I installed a Shimano 600 headset on an old Vitus frame and fork (threaded). The headset came with the usual keyed washer that goes between the top race cap and the locknut. The problem is that the threaded steerer on the fork doesn't have the slot machined through the threads that holds the "key" on the washer so it doesn't turn when you tighten the locknut. Also, the stack height is 2mm too high so the washer wouldn't go on even if I filed off the key on the washer.
Would the headset hold the setting if I just tighten the locknut against the cap (without the washer)? I tried it once but it loosened after a couple of rides. Should I make it tighter?
I don't want to take a couple of headset wrenches along on every ride!