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Old 05-09-09, 02:18 PM   #26
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REI Novara Buzz FlyBy handlebar post recall

More info regarding the "frozen" REI Novara Buzz FlyBys:

johnny99 posted this news clip from Bike Biz (thanks Johnny :-)

Excerpts from the article:

"Dahon is currently conducting a voluntary recall for handlebar posts fitted to certain numbers of selected 2008 model year bikes."
"Issue - A combination of inaccurate machining and inconsistent quality of material can cause the radius handlebar post to crack and break, posing a fall hazard (2008 models only)."
"Solution - Dahon will be supplying new handlebar posts for all affected bikes via your point of purchase."
"Dahon Global will be making an announcement within a few days relating to other territories, to ensure legal requirements are met, after due process has been followed."
La2sei recently purchased a FlyBy from REI and got this email (that I'm copying from the Recall forum to this forum:

"Dahon has recently notified us that the handle post used on some of the 2009 Dahon bikes and the 2009 Buzz FlyBy may not have been manufactured to specification. This potential manufacturing defect could allow the handle post to fail at the hinge, posing a safety hazard to the rider. Only bikes produced during a specific time period are affected, and Dahon is currently trying to establish what that time period is.

Until the issue is resolved, it is not advisable to ride your FlyBy. As soon as Dahon provides us with more information we will pass that information along to you directly (assuming that you are a member and that we have a record of your purchase) and post information on at the following link. We are expecting more details from Dahon in the very near future.

In addition, Dahon is working with the Consumer Product Safety Commission (CPSC) and may announce a recall notice soon. If that is the case, and your bike is affected, you will receive an official notification from the CPSC regarding the steps you will need to take to make the bike safe to ride again. It is my understanding that a properly manufactured handle post will be available shortly for owners of bikes affected by the recall."

I'm glad it's not an engineering design flaw but rather a (potential) materials/manufacturing flaw.
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Old 05-12-09, 12:40 PM   #27
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I really like the Novara-Dahon folder but as some have said it is out until July. Any other suggestions to buy now? Plus is Dahon's stem issue resolved? My LBS still won't reorder.
Akiva S.
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Old 05-12-09, 04:24 PM   #28
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There are now recall instructions for the US and Canada on the Dahon site. I didn't see it on the main page, but here is a link.

Last edited by faffer; 05-12-09 at 04:30 PM.
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Old 05-12-09, 04:24 PM   #29
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The info regarding the recall is now on Dahon's site, and lists the Novara flyby and shuttle.

(oops, almost simultaneous post)

I spoke with a bike tech at REI and they expect to have the replacement part in two weeks.

Last edited by la2sei; 05-12-09 at 10:31 PM. Reason: double post, more details
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Old 05-13-09, 08:17 AM   #30
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If you're still looking for a Flyby...

Since I purchased my Flyby last year (see my 3-22-08 post on pg. 1 of this thread), my financial and geographic conditions have changed considerably. I got laid off and moved to St. Louis! The end result is that my Flyby only got ridden about a dozen times on rides 10-30 miles and has otherwise been stored away from harm in my closet, like new. If anyone is still serious about buying one, PM me.
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