It was like that from the beginning where the bike was under post-sales
maintenance at the LBS. That was a pro shop in Germany. They said "it
happens" on some of those roads in Eastern Belgium where many of my
rides were. The roads there often were in deplorable condition. Like
they are starting to be in California because of mismanagement of budgets.
>>
>>> I might comment that I have a Shimano 600 head set on one of my bikes
>>> that has never come loose :-)
>>>
>>
>> It it this type with the knurled nuts?
>>
>>
http://imgs.inkfrog.com/pix/coronadelmar/Shimano_600_HP-6207_Headset_02.JPG
>>
>> How hard do you torque down the top nut? Mine works ok on regular roads
>> but it does come loose on gravel roads and dilapidated old highways.
>> Also during even the shortest offroad stretch if sufficiently gnarly. I
>> use thick leather plus vise grips to tighten it and give it a lot of
>> muscle. Maybe I should add a pipe extension for even more torque.
>>
>> I've even thought about filing down the nuts to get rid of this
>> nonsensical knurl so I can use regular wrenches.
>
> I'm not sure what you are referring to when you use the word "knurl"
> as there isn't any knurling on the reference you posted.
> knurl -
https://en.wikipedia.org/wiki/Knurling
>
Well, I meant a really coarse and wavy knurl.
> I may be wrong but the head set I referred to, which doesn't look like
> your reference, is on a bike that was originally equipped with a
> complete Shimano 600 group set and I had assumed that the head set was
> Shimano 600 also.
>
Shimano made them both ways. One with classical hex nut structure and
then, whatever possessed them, the wavy version which makes no sense at
all. Unfortunately I have the latter.
Amazing, especially since you can only hold the lower nut with your
fingers if you don't want to damage its surface. In Europe I was not the
only one where this steerer kept coming loose. Aside from me it was
mostly Belgian riders who complained. On the well paved surfaces of the
Netherlands or Germany it held on well. Eastern Belgium, different story.
> To adjust I tighten the top bearing race until when I hold the front
> brake and push the bike forward and backward I feel no movement of the
> head bearings. I then hold the upper race so that it doesn't move and
> tighten the lock nut. Then, to check, I try again moving the bike
> against the front brake and also holding the front of the bike in the
> air swing the handle bars back and forth throughout their maximum
> travel to be sure that the bearings are not "binding".
>
> As I mentioned, there is play in all threads and it is possible that
> tightening the lock nut can move the upper race sufficiently, even
> though it doesn't rotate, that it is too tight. Thus an "after adjust"
> check.
>
Yes, like the QR does to axles where you have to leave an ever so slight
play when not mounted. Which reminds me, I have to get rid of the %^&#!!
QR on my MTB front axle.
> I tighten the lock nut with a wrench that is 9 inches long, overall,
> and just give it a good tug, with one hand. Holding the upper race
> stationary.
>
Do you think a "good tug" with your arms muscle is in the vicinity of
the 20 lb-ft Jay mentioned? I am not too muscular but have stripped 16mm
threaded crane hooks so I'd like to torque it down in a more controlled
fashion. Could not find a formal Shimano torque rating for it.