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Old 08-17-25 | 09:50 PM
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maddog34
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From: NW Oregon

Bikes: 1982 Trek 930R Custom, '91 Diamondback Ascent w/ XT, XTR updates, Fuji Team Pro CF road flyer, Specialized Sirrus Gravel Convert, '09 Comencal Meta 5.5 XC, '02 Marin MBX500, '84 Gitane Criterium bike

i was waiting for someone with an OCR to weigh in.... hmmm,
i'd suspect you have one or more parts inverted/flipped, and that is preventing a successful reassembly.

why are there two split rings shown? usually only one is used, against the crown race... and only if the lower bearing has an inner chamfer.
was the smaller, upper row split ring used in the frame or upper cup? is the headset a semi-integrated, or fully integrated style?
are there two pressed in cups, or just a properly bored head tube(part of the frame) that the bearings set in?

listed from top down..... tapered cap, seal, wedge split ring to center up the bearing, bearing with inner chamfer up,...
bottom bearing onto lower split ring.

this is a typical assembly order of an integrated headset.
add upper and lower bearing cups if it's a semi-integrated headset.

note the lack of an upper split ring beneath the bearing.... your pic shows one in that top row.

and if that upper seal is installed upside down, it won't fit well.

some of the absolute biggest, most destructive, messes i've seen were bad headset "assembly" attempts by confused owners. they tend to add or subtract parts, and pound things into places they shouldn't be in.
i have a Felt Virtue Three here right now that had a caged bearing headset rammed into an Integrated frame head tube, and done ALL wrong !
it would BARELY turn.
the bike WAS a 4K dream machine before the high end parts were removed, and the butchering began.
present value, with the damaged cheapo fork, cheap/mismatched mechanical disc calipers, and low end SRAM parts? $250, maybe.
the bike was originally built with XT and XTR parts, hyd. brakes, etc, when new.
the nice Fox rear shock is one of the few original parts.

it will, at least, be rideable, once it leaves here... sigh.
even the rear hub axle set was assembled badly... the brake disc was firmly against the caliper mount... the mount had been filed in an attempt to create clearance.
the jam nuts were swapped... once they were reversed, all was well.

try assembling without the upper seal.. see if it works better.
see if leaving that upper aluminum split ring out helps.
etc.

Last edited by maddog34; 08-17-25 at 10:44 PM.
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