Bicycle Mechanics - 07 Giant TCR Headset Issues

No matter what I do I can't get the headset adjusted right, there is a fore & aft clunk/notchiness that can't be adjusted out. When everything is tightened properly I can move the spacers a little bit, they'll spin around as well.

I'm starting to think I'm either missing a piece or the steerer needs to be cut. The frame is new, fork uncut, headset was installed when I got it.

I'm a little frustrated with this build, the frame has been sitting around forever, I finally build it up & I still can't ride the damn thing :twitchy:

Some pics:
http://img197.imageshack.us/img197/5840/pa220332.jpg

http://img197.imageshack.us/img197/5585/pa220331.jpg

http://img197.imageshack.us/img197/8629/pa220325.jpg

http://img197.imageshack.us/img197/3374/pa220326.jpg

http://img197.imageshack.us/img197/6921/pa220328.jpg

Last one is the rubber gasket on the piece I was holding in the prior photo.

Is there a piece that is supposed to center the tube that would eliminate the play I'm getting?

Sorry about the scattered thoughts...my brain is about to fall out. I needs me some help. Please!

One really common mistake when reinstalling headsets is the orientation of the caged bearings. They are only supposed to go one way although you CAN fit them the wrong way and you do end up with a rough running bearing which is impossible to adjust.

The "caged" side of the bearing goes against the larger, outer bearing surface and the inside/open side of the bearings goes against the smaller/inner bearing race.

EDIT: and I've read your post again. Yes it is likely that you need to cut down the steerer tube. You can put a few more spacers in there (up to 50mm of spacers) but you wouldn't want more than that in most cases.

Anthony

These are cartridge bearings, I'm pretty sure I installed them correctly. The tapered outer edge down (top bearing). Tapered outer edge up(bottom bearing). If that makes sense.

One really common mistake when reinstalling headsets is the orientation of the caged bearings. They are only supposed to go one way although you CAN fit them the wrong way and you do end up with a rough running bearing which is impossible to adjust.

The "caged" side of the bearing goes against the larger, outer bearing surface and the inside/open side of the bearings goes against the smaller/inner bearing race.

EDIT: and I've read your post again. Yes it is likely that you need to cut down the steerer tube. You can put a few more spacers in there (up to 50mm of spacers) but you wouldn't want more than that in most cases.

Anthony

Sigh.

The guy has an integrated headset with cartridge bearings. You'd have to be a massive idiot to install this incorrectly. Cage direction has no bearing on this problem (pun not intended) since there are no cages

These are cartridge bearings, I'm pretty sure I installed them correctly. The tapered outer edge down (top bearing). Tapered outer edge up(bottom bearing). If that makes sense.

Let's ascertain your installing the correct things in the correct order. From the fork crown up to the topcap, label your photograph with numbers depicting the order. After all that is said and done, you might as well quickly check that you have enough spacers on your fork to set the preload. A 5mm at the top should clear the top of the steerer by at least 2-3mm.

Okay, here's the order (fork crown is already on fork):
http://img32.imageshack.us/img32/7961/labeledparts.jpg

http://img32.imageshack.us/img32/8839/pa230333.jpg

The slight gap under the top cap:
http://img32.imageshack.us/img32/9506/pa230337.jpg


Are parts 3, 4 & 5 supposed to be assembled into one unit? I just found these instructions on the Cane Creek site:
http://www.canecreek.com/manuals/Headset_Instructions/110/110_IS_Instructions.pdf

I just put the parts back on like I found them. Which isn't saying much since I've never dealt with headsets...ugh.

isn't the problem that you have a gap between the top spacer and the cap? The top spacer should be higher than the steerer and tightening the cap will tension the headset.

Yes, that's the general problem, I guess that's what is causing the play as well. I just want to make sure I have this thing together properly so I don't have to worry about anything else happening down the road.

Well add another spacer on the top.

Yep - looks like it was just a matter of not enough spacers.

Who knew? Not enough spacers on a road bike? I'm going so Fred-riffic by adding another spacer :D

I'll give it a try.

Thank you all for the help, it's greatly appreciated.