How to Overhaul a Bike's Headset

Headsets get a lot of abuse. They catch a lot of water and crud coming off the front wheel, and they are submitted to constant vibration. These directions are for standard ball bearing or needle bearing headsets. If you are having problems with a sealed bearing headset, you will either have to replace the cartridge bearings or the whole headset.

Difficulty: Easy

Instructions

Threadless Headsets

1. See related eHow "Adjust a Bike Headset" for more information on threadless headsets.

2. Clamp bike into repair stand.

3. Undo front brake.

4. Remove the front wheel.

5. Unbolt top cap with a 5mm Allen wrench.

6. Unbolt the stem. Hold the fork to keep it from falling out.

7. Remove the top cup, compression ring and any spacers. Remove any seals, noting their position and orientation. Remove bearings and put them aside on a rag.

8. Remove the fork. Be ready for the bearings from the bottom cup to fall out. Again, remove any seals, noting their position and orientation. Put bearings on a rag, keeping them separate from top bearings (in some cases, they will be different sizes).

9. Clean bearings in a jar with solvent. You might want to consider replacing them with new bearings.

10. Wipe out both headset cups with a clean rag. Inspect bearing surfaces for pitting. If there is excessive pitting, you may need a new headset.

11. Grease all bearing surfaces.

12. Flip bike upside down in the stand. Replace bottom cup bearings, seals, and insert fork.

13. Swing bike back right side up, holding onto the fork.

14. Replace top cup bearings, seals, top cup, compression ring and any spacers.

15. Slide on the stem.

16. Replace the top cap and bolt.

17. Adjust headset.

Threaded Headsets

18. See related eHow "Adjust a Bike Headset" for more information on threaded headsets.

19. Clamp bike into repair stand.

20. Undo front brake.

21. Loosen the top locknut on the headset (it helps to have the front wheel in place if the locknut is on tight).

22. Remove the front wheel.

23. Remove the stem.

24. Undo locknut the rest of the way. Remove the locknut and top cup. Remove any seals, noting their position and orientation. Remove bearings and put them aside on a rag.

25. Remove the fork. Be ready for the bearing from the bottom cup to fall out. Again, remove any seals, noting their position and orientation. Put bearings on a rag, keeping them separate from top bearings (in some cases, they will be different sizes).

26. Clean bearings in a jar with solvent. You might want to consider replacing them with new bearings.

27. Wipe out both headset cups with a clean rag. Inspect bearing surfaces for pitting. If there is excessive pitting, you may need a new headset.

28. Grease all bearing surfaces.

29. Flip bike upside down in the stand. Replace bottom cup bearings, seals, and insert fork.

30. Swing bike back right side up, holding onto the fork.

31. Replace top cup bearings and seals. Thread on top cup and lock nut.

32. Adjust headset.

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