Originally Posted by
onespeedbiker
As said before, any extra grease will simply seep out and not affect the working of the headset. The simple answer is you did not put it together correctly. Maybe if we knew the headset we could give you some things to check..
+1. I always "overpack" even cartridge bearing headsets, both threaded and threadless, to let the excess grease act as a water and dirt seal to supliment whatever seals the manufacturer provides. All the excess does is ooze out and gets wiped away with a paper towel. It never causes any binding or lack of smooth rotation.