Levo Gen 2 Headset creak/ Loose fitting headset bearing

[Dav1dlev0]

Hi, I’ve had issues with a creaking headset on my 2019 Levo comp.
I adjust it and after a couple hours riding it’s will start to creak, on further inspection the top headset bearing is really loose in the frame.
my local specialized dealer contacted spec and they have said it’s fine as the taper holds the bearing in place.... (even tho as soon as the tech saw it he said “that can’t be right!”)
anybody else have the same issue?
I’ve attached a YouTube link so you can see what I mean.

 

[JetSedgwick]

hmmm. I feel a tiny bit of 'play' in my bars and have been thinking about where it comes from, maybe this is the culprit.

 

[KeithR]

I had to tighten mine (Levo SL Comp) up last week - a load of play had developed in the headset, and was the source of an annoying creaking noise that suddenly became noticeable mid-ride.

But - so far - it's staying tight.

 

[paquo]

i wonder if there is any way to "shim" that. My bike has a creak from that area as well as the shock area

 

[Dav1dlev0]

i wonder if there is any way to "shim" that. My bike has a creak from that area as well as the shock area

So as an experiment I put one layer of insulation tape around the widest part of the bearing (not on the taper) and everything stayed tight and quiet. So long term I maybe use loctite bearing fit to create tight fit.
Seems a shame the to have to do that on an expensive bike and that specialized say that this poor tolerance is acceptable.
surely the loose fit will create wear and only get worse?

 

[aklemm]

I'm getting a similar sound on my 2021 Levo SL Comp. Seems to happen when I'm putting more power down on moderate to aggressive climbs. I don't notice it when casually pedaling or when I'm pointed downhill. I didn't notice it on my test ride prior to purchase.

My guess is a creak in the headset or a cable rattle.

I have the SWAT everyday carry tool in the headset. I plan on taking the headset apart and reinstalling to see if that fixes anything.

 

[Dav1dlev0]

I'm getting a similar sound on my 2021 Levo SL Comp. Seems to happen when I'm putting more power down on moderate to aggressive climbs. I don't notice it when casually pedaling or when I'm pointed downhill. I didn't notice it on my test ride prior to purchase.

My guess is a creak in the headset or a cable rattle.

I have the SWAT everyday carry tool in the headset. I plan on taking the headset apart and reinstalling to see if that fixes anything.

Would be interesting to see how the fit of the bearing is compared to mine, Every other bike I’ve owned the the bearings have been a good push fit.

 

[Jonesanthony]

This happened to me after 3 months. Went back to dealer for rebuild.

I have been without my bike for 12 weeks this year because of warranty issues.

I am now 3 weeks into a further warranty claim with creaking from from front end I suspect it be headset.

My bike has gone back to specialised for exactly this issue, plus a crack appearing in my head tube vertically.

@specializedridercare would be good to have some public comments from you about this issue.

 

[Dav1dlev0]

This happened to me after 3 months. Went back to dealer for rebuild.

I have been without my bike for 12 weeks this year because of warranty issues.

I am now 3 weeks into a further warranty claim with creaking from from front end I suspect it be headset.

My bike has gone back to specialised for exactly this issue, plus a crack appearing in my head tube vertically.

@specializedridercare would be good to have some public comments from you about this issue.

Seems like a fairly common issue, would really like to see if other frames have the sloppy fitting bearing like mine?
i understand the principle of relying on the taper to hold the bearing in place once preloaded but it seems this would be a not issue if the bearing was a good fit to start with.

I agree it would be great to hear directly from @specializedridercare

 

[KeithR]

Seems like a fairly common issue

Well not really - a handful of vaguely related replies (my headset was just loose - it's otherwise fine - and nobody else has confirmed the tolerance problem you report) does not a "fairly common issue" make...

Not dismissing your experience, just trying to keep a sense of proportion.

 

[Dav1dlev0]

Well not really - a handful of vaguely related replies (my headset was just loose - it's otherwise fine) does not a "fairly common issue" make...

Seems to be lots of threads related to loose headsets, but maybe not all caused by the same issue.

 

[fraatti]

There is little play between parts and that makes noise. Some grease to right place will cure that. It took less than 10 minutes to do that.

Levo Gen 2 - Squeaky headset

Can anyone help me get rid of a sneaky headset

www.emtbforums.com

 

[Dav1dlev0]

There is little play between parts and that makes noise. Some grease to right place will cure that. It took less than 10 minutes to do that.

Levo Gen 2 - Squeaky headset

Can anyone help me get rid of a sneaky headset

www.emtbforums.com

Thanks for the advice, unfortunately I’ve done this (also tried aluminium spacers instead of the composite ones) and does stop the noise but only for a few rides.
When you greased yours was the top bearing a similar fit to mine?

 

[Mikerb]

it could just as easily be the bearing that is not within tolerance.......also the outer casing may expand to take up that slack when torque is applied to the inner race. I would be inclined in the first instance to try another 1 1/8 bearing but meanwhile pack it with grease. I think there are several reports of loose headsets because along with a bit of cable stretch it is one of those things that requires further adjustment on a lot of bikes after the first few weeks/months of riding.

