This is very frustrating, and I'm looking for some advice on what this may entail. The bike is a 2016 Novara - Safari, and when I received it, of course it was shipped with the front wheel detached. When I went to put it on it was almost impossible because the width of the space between the fork-mounts is a bit to narrow. I finally got it on but it took a lot. After that I forgot all about it and have just been building it up and have done a few rides. Last night I went to pull the front wheel off and was immediately reminded that this issue exists.

Clearly this is a warranty issue, but is there a simple and safe fix I can do myself, or if I do pursue this thought its warranty, what will they or should they do about it? I suppose attempting to brute-force bend it into shape is not going to work since the legs will likely not bend uniformly, thus making the wheel mount crooked, so the proper thing would be to replace the fork with a new one. Does this sound right?

Also I really like this bike, and don't really want to get it refunded. If I do I'm really not sure what I'd replace it with. I like the tough build of it, and the geometry and wide wheels.

The fork is damaged. Take it back to REI and get a new bike. Of course there is the issue that you've ridden the bike for a while, so who's to say you didn't damage it yourself? Hopefully they will take your word.

You could also take the fork to a frame builder and have it straightened in a jig. This would cost around $100.

Not necessarily an REI warranty issue. Could have been damaged in shipping. Either way, you should have reported it right away, and i'll bet it's too late to go after the shipper.


BTW...How about some photos of this build.

Didn't REI just clear out all their Novara bikes? There may be nothing left to replace it with.

Easy fix. Just take it to the LBS and they can fix that in 10min.

You have been asking so many questions about this bike and this is the first time you noticed this ?

If this issue is only that the width of the fork's dropouts isnt wide enough, as mentioned, a local shop cant widen the dropouts and ensure that they are evenly spaced between the center of the fork. It isnt a tough job and wont cost much.

If the issue is not only that the spacing isnt wide enough, but also that the dropouts arent square with one another, then its a bigger issue. It can still be adjusted, it just isnt as quick of a fix.


Rear dropouts on older bikes(70s and 80s steel) are coldset(permanant adjustment) most any time new wheelsets are used. Its a relatively common and easy process.



I would hope REI would have the tools to properly widen your fork, as they have certified mechanics.

There was no apparent damage to the shipping box or anything else when I received the bike, but who knows? I suppose anything is possible. The bike has only been ridden twice since I got it, and has never been so much as dropped from a stand still, and has zero signs of any damage.

I spoke with an REI rep, and was told that since the bike was discontinued a while back, there are no more available, and no spare parts to be had. But they do have a few still in stores unsold, so they will swap out this fork for a good one from one of those for me. Sounds like problem solved, and I'm glad; I did not want to have to return this bike.

Interesting. So the problem gets passed along to some other poor sucker.

Much more likely they should just do the 10-minute expander job in their workshop while it's still on the bike.

They didn't say they were going to put it on the donor bike and sell it. I wouldn't expect that, but I'll surely ask.

Huh? No spare parts, discontinued model? What do you expect them to do that keeps it cost-efficient? Dump the whole new donor bike just for your repair.

I could almost guarantee they will readjust YOUR fork and you won't be any the wiser unless you stand in the workshop and watch the job, or mark the fork.

Sounds like you are going after the poster and holding them responsible for what REI might do. If thats the case, thats lame. If that isnt the case, then why post what you posted?

Most bikes are shipped with a fork spacer installed to prevent what happened to your bike. Was one installed or loose in the box?

I'll bet they sell the bike with the repaired fork at one of their "garage sales". They are upfront about the repairs or defects, and sell the merchandise at a very good prices.

Yes, the plastic spacer was still on the end of the fork.

+1.

Although TBH, it seems like more work to swap out the fork than just exchange bikes. In any case, if they gave it to me for a hefty discount, I'd buy it.

They don't have anymore in my size, so they are gong to have to take one from a larger bike and cut the fork down a bit if needed.

It will probably end up in REI's garage sale as a returned item.

No! don't do dat~!

in your tire thread you mentioned the bars were too low.
if the fork be coming from a larger donor bike, tell them not to cut it down.
just add a couple spacers, giving you more adjustment range.
if you're changing stems, take the new one with you, let them switch.

you can always cut the fork shorter later.

I was thinking about that too. I already installed the stem-riser and it added enough height, but if they don't cut the new fork down I suppose a bit more range to play with couldn't hurt, right?

+2 about not cutting the steering tube!

It will also look a lot better Due to fit issues, I have replaced the forks on a couple of my bikes with forks that do not have the steering tubes cut. While I usually subscribe to the "function over form" philosophy, I tried a stem riser and was not very happy with it.

I still have not cut the steering tube on my LHT. It came uncut, and I was going to cut it once I dialed it in. That was 6 years ago!

There was a bike on hand with the same steering-tube length, so it's in with no problems. All tings considered, it looks like the bend occurred during shipping as has been mentioned. REI was great, and has really taken good care of me. Now I can move on with completing my build. Getting it done is taking way longer than I'd like, but I'm sure the results will be well worth the work and the wait.

REI = $2.4 billion (USD) in sales last year, they'll give you a new fork, and nobody needs to worry, they aren't gonna resell a defective fork.

"Putting an image of a flat screen TV on a box containing a bicycle reduces the chance of damage during delivery by up to 80%." lol

What happened when a bike company started putting TVs on the sides of its delivery packages | The Independent

Great story!

I work on trail crews, and we noticed after 9/11 that trail signs printed with the American flag didn't get shot at. Now you see the flag on everything that can handle it. (And I've heard that's kind of creepy, from Warmshowers guests from other countries.)

Love that. Totally brilliant!!