I serviced my headset few times on my new bike, each time without problems. But when I was serviced it few days ago, I had play in the headset that I couldn't get rid of. First I unscrewed top cap, then loosened and removed the stem, removed the spacers and cover. Then I degreased bearings and cleaned everything. Then I regreased the bearing and put everything back together.
This time there's play in headset when I move the fork. So I unscrewed stem and tightened top bolt until there's no play, but now I can't rotate the bars without using a lot of force. When I do that, it makes rubbing sound like there's no bearings -- just metal to metal contact.
I spent 30 minutes trying to find the balance where I can steer and there's no play in the bearing. However it seems like this sweet spot is no longer achievable.
What could cause this issue now, when before I was consistently able to properly adjust the headset preload?