I know that there are a good number of people running non-cartridge headsets that might not know how to repack/maintain this piece of equipment. These instructions can be applied to most non-cartridge bearing headsets, like Tange, Shimano, Campy, etc.

Tools I used:

32mm wrench, toothbrush, grease, rags, beer, pencil, allen wrench set

1. Remove stem/handlebars set-up.

2. Remove top nut on headset (32mm wrench).


3. Remove spacers (if there are any) by hand.

4. Remove top bearing cup (32mm wrench)– note: do this slowly to prevent loss of loose bearings.


5. Slide fork down slowly out of headtube. Again, do this slowly as to not lose any bearings or damage the bearing cages.


6. Wipe grease off all four surfaces that contact the bearings. Run a pencil on these surfaces to check for pitting and wear.

If contact surface is pitted, you can continue to run the current headset until it is totally useless, or replace it. Your call.

7. Clean bearings and cages (I do not remove the bearings from the races).
Use a small glass or plastic tub. Place one cage/bearing set in at a time and coat with biodegradable degreaser and let sit for a few minutes.


Things to do during this time:
-Enjoy a beer or another favorite beverage.
-Call your significant other (If you do not have a significant other, weep quietly).
-Contemplate running for the presidency of a far-off nation.
-Plan next trip to oral surgeon.
-Start a whiny thread about IRO.

After soaking, brush ‘em up (careful not to dislodge a bearing or two…or more) gently with the toothbrush to get the grease out of the cage area.
*note – you can replace the bearings/races if you wish to do so. Make sure you obtain the correct parts as per your headset manufacturer’s instructions.

8. Brush dirt/grease from threads on steer tube. Regrease as you see fit.


9. Make sure everything is dry and pretty! Regrease top race and seat the bearings. Do the same on the fork race. Grease cups (loose and seated).


10. Install fork:
Re-install top cup. Replace spacer and top nut: Hand-tighten (do not fully tighten this yet!) everything back together.


11. Check for smoothness – if not that smooth, try a little more grease…or less. Depends on how much you initially applied!

12. Once it is nice and smooth, grab your wrenches and snug up your nuts! DO NOT OVER-TIGHTEN. This may induce pitting over time. The fork should spin freely.



(see next post in thread for final result...)