Headset/Horncast Fouling

[pauLI]

Hi all
looking for some advice or thoughts on why this may be happening
I am in the process of building my GT after it has been stripped,blasted and painted, the bike was complete and used prior to the strip down
I have got it all back together now but have noticed a faint line in the paint on the gear change side on the top of the horncast
It would lead me to believe the headset is rubbing, I say rubbing at its making no noise and when you move the bars its not sticking or anything, so im at a loss
anyone had this before or any thoughts on how to rectify this?

for ref; the only things that have change except the paint is I replaced the incorrect mudguard (gp) with an original fibreglass one which I got off Colin and the GT owners club
and all the rubbers are new scootopia ones

cheers
paul

[roli150lam]

Masking tape over the 'faint line' turn bars to the left,check masking tape for any mark.If no mark visible remove and replace the tape turn to the right and check again.Before you do that is the gap between handlebars and horncast equal all round?

[pauLI]

I have done the making tape and it scuffs it up towards the gear side so definitely something wrong
Also the gap between the chrome ring and headset is the same all the way round

[Warkton Tornado No.1]

You should be able to ‘waggle’ the horncasting & possibly the legshields over a little to the throttle side to give clearance.

Loosen the fasteners of the horncasting including the ones under the badge/shield & gently push it to the right side & nip up the fasteners in that position.

If that’s not enough, the horncasting will need to come off so that you can loosen the fasteners of the legshields hidden by the horncasting & follow the same procedure as with the horncasting.

You only need a nat’s to gain clearance.

Good Luck!

[ToBoldlyGo]

Is it possible the legshields might have had some work done and the horncast is fixing higher for some reason?

[roli150lam]

As you turn your handlebars/headset have a look underneath,possibly the underside of the headset touching.You may be able to fix by loosening the clamp bolt and lifting the headset a smidgen.

[pauLI]

So tonight I removed the horn cast undid the bolts that hold the leggies on and put a rubber washer between the leggies and the bracket, did it back up refitted the horn cast and success no rubbing
I then seated the headset and did up the pinch bolt and now it seams the underside of the headset is rubbing on the chrome ring
I am at a total loss and seeing more and more chips in my newly painted back
Seriously f**ked off

[dave81]

I had a similar problem when rebuilding my GP. I don't know if the mounting is the same on a GT but where the bolt goes through the clamp on the forks the location is a slot in the top of the forks. When you lift the handlebars and go to tighten the clamp bolt the the handlebars drop down under their own weight. I had to hold the handlebars up when tightening the bolt or just nip the bolt up and then lift the handlebars up and they will hold up by themselves. Then you can tighten the bolt.

[Warkton Tornado No.1]

I’ve given this some further thought based upon your latest explanation. Hopefully, I’m right for your scenario.

The slot in the forks needs to provide adequate clearance for the pinch bolt. Otherwise, as you tighten it, it will go wherever it feels.

To prove that is the case, you can do one of two things.

Preferably, remove the headset, mask up everywhere & make the fork slot bigger & better, even higher if need be. Clean up & refit starting with a big gap between headset & ring & gradually reduce the gap.

The non-preferred method is to put (hopefully a spare) pinch bolt in your pillar drill & reduce the diameter where any fouling to the fork slot has been occurring. Then clean up & refit as above.

[pauLI]

well after myself and a mate spent an hour or so yesterday head scratching and trying nipping the pinch bolt with the headset at different heights on the fork stem
we finally had a eureka moment and added another washer to the pinch bolt and hey presto, no more rubbing
cant explain why this worked but it did
thanks for all the help/ideas
paul

[WXboy64]

glad you solved it Paul...post some pics so we can all (me!) enjoy the repaint - cheers Keith/Norwich