Fitting replacement headset

flatblackbuddy · Post by **flatblackbuddy** » Thu Nov 03, 2011 3:32 pm

I'm putting my Buddy 125 back together after my crash from a couple of months ago, and I'm having some issues getting the upper and lower headsets to snap back together on the headlight side. It appears that the tabs on the upper headset are aligned too far out to fit in the notches on the lower headset. Specifically I'm having issues with the tabs closest to the grips on the headlight side of the assembly.

I'm thinking about cutting the tabs down on the outside to relieve the fit issue, but wondering if this will weaken the overall fit and lead to cracking. Has anyone had this issue in the past? What did you do to fit the two together? I have tried all combinations of loosening and tightening the screws that hold the two pieces together, to no avail.

PLEASE HELP!

Post by **ericalm** » Fri Nov 04, 2011 7:13 pm

I wouldn't cut the tabs down… yet…

I will say that there are probably a ton of Buddys out there with broken headset tabs that the owners are completely unaware of!

Can you post pics?

viney266 · Post by **viney266** » Fri Nov 04, 2011 8:00 pm

Yeah, I"ll bet something is off. You do have to be kind of "aggressive" to get them to pop in place. But if Its all on correctly they should "snap" together tightly. Check your work one more time make sure you have everything tucked where it needs to be.

Skootz Kabootz · Post by **Skootz Kabootz** » Fri Nov 04, 2011 8:52 pm

FWIW the times I've opened up my headset I have found it a bit fiddly getting it all snapping back together as it should. I would caution removing the tabs though as others who have inadvertently broken their tabs off have reported really annoying rattles as a result. Personally, that would drive me crazy.

flatblackbuddy · Post by **flatblackbuddy** » Fri Nov 04, 2011 9:58 pm

Thanks guys. You talked me out of cutting the tabs down. I ended up unscrewing the lower headset from the steering down tube. I was then able to snap the headset back together (headlight side first) and screw it all back together.

It's finally complete and I took it out for a ride today. First time in two months. Great to be back out there!