 

[Mikerb]

it could just as easily be the bearing that is not within tolerance.......also the outer casing may expand to take up that slack when torque is applied to the inner race. I would be inclined in the first instance to try another 1 1/8 bearing but meanwhile pack it with grease. I think there are several reports of loose headsets because along with a bit of cable stretch it is one of those things that requires further adjustment on a lot of bikes after the first few weeks/months of riding.

my headset took a few months to finally settle down with 2 or 3 adjustments in that time but has been fine for 12 months thereafter. when I service it I use quite a bit of grease everywhere!! I also find with this design of headset the older recommended method of setting the headcap torque ( ie until it starts to restrict the free movement of the bars) does not work because you are merely ensuring there is no play and not preloading bearings. It is easy therefore to both apply too little torque, in which case as soon as some of the grease has been squeezed out it will feel loose, or too much torque, in which case you effectively start to destroy the bearings. I use a torque wrench at 5nm.

 

[Dav1dlev0]

it could just as easily be the bearing that is not within tolerance.......also the outer casing may expand to take up that slack when torque is applied to the inner race. I would be inclined in the first instance to try another 1 1/8 bearing but meanwhile pack it with grease. I think there are several reports of loose headsets because along with a bit of cable stretch it is one of those things that requires further adjustment on a lot of bikes after the first few weeks/months of riding.

I’ve tried this to unfortunately! Bearing measures up perfectly and a replacement fits exactly the same.
grease works temporarily. The only real fix has been to shim it but I’m keen to know if other bikes have this loose a fit?

 

[fraatti]

Thanks for the advice, unfortunately I’ve done this (also tried aluminium spacers instead of the composite ones) and does stop the noise but only for a few rides.
When you greased yours was the top bearing a similar fit to mine?

I changed fork earlier and cleaned and greased bearings at same time. I think I might notice it if the fit was so loose as yours.
Actually I didn't tried it without grease. I used some thick stuff and just pushed bearing back.

My noise was similar than in this video. It just happened while driving.

 

[XBLASTOFFX]

Hi, I’ve had issues with a creaking headset on my 2019 Levo comp.
I adjust it and after a couple hours riding it’s will start to creak, on further inspection the top headset bearing is really loose in the frame.
my local specialized dealer contacted spec and they have said it’s fine as the taper holds the bearing in place.... (even tho as soon as the tech saw it he said “that can’t be right!”)
anybody else have the same issue?
I’ve attached a YouTube link so you can see what I mean.

Just an FYI...

Specialized specs an IS42/28.6 bearing on these bikes.
Many manufacturers use an IS 41/28.6

That one mm difference might be what you are running into.
I would pull the bearing and put some calipers on it to make sure no one mistakenly installed the wrong bearing.

 

[fraatti]

I had these bearings installed in 2020 levo

 

[Dav1dlev0]

Just an FYI...

Specialized specs an IS42/28.6 bearing on these bikes.
Many manufacturers use an IS 41/28.6

That one mm difference might be what you are running into.
I would pull the bearing and put some calipers on it to make sure no one mistakenly installed the wrong bearing.

Thanks, that is the standard bearing that measures 41.8mm which I believe is the spec of a IS42/28.6
My frame measures at almost 42.8mm

 

[Dav1dlev0]

I had these bearings installed in 2020 levo
View attachment 41623

View attachment 41624

Do you know how the fit was on the top bearing?

 

[fraatti]

Do you know how the fit was on the top bearing?

No, I didn't measure it, just took photo of the bearings.

 

[fraatti]

I will make lower leg service today. I can measure bearings fitment at same time.

 

[kneecap]

Is there any reason why we can't just install a new standard bearing set with the outer flange exposed on top of the headtube like all other bikes?

 

[fraatti]

Here is the dimensions from my bike (levo 2020). Freeplay at top around 0,20mm

Lower one, freeplay around 0,15mm.

 

[Dav1dlev0]

Here is the dimensions from my bike (levo 2020). Freeplay at top around 0,20mm

View attachment 41869
View attachment 41872

Lower one, freeplay around 0,15mm.
View attachment 41870

View attachment 41871

That’s much closer to what I’d expect, mine is almost 1mm which is apparently acceptable according to specialized ? Thanks for taking the time to measure!

 

[Mikerb]

Sounds about right given the potential different expansion rates of the bearing, headstock and fork steerer....and manufacture tolerances.

 

[Roger20]

Just adding to what has been said, this is what is shown at Section 5.3 of the user manual for my 2020 Turbo Levo

"The headset uses a 1 1/8” (41.8mm x 30.5 x 8mm, 45x45°) Campagnolo Standard compatible upper bearing
and a 1.5” (52mm x 40 x 7mm, 45x45°) lower bearing. Ensure that replacement bearings are compatible with
the Specialized headset specification. No tools are needed for installation or removal of both bearings. Grease
bearing surfaces before installation."

 

[Binhill1]

Reding your post Dave i have similar issues. No noise but bearing a loose fit. Few threads one mentions putting pdf tape on. Im going to video play and send to my dealer as he suggested. Ideally i want to take it to spesh dealer and see what they say.