Trouble installing an OD2 integrated headset
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  1. #1
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    Trouble installing an OD2 integrated headset

    I'm building up a Giant TCR Pro with the OD2 steerer. It has an integrated headset, and I'm having trouble installing it.

    There is no fork crown race. As I understand it, this fork does not use one.

    I placed the bottom bearing in the frame. Then I put in the steerer. Next, I put the top bearing and the compression washer (the blue washer that has a split and a lip) inside the top bearing. Everything is flush. I put the micro spacer on top of that, and last I put on the top cap. Here's the problem: there's a lot of resistance and binding.

    At first, I thought it might be that I need a second micro spacer, but it's not the top cap that's rubbing. If I take the top cap off, it's still very stiff.

    I find that if I don't seat the blue compression washer all the way down, that the fork moves more freely, but then there is a gap between the top cap and the head tube.

    Any suggestion?

    Side note: I'm using the top cap to press the compression washer into the bearing. It's a very tight fit, and that's the only way I can figure to get it down in there.

  2. #2
    'brifter' is a lame word.
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    Sounds like you've got everything together the way it should be. If you don't seat the split compression ring completely when you put it together your headset will be loose the instant you start riding the bike. The split ring should seat very easily into the upper bearing, I normally put the bearing and the ring into the frame then slide the fork up.

    Grease everything.
    Drop lower bearing onto fork.
    Put upper bearing and split ring into the frame.
    Slide fork in. Sometimes you'll need to have the internal expander loose to do this, then tighten.
    Install top cover...spacer(s)...stem...top cap.
    Adjust.
    Tighten stem.
    Done.
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  3. #3
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    So why is it so stiff? It seems fine until I put in the compression washer.

  4. #4
    'brifter' is a lame word.
    Reputation: cxwrench's Avatar
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    Without seeing it in person I can only guess. Seems like the only thing would be that something is rubbing somewhere.
    I work for some bike racers
    I've got some bikes, some guns,
    and a bunch of skateboards

  5. #5
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    Hmmm. When I align the top, but loosen the bottom (so the fork is an inch below the head tube), it spins freely. When I align the bottom, but loosen the top, it also spins freely.

    Would it matter that I don't have the star nut installed?

  6. #6
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    Quote Originally Posted by TiCoyote View Post
    Hmmm. When I align the top, but loosen the bottom (so the fork is an inch below the head tube), it spins freely. When I align the bottom, but loosen the top, it also spins freely.

    Would it matter that I don't have the star nut installed?
    How are you compressing the system without a star nut or compression plug?

  7. #7
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    Quote Originally Posted by 202cycle View Post
    How are you compressing the system without a star nut or compression plug?
    I'm not, the top cap is holding it in place. Does it need compression to feel smooth?

  8. #8
    Rub it............
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    Quote Originally Posted by TiCoyote View Post
    I'm not, the top cap is holding it in place. Does it need compression to feel smooth?
    You need a star nut or compression plug to properly set the pre-load on the bearings.
    You can't fix stupid.

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  9. #9
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    Quote Originally Posted by TiCoyote View Post
    I'm not, the top cap is holding it in place. Does it need compression to feel smooth?
    What are you threading the top cap retainer nut into? There must be some kind of plug inside the steerer...

  10. #10
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    Shouldn't it spin freely, if there is no pre-load?

    When I said "top cap" I mean the conical spacer that goes on top of the head tube.

  11. #11
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    Quote Originally Posted by TiCoyote View Post
    Shouldn't it spin freely, if there is no pre-load?

    When I said "top cap" I mean the conical spacer that goes on top of the head tube.
    It should, maybe. The system is not complete without the stem and compression pug in place and it has been adjusted to the proper compression. Without everything securely in place, there's no telling what could be causing the binding. Unless, of course, you provide some pictures of what is actually going on.
    1. Are you sure the fork does not use a crown race?
    2. Are you sure the bearings are not upside down?
    3. Is there possibly some paint on the rim of the bearing cups?

  12. #12
    'brifter' is a lame word.
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    Quote Originally Posted by TiCoyote View Post
    Shouldn't it spin freely, if there is no pre-load?

    When I said "top cap" I mean the conical spacer that goes on top of the head tube.
    The part that covers the bearing is the 'bearing cover'...the cap that goes over the stem is the 'top cap'.
    I work for some bike racers
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  13. #13
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    Well?

  14. #14
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    Quote Originally Posted by 202cycle View Post
    It should, maybe. The system is not complete without the stem and compression pug in place and it has been adjusted to the proper compression. Without everything securely in place, there's no telling what could be causing the binding. Unless, of course, you provide some pictures of what is actually going on.
    1. Are you sure the fork does not use a crown race?
    2. Are you sure the bearings are not upside down?
    3. Is there possibly some paint on the rim of the bearing cups?

    1. Yes. I have done some research on this message board as well as others. None of the TCRs use one.
    2. The bearings are not upside down.
    3. Possible.

    I'm taking the bike to a shop next week to have them cut the steerer tube and install the BB. Either it will be smooth once they install the star nut and set the preload, or they will sort out whatever the problem is.

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