Lesson Learnt: Don't mess with the star nut. Ever.

[deepakkini]

After a harrowing month without riding the bike, courtesy this: viewtopic.php?f=12&t=11424&p=126406&hilit=headset+disaster#p126406

1/ Finally used a hacksaw to cut the top cap (it took ages) with significant damage to the stem.

2/ Went to the college workshop, begged for a hammer and a punch, set up the fork on a vise and hammered the bolt+star nut (the two pieces that had got "screwed" up!) combo deeper into the steerer with the intention of getting it out. After a point, it just remained there and refused to budge. So I just left it there and hammered in a replacement.

3/ The fiasco cost me 3k (new stem and star nut/top cap/bolt) and increased laziness to do anything (it was hell for a month without the bike).

4/ Turns out that the headset came assembled with 5 ball bearings "missing". Can someone at Cannondale explain this?

Anyways,

The trick to remove the star nut in case it gives you trouble:
http://forums.mtbr.com/shocks-suspensio ... 30067.html

The tip:
A bit of the top cap is left on the bolt lodged in the steerer, and occasionally makes a noise just to remind me not to overtighten the cap bolt, because you NEVER MESS WITH THE STAR NUT. EVER.

Guess some of you might have already known that

[hac]

What is the reason behind getting that star nut removed?

[rahul13]

Or just buy the Hope Head Doctor and never worry again



http://www.jensonusa.com/Hope-Head-Doctor
http://www.wiggle.co.uk/hope-head-doctor-expander/

[deepakkini]

@ hac - viewtopic.php?f=12&t=11424&p=126406&hilit=headset+disaster#p126406 explains it all.

@ rahul13 - 1.5" not available. That's another disadvantage of buying unusual stuff.

[rahul13]

@ rahul13 - 1.5" not available. That's another disadvantage of buying unusual stuff.

1.5? Really? I'm surprised. Which model Rockshox and what size axle?

[deepakkini]

It's a Trail SL frame. 1.5" non tapered to accommodate Cannondale's in-house Lefty.

The fork is a Rockshox Recon Silver TK Solo Air with a 1.5" steerer, quick release axle, Formula DC 20/22 hubs.

Just recently installed an FSA 1.5" star nut and top-cap to replace the one I screwed up during the said fiasco.

Also bought an FSA stem which I want to sell as the reach is too short.

1.5" stuff is really expensive. The stem I bought was marked $135 on CRC. I got a 76% clearance discount so I bought it. All the other items were around the range of $70-$80.

[jhobert]

Do you still have the stock cannondale top cap? My star nut still ok but the top cap is messed up and Im having problems finding the place to buy the stock top cap. If you still have it and still in good condition if you want Ill buy it from you.