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Old 02-24-06, 09:01 PM   #1
willy6743
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Fork does not fit all the way into headset on new Pinarello

Hey all,

My new Pinarello just arrived (WAHOO!) and I started putting it together (I've done a few bikes before but none this nice). Anyway, The fork doesn't seem to fit all the way into the headset - there is about a 1/8" to 1/4" gap where it should fit, but doesnt' seem to want to. I'm hesitant to be too forceful with it since I'm not sure if this is normal or if it needs to be milled down. Any thoughts?

Also there is a very small lip on the fork which is preventing it from sliding through the sealed bearings - this is basically the cause of the problem.

Thanks a ton!

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Old 02-24-06, 09:07 PM   #2
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I had to carve a curved block of wood to tap the fork fully into the bearings on a Pinarello I did a while back. The only other thing might be a non compact fork on a compact frame, tho that does not look like the issue here.
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Old 02-24-06, 09:23 PM   #3
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Well, I guess my concern was if I were to get the fork in place (forcefully) then get the measurements all set so that I could cut the top of the fork down - getting the fork back out would be rather difficult. My Cannondale Fork on my other bike snug, but doesn't require a large amount of force to remove.

Thanks!
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Old 02-24-06, 09:30 PM   #4
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I just noticed that is an F4. The fork should mate up with just a little line showing. I have had to do some that required a pretty good tap to get in place. It is not a true head set but a set of spec'd bearings(I think) Rather than remove the fork, mark the top of the stem, remove the stem and cut 3mm below the line with the fork in place. I use a jig but you can do it free hand with tape for a guide. This saves a couple of steps, just be sure to cut away from the frame if you do it freehand.
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Old 02-25-06, 07:28 AM   #5
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I had the same problem. One person holds the frame and the other knocks it in place. Don't rest the frame on anything solid or you will damage it.
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Old 02-25-06, 08:57 AM   #6
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Ok, I'm glad to hear that this is not unusual! I'll get the fork cut down to size and then attempt to knock it into place. Thanks for the advice!
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Old 02-25-06, 12:32 PM   #7
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Not seeing things first hand so take this for what it's worth but could you sand the upper edge of the ridge to feather it into the steerer? That way it should go into place with less force.
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Old 02-25-06, 12:39 PM   #8
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I have the same frame, and had the same problem. Same problem with my Opera Leonardo by Pinarello. I called Gita to confirm.
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