Headset Replacement


Getting ready

It is advised to wear suitable protective personal equipment (PPE) and be in safe working environment. Before starting this maintenance process, below tasks must be completed:

  • Disconnect battery / power supply
  • Housing Removal

Tools required

Torque Driver
Allen KeySS324-6 | Bahco Hex Key, L Shape 6mm Ball End | RS Components 

Parts required

You will need to prepare the listed parts for this maintenance procedure.

Headset Bearing
x 2 units
Headset Cup
x 2 units

Steps to follow

Step 1 Preparing Headset Unit

1.1

Collect 2 units of Headset Cup & 2 units of Headset Bearing.Slot the bearings into the headset cups.

1.2

Check the alignment & ensure that the bearings is fitted nicely. 

Step 2 Removing Stem & Fork

2.1

Using 6mm Allen Key, loosen up the side screws on the stem.Loosen up the screw until the stem can be easily twisted and loose from the fork.
2.2

Using 6mm Allen Key, loosen up & remove the top screw on the Top Cap.
2.3

Remove the Top Cap along with the Phone Mount.
2.4

Remove the Stem and secure it on place where the cable won’t be pulled.

2.5

On the Frame, remove the headset crown by sliding it out from the Fork.

2.6

Then, remove the headset collar by sliding it out from the Fork.

The Fork can now be removed by sliding it out from the frame.

Step 3 Removing old Headset units

3.1

Remove the 1 unit of old Headset from the top side of the headtube.
3.2

Continue to remove 1 more unit of Headset from the bottom side of the headtube.

Step 4 Removing old Headset units

4.1

Take 1 unit of Headset and insert it into the top side of the headtube. Ensure that the headset cup is fully flushed into the headtube. 
4.2

Insert the headset press tool from the top side of the headtube and its clamp unit on the bottom side. Screw in the nut from the bottom until it is partially tightened.
4.3

Using a wrench, tighten up the nut until its fully tightened. Make sure that the top headset now is fully flushed into the headtube without any gap.
Remove the nut, clamp unit and the headset press tool.
4.4

Take 1 more unit of Headset and insert it into the bottom side of the frame’s headtube. 

Ensure that the headset cup is fully flushed into the headtube.
4.5

Insert the headset press tool from the top side of the headtube and the clamp unit on the bottom side. Screw in the nut from the bottom until it is partially tightened.

4.6

Using a wrench, tighten up the nut until it is fully tightened. Make sure that the bottom now is fully flushed into the headtube without any gap.
Remove the nut, clamp unit and the headset press tool.

Step 5 Re-installing Stem & Fork

5.1

Using 6mm Allen Key, loosen up the side screws on the stem.
Loosen up the screw until the stem can be easily twisted and loose from the fork.
5.2

Insert the top headset collar around the fork’s steerer tube until it is fully flushed with the headset’s bearing.
5.3

Insert the Headset Crown by slotting it around the fork’s steerer tube.Insert until it hits the headset collar and is fully flushed.
5.4

Re-install the Stem by inserting in onto the fork’s steerer tube.Insert the stem until it is fully flushed.
5.5

Re-install the Headset Cap and Phone Mount.Align the Headset Cap and the Phone Mount with the screw holes inside the steerer tube.Insert the nut and secure the Headset Cap and Phone Mount.

5.6

Gently tighten up the nut until the stem is fully secured.

5.7

Adjust the orientation of the Stem until it is 90 degree perpendicular to the Fork.

5.8

Once the stem’s orientation and alignment are correct, firmly tighten all M6 screws on the right side.Gradually tighten all screws until the Stem is firm and cannot be twisted. Avoid over-tightening to avoid parts damage.

End of Article

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