Headset Replacement

In rare instances you might need to replace the headset cups in your frame. The cups can become pitted, making the steering feel notchy. You can sometimes get around this by removing the ball bearings from their retainers and adding extra ones so they completely fill the cups. Otherwise you can buy a new headset and install it. First you need to remove the fork (see my previous post):

I used a 10mm wrench to remove the brake so I could get to that crown race. The headset pieces are not always interchangeable, so I like to replace everything as a complete set. The fork crown race comes off with a hammer and punch:

Give it a few taps while alternating on either side of it. It will eventually slide off. Next I use a section of 1" PVC pipe to seat the new race into position. It's a press fit, so make sure it's fully seated:

Now comes the really fun part. You need a special tool to remove the cups inside the head tube. You can spend some money for a special headset cup remover. I'm fairly handy, however, so I just made this out of a piece of 1" electrical wire conduit:

I used an angle grinder to make 3 cuts at one end, then spread them apart a little bit with pliers:

It seems to work pretty well. Next you slide the tool into the frame and hammer the cups out:

You'll probably have to hit pretty hard, so make sure the frame is well supported (I just hold it in one hand while striking the tool with the other). Repeat for the other cup. Now set the new cups into position, then press them in:

If you don't have a big vise, a bike shop can usually do this step for cheap. The important thing is to center the vise jaws on the cups, and press them in straight until they are fully seated. Finally, just pack the bearings with grease and reinstall the fork. Again, not all headsets are compatible with all forks (especially on really old bikes) so good luck finding the right replacement!