grasscutter

Howdy. Doing tear down, tune-up of a craigslist throwaway, that I'm gonna use for an around town commuter. An old 79 schwinn world sport. When I pulled headset apart, I laid everything out in order (spacers, races, shims, etc), so I would have it lined up for re-assembly.

But somethings not right! No matter how I assemble it, the top bearing is exposed! UGH. Maybe it was missing a piece to begin with? IDK...

Does anyone have an exploded view they could PDF email me? Like from an old repair manual. I searched online, looked through my bike books. No avail. They all show like 1 or 2 general pics, and a written how to, but I need the pics to match up what I've got.

Much appreciated. Zac.


Can email it direct to grasscutter96@yahoo.com

dobber

uʍop ǝpısdn ǝɔɐɹ ƃuıɹɐǝq ǝuo ʇoƃ ʎןqɐqoɹd ǝʌ,noʎ

Esteban32696

LOL--- Don't let it bother you ! We have all done it at some time !

grasscutter

Ok. I checked the bearings, either being upside down, etc. They are correct. Not sure what else to do.

jtarver

You didn't happen to remove anything from the mix before assembly did you? Maybe a reflector or brake cable guide? If so you usually need to replace it with a washer the same thickness to maintain the proper spacing. Probably not, but could be the prob.
P.S.- I have a similar bike, it's kinda heavy but really a very decent ride.(It lives at my In-Laws or I'd go pull it apart for you). Good luck...

LarDasse74

You can do a check to make sure the headset parts will go together when they are not on the fork - remove the fork and put the bearing onto the top bearing race installed in the frame... then take the top adjustable cup/nut that should be the first thing you thread onto the fork and see if you can fit it onto the bearing and top race... it should fit together neatly and you should be able to turn it to feel the bearings rolling between the cup and cone. If it does not fit together then examine the assembly and see where the interference is and fix t. If it does go together smoothly then your problem is likely involving the interface between the adjustable cup/nut and the fork - something has got to be physically stopping it from going together.

Pictures would help 1000000%.

Good luck!

grasscutter

Ok. Pic #1 is how I've got it together. It seems to me the top bearing is exposed? Other older bikes I've got, the bearing is 'covered'. Don't know how else to explain it.

Pic # 2. Is everything laid out exactly as I took it off the top. A, B, C, D, E (bearing, I left in the top race)

Pic # 3. This is the bearing I left in the top race. It sits down in nicely, but...I don't know. Somethings not right.

Where did I go wrong? What order should these parts be assembled? Am I missing anything?

Thanks.

Wanderer

Looks like D is upside down.

Wanderer

You should be able to loose stack them on top of each other to see exactly how they go together.
Bearing, cone, bracket, washer, locknut on top

grasscutter

Ok. I put 'D' in the way I did, because it seemed that the cone part of 'D' needed to go 'down into' (like an inner race), into the bearing. Wrong?

ultraman6970

There are a couple of things backwards in that set up. as somebody else said, D or B are like a cone where the bearings have to lay into.

keisatsu

Ok, it looks like you have TWO cones there... B and D unless I'm looking at something wrong.
It should go:
Locknut
Washer
Brake stop
Cone
Bearing

jtarver

That headset looks jacked up! No offense, but I think you need to have a friend or mechanic help you out. Or just put in some reading time at https://www.sheldonbrown.com/headsets.html. Good luck, follow the info for threaded headsets.

wrk101

+1 Take it to a shop, they will be able to reassemble it in a minute or two.

Take digital pictures prior to disassembly, stack pieces in order, and zip tie them together. Once you get familiar with bike construction, you will not need to do this, but stacking and zip tying together is just a good practice.

+1 D is upside down.

+1 Loose stack them, they should fit together well.

Wanderer

Did you put a cone in the bottom**********

ultraman6970

One lego set for the OP

grasscutter

Ok. 'D' is actually 2 parts. And was upside down. The top part of 'D' is the race. It fits in perfectly.

I think I've got the wrong fork.

Assembled as shown:

1st pic-
nut
washer
brake cable holder
race
bearing

2nd pic-

brake holder
race
bearing

The fork is just too long! It's likely not the original. What are my options now? Cut it to size? Or find a spacer to take up the slack?

**Yes, I will be taking digital pix and using zip ties from now on....

Wanderer

If you have it all back together, correctly, just cut it to size. Might want to enlist some LBS help here. j

wrk101

The confusing part is you started the thread by saying you tore the bike down. Did it have the original fork, and did the headset fit? If so, just measure the difference.

I would recommend you just take it to a bike shop, it won't cost you much. Once you cut a fork, it is cut. Better to have someone with experience do it.

Also, given the condition of the headset in your pics, I would get a new headset. You can get them for around $10. You will need to reuse the cable holder.