So, I have a Cane Creek C-2 threadless headset on my 2000 Cannondale R1000 and I have just ripped it the F' apart because it was rattling... it's missing a bearing; how does this occur?! any advice? should I repair/replace? if replace, what with? if repair, how so (I AM mechanicly inclined, though I am a noob at bike repair)

thanks in advance

Missing a bearing!!!!!! Those have sealed cartridge bearings, I can only imagine how crappy it must've worked if it was missing one of the two bearing assemblies that it's supposed to have. Or did you rip open one ot the cartridges and find that there was one actual bearing missing out of one?

If you can't get parts from your LBS, use the info below.
https://www.canecreek.com/store.html?&no_cache=1
C2 1" bearing kit #HS-1032 $14
C2 1-1/8" bearing kit #HS-2032 $15
Peter@canecreek.com
Peter Gilbert
800-234-2725 ext:316

Yup, you ain't missin' a thing. C2 is pretty standard setup. Upper and lower SEALED bearing, crown race, 2 cups, top cover and cap. What part do you think you are missing?

bingo.
Thanks for this!
I opened up the bearing cup... saw all the little bearings, and one was missing. I did'nt drop one; it's just not there! I've never taken apart this headset before, it has always ratteld very slightly but in the past day or two it got very noticable.

I don't think it's unusual to have a space in there where you'd seemingly expect to find another bearing. I know that some mechs use the method of "fill it up, then take one out" on loose-ball installations. If the race is completely full then the bearings will have friction against one another. You shouldn't add another bearing if it causes all the bearings to fit tightly against each other.

Probably just needs some grease or perhaps the rattle could be attributed to something else entirely.

Yes! Not all bearings are "Full Compliment"

I brought the headset (but not the bike; bright, huh?!) to my local LBS and the mechanic expressed this very thought; I'm going to bring it to them tomorrow unless someone can throw me a bone as to how I may remedy this myself. Thank you, again!

*edit* I repacked the bearings with new grease, but after re-assembly it is still 'loose'... perhaps I did'nt tighten/assemble it correctly... I can't figure out what the heck is up


**edit #2** So... if I need a replacement headset, what do y'all recommend?

Ever since I read here that you should fill the cup and remove one bearing here a couple of years ago, I've tried it on every hub, headset, bottom bracket that I've rebuilt with loose balls and 100% of the time I've ended up with one less bearing than there should be. I must be doing something wrong. If so many people believe it and it's on the Internet it must be true. I guess I need to find a way to stuff one more ball in there without pushing any others out so I can remove it and have the right number. I rebuilt a Campy Record hub today and it had 8 balls per side instead of the required 9. I wonder if the last person who worked on it had the same problem?

The idea is you apply a thin grease layer, and then fill it up with bearings. Then firmly replace the cup. Then gently remove the cup again, without disturbing the bearings. Look at how the bearings are seated. If all the bearing are sitting perfectly in a circle then you do not need to remove a bearing. If one bearing is sitting even slightly off, then you remove one.

I don't follow your description. It would make sense to me if you said that you put the balls in the cup and then inserted the cone. I just don't have to go through all that to determine when I have the correct number of balls in the cup. I always double check by counting, but I'm always right. The fact that I've been doing it for about forty years may have something to do with it, but I don't remember it ever being difficult.
A finger or thumb works just as well as a cone for seating the balls. Too many won't fit and you don't have enough if another one will.

+1

Not rocket science. If it's too hard, just stick a Chris King in there and fuggedaboudit. I just rebuilt a customer's King that had been COMPLETELY SIEZED by disgusting salty sweat crud and utter corrosion on the steerer tube...I had to pound the fork out with a mallet and when it came out it took the inner race out of the lower cartridge with it...bearings went everywhere. I cleaned it up (had to take the steerer to a wire wheel to get all the sh*t off it, the salt had etched and pitted the aluminum it was so bad), repacked the cartridge and popped it back together with a press...felt practically new again. If I wasn't a believer in King headsets before, I am now.