FSA Orbit II not sitting flush with fork crown?

[Shackleton]

Hi All,

I recently serviced my partners Thorn Raven Tour and when I put the fork and frame back together I noticed the FSA Orbit II headset wasn't sitting against the crown of the fork (See the attached picture) as it does on my Thorn Nomad. Is this normal, did i do something incorrectly and/or do you have any solutions to the issue?

Thanks,

Brian

[Danneaux]

Hi Shackleton!

It appears the lower rubber seal is not fully seated and may instead be pushed up inside the lower cup, keeping the assembly from seating properly.

This thread should help: http://thorncyclesforum.co.uk/index.php?topic=2636.0
...and this one...
http://thorncyclesforum.co.uk/index.php?topic=2414.0

Assembly diagram here: http://img87.imageshack.us/img87/5164/fsaorbitxliidiagram.jpg
Thorn used to have a little photo-essay showing proper assembly linked to their old FAQ page. It showed the assembly very clearly.

Best,

Dan.

[Shackleton]

Ahhh thanks Dan. i'll give the suggestion in that second forum a go. That should do it!

Thanks,

Brian

[Danneaux]

If it doesn't work, just give a shout, Brian.

Best of luck!

Dan.

[Shackleton]

Hey Dan,

Sorry for the late reply. I took the fork and headset apart and put back together as per the diagram and it appears the rubber ring is  too big. It just falls to the bottom of the fork no matter what I do with it? Any suggestions?


Cheers,

Brian

[Danneaux]

Hi Brian!

To followup...

I see Thorn have re-posted their FSA headset assemply photo-tutorial. Perhaps it will help:
http://www.thorncycles.co.uk/sandbox/thorncycles/fsa.pdf

If this helps -- or fails to -- please let us know.

All the best,

Dan.