Bicycle Mechanics - Cannondale Fork Install.....Problem II....

I posted a thread yesterday about the problem I was having with the top-cap, (thread located here http://www.bikeforums.net/showthread.php?t=245283 ), so today I went to a cannondale dealer and it turned out I had the wrong bolt, I needed a longer one.

So I got home all excited to finally install the fork, but then hit another snag. When I tighten the top-cap down, the entire headset siezes. The wheel and handle bars do not turn. Its possible that I re-installed the headset incorrectly, but I am pretty sure thats not the case. I am using the stock FSA alloy headset, and I noticed that the bike that the fork originally came on uses a carbon headset. Could this possibly be the source of my problem? These are both integrated headsets, and I am converting from a slice ultra with aluminum steerer, to a full carbon c'dale fork.
Any suggestions on how o fix this latest problem?
Below is a pic of my bike now with the sized fork.
Thanks for your help in advance!

Sounds to me like you should probably let someone who knows what they are doing work on your bike...

Just how tight did you tighten the top cap? What happens if you back it off until the bolt is loose, and then just snug it up?

You are likely over tightening the cap.

I am not tightening the top-cap excessivly at all, when I back it off a few times the fork has play in it and is loose.

you have to find the happy medium

Its definatly not due to tightening the top-cap too much. There seems to be a problem with the headset, maybe not enough grease. Also it could be that the bearings need to be pressed into the headtube, although I didnt think that was required for FSA integrated headsets. I guess I will just have to bite the bullett and take it to the LBS. :(

grease is def. not your problem.

I am not tightening the top-cap excessivly at all, when I back it off a few times the fork has play in it and is loose.

I think your decision to take it to the LBS is the correct one given your lack of experience and your response above. But if you insist on trying to make this repair yourself you should carefully follow the instructions outlined in this link:

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

Bob

Just back from a ride, took my bike to the lbs this morning and they took care of everything. Turns out that I was missing a part for the headset, the crown race. It was stuck on the old fork, I saw it on there, but covered in grease it looked like it was apart of the aluminum steerer, so I didnt give it a second thought as being part of the headset assembly. I looked at the FSA generic headset instructions online, and several models did not use this part(crown race) so I assumed I had one that didnt need it.

While I was at the LBS I got an Ultegra chain and Deda grey bar tape.

I went for my first ride today with the new fork and it definitly smooths out the ride.

I looked at the FSA generic headset instructions online, and several models did not use this part(crown race) so I assumed I had one that didnt need it.



EVERY headset from every manufacturer uses a crown race. Its specific to the headset and vitally important, as you found out.