I see that there's no answers yet so I'll try.
Firstly you say "play". Normally this means you can feel it by locking the front brake and rocking the bike back and forward.
Is that correct?
First simptoms was when i go down from sidewalk, some clunking in the headset. Of course i get back to the "service guy", and he insist that is normal. When u lock the brakes there was no play when u rocking bike back and forward (since it was everything overtighten).
Next simptoms was front end become totaly unstable going high speed (like 50-60 km/h), and specially side wind.
Again i reacted, buy that "service guy" was convincing me that is normal.
And thirt stage was not having play from rockin brakes, but after some ride play again (when u hold brakes and rock ur bike forward/backward). And this play beeing more and more (and when u overtighten u can feel the roughness of bearing, but play still there).
U must understund that i was coming from whole life riding MTB (from 1998 with suspension fork), and never ever had a chance to ride a Road before. So this FP3 was my first road, and switched from MTb to road then.. On MTB i know how to replace oil in the fork, or disks, and totaly different everything (i had Specialized Stumpjumper 1999), then Specialized EPIC Marathon Carbon 2007 (i still ride this one).
The idea was to buy the cheapest nice bike i found, and if like to upgrade in the future.
Also i was working a lot, and totaly without any free time to service my self (also did not have proper tools). So that why i went to "best Pinarello service guy", and went there with a friend who i trust him..
But last few years, we realize that that "service guy" is not honest, and ass*ole and if u did not buy from him, then he can do something like that (overtighen spokes and broken rim for example, or warranty issue which he refuse to do it and blame customers.. Or we found that so many people replace bearings every few months...Also he is working in semi legal way, but declare him self as Pinarello dealer.. When i went to Pinarello in Italy last year, i realized he is not official dealer. He just buy things like regular guy on Sales (even second hand then clean them up, and sell as new sometimes), just to have idea. Of course then i did not know this.. I just wanted to go in nice service, and not so many service options where i live..
Of course last two years i service things my self and u realize now why. Also now u realize why i started buying my own tools (ok, i found that i like working my self) (and i will never ever buy something or suggest to someone to buy something from that guy,or to bring something for service..
And this is not just me.. I found many of local guys who ride a lot to refuse to buy anything Pinarello, and they switch to different brands just because of this. How he was succesfull?? In that period there was not so many bike shops where u can buy nice Road Bike, and he was only one who was selling Campagnolo.. Lucku us there is now nice official Campagnolo and Bianchi dealer, so there is no need at all to go there. The same guy sometimes was refusing to sell something (when he know that someone need something urgently), just to play like he is very important and u have to care about him. Not him about u as customers.. Im sorry that i got this stories from people late.. But never mind.. Nice lesson learned..Anyway no need to waste time about this "service", lets continue in trying to solve the problem...
If so, it means that the assembly was wrong from the start and you should not have ridden the bike at all until it was fixed.
After six years of using it like that it's impossible so say what damage may have been caused.
I suspect the stack was wrong initially, preventing the proper preload, but that's only a guess.
You show a couple of misunderstandings about how a threadless headset works:
Since did not have enough time, and injuries in 2015 , and also was riding MTB this bike was not riden too much (like 5000 km overall). When i found that i like road bikes, i bought a new C60. I explained the whole situation few lines before this.. But ok.. Maybe there is some fault at my side as well, but sometimes u trust to some service guys.. And maybe i dont understunt everything, but here im to learn
(maybe too late now).
since the play was from first day, and except overtitgheting (when i checked lke 7-8 nm, which is excess)
There is no set torque value for the top cap. It should be tightened enough so that there's no play. If play cannot be eliminated than the first thing to check is the stack to ensure that the cap is not bottoming on the steerer tube.
I checked this many times.. As u can see on this picture stack is more then enough. Also i was checking many times if plug that u install in the fork is ok or not.. So if was that simple, i would not have problem
when we replaced the fork few days ago, the bearings came out together with the fork (the down one), which was a bit strange, since i know this bearing have to be pressed in in the headtube,
You seem worried about bearings dropping out. It's normal. They are not a press fit. The system relies on the taper of the bearings and seats, when compressed, to be stable.
This is the bearings i removed, and this is the same sistem i have:
And i guess i have the same system:http://singletrackworld.com/forum/topic ... lo-headset
Seem that is often problem of Pinarello's
You seem to have been badly advised so far, and need to improve your understanding of how these things work. I can only suggest you find a better mechanic to check it in person, and see if it's possible to recover a workable and safe solution. The internet can only help so much.
One of the things why i follow forums is to learn the things and understund how they work.. Now im trying exactly what u suggest
But never mind. If u understund how this work, and if u have idea how to fix it now, please suggest the solution.. Or what i can do right now, as i it is to try to ride this frame and bike.. If there is sollution..
Yes, some Pinarellos did indeed have pressfit cartridge bearings in the headset. I’ve had to use a bearing extractor to remove them. It wasn’t an FP3 but it was probably the same vintage. They look more like just large non angular cartridge wheel bearings. If they are these type and they are just “falling out” then indeed there is a problem.
Having a hard time remembering, but I am pretty sure my FP3 had a pressfit lower headset bearing actually. I did have some issues with longevity with that bearing as well. I believe i went through two new ones in a season (I normally have to replace them every 3 or 4 years on my other bikes...). It was a strange design with the head set bearing set up in the head tube a little bit.
I'll post again the link of headset explained in Fp2 and i guess is the same in Fp3 as well..http://singletrackworld.com/forum/topic ... lo-headset
And again the picture of the bearings (down one, and top one). So is there any solution u suggest to try to solve this problem?
Thanks a lot to everyone..