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I noticed a definite clunk coming from the headset, so I tightened it, it reduced but didn't disappear, and the amount of preload required to get rid of the clunk was unbelievable!
I then noticed that there was play between the top cup (A) of the headset and the bit that is pressed into the frame (B).
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I took everything apart, cleaned everything, damn it was dirty and put it all back together. It's slightly better, but the play is still there, I would say 0.5-1mm play between A & B.
What the hell is wrong!?
BTW photo is not of the correct bike, I grabbed it from google. Bike is a Genius LT 1.5" tapered steerer with Syncros headset.
First thing I look for is the condition of the tapered plastic rubbery washer with the split in it... Is it there? Is it in tact? This accounts for the slop in your headset.
You shouldn't have to preload the bearings excessively as described.
When the stem is on how close to the top of it is the steerer?
Are you using carbon spacers?
The rubbery washer with the split, is in OK condition..
There is about 3mm space between the steerer and stem.
I don't think they are carbon spacers, but I'll check when I get home at 3.
I couldn't get the washer with the split in it, to sit flush with the headset. Everytime I pushed it down, it popped back up..
There is about 3mm space between the steerer and stem.
Is that 3mm after you've compressed everything and tightened the stem? it's possible you're using up all the available clearance without taking up all of the play.
Worth taking the top cap off and seeing how close it is to the top after you've tightened everything
I've had a look and once tightened there is about a 2mm gap between the steerer and stem, so that should be ok.
I've now taken it apart, put it back together and the knocking has vanished! There is still a little play between A & B, is this normal for a 1.5" tapered headset?
Also, do these headsets need more preload? I've had to tighten this one a lot more than I have ever before on a 1.25" headset.
Is there a cartridge bearing in there with say, a 45 degree angle on one side - have you put it in the right way around to it mates with the same angle as the headset cup?