Bicycle Mechanics - Headset problem help

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sisddwg
08-25-11, 10:15 AM
I just installed a Shimano 600 HP 6400 headset. This is the one with balls and retainer. Everything works fine as long as I don't install the lower race dust cap. If I try to use the dust cap the final adjustment will be too loose or too tight. Any suggestions will be greatly appreciated.

chi-james
08-25-11, 11:35 AM
maybe the bearing cages are oriented incorrectly? are both sets of bearings the same size?
sisddwg
08-25-11, 11:47 AM
Excellent thought but the cages are oriented correctly. Both sets of bearings are the same size. Thank you.
maybe the bearing cages are oriented incorrectly? are both sets of bearings the same size?

bikeman715
08-25-11, 12:14 PM
the dust cap will cost a little drag as any seal does .
sisddwg
08-25-11, 12:24 PM
the dust cap will cost a little drag as any seal does .

I agree with you but this is more than a little drag. If I adjust the headset to eliminate looseness the drag is really excessive. Perhaps using it this way for a period of time will eventually eliminate the drag. What do you think?
HillRider
08-25-11, 04:57 PM
Those seal rings had to be installed oriented the proper way. There is a little lip on the outer edge and, while i don't remember which way it had to face, only one way was correct. Try turning the seal over and see if it helps.

BTW, I had that exact headset on a '92 Trek 1420 as a replacement for the OEM Tange which wore out and brinelled in 4000, miles. The HP-6400 lasted almost 20,000 miles.
sisddwg
08-27-11, 07:02 AM
Those seal rings had to be installed oriented the proper way. There is a little lip on the outer edge and, while i don't remember which way it had to face, only one way was correct. Try turning the seal over and see if it helps.

BTW, I had that exact headset on a '92 Trek 1420 as a replacement for the OEM Tange which wore out and brinelled in 4000, miles. The HP-6400 lasted almost 20,000 miles.

Well, that's about the only solution I can think of also. Thank you.