorrow when I hope to head back down to Glentress.