Broken hub where can i find replacement

v:* {behavior:url(#default#VML);} o:* {behavior:url(#default#VML);} w:* {behavior:url(#default#VML);} .shape {behavior:url(#default#VML);} A lot of locking problems are just poor lubrication so before you start opening parts, get a can of Silicon Spray (Bugaboo use to include a can in their maintenance kit). Any hardware or Gas Station will sell it. Don\'t use Oil based lubricants like WD40 the main reason being they stain fabrics and attract dirt. Remove the seat unit and lay the stroller on its side faulty hub down. Now look on the inside edge of your handle where it joins the plastic hub, you\'ll see two slots in the plastic hub and a wire rod in the lower slot. Spray into this slot so lubricant flows down inside the hub. Now wipe off excess with a paper towel and work the release button a few times. If you are lucky your handle now works. No luck? Then we have to see if the fault is in the hub or the release button. Press or pull the release button while watching the wire rod in the lower slot. It should move 6 to 8 mm. If there is a resistance to this, the hub is at fault. If the rod seems to move freely but the hubs remained locked try pulling the rod a bit further up with a small pair of pliers. If this releases the hub you have a release button fault. If the hub is still locked the fault is in the hub. Bugaboo handle issues can be caused by faults in either the release buttons or the hubs and the first job is to try and diagnose the part causing the fault. I\'ll describe how the locks work then go into more detail on each part. Two aluminum lock pins sit in channels of the inner hub and extend into pockets in the outer hub, locking the hub. These lock pins are retracted by the rotation of a plastic disk connected to the ends of the lock pins by two small plastic pins on the disk. A wire rod clips into the disk and runs up the handle to the release buttons. There are two versions of the release button. The older pull up knob type (Gen 1) and the newer rocker button type (Gen 2). Both versions pull up the wire rod, the Gen 1 rod clips into a black plastic block in the handle and the release knob screws in to it. The (Gen 2) has a rocker button that moves the rod up via a white plastic block clamped to the wire rod by two small Alan/hex screws. A compression spring sits above the plastic blocks of both versions held by the caps where the upper handle comes out. The spring keeps the downward locked position until upward moment from the release buttons unlocks it. Check that the cap is fixed down. If not that is most likely your problem. If you are missing a spring your local hardware shop can find something similar. It does not have to be exact but if using a different spring change both sides so both sides have the same \'feel\'. . Release Button Repair The old pull up release button (Gen 1) rarely fails which is fortunate, as you have to drill out the rivets in the handle holding the hubs to pull it out. The (Gen2) is easier to get to which is fortunate as it does fail and can be your problem the most common fault being the two screws holding the rod coming loose. From the brake (left) side remove the two Phillips screws and the inner half of the assembly will come off rocker button attached. The brake lever, inner brake release button and spring will be loose so carefully place aside in a small container till ready to reassemble. The right side has no screws it just clips together. Use a small flat blade screwdriver to pop the joints on the front and back edges, the inner plate with rocker button attached will come free. There is a metal plate sitting over the hole the rod is in. Take time to remember how it fits in the hole and the angle you take it out. This will make putting it back much easier. The wire rod runs though a white plastic block clamped by an inner metal block with two inset hex screws. The hex key is 0.05 inches or a 99-20 if you have Xcelite hex drivers. Adjust the rod by pulling a few mm though the block and relocking. Don\'t take up any more then required to unlock the hub other wise the locking rods won\'t fully engage in the hubs when locked. Hub Repair 1/. Remove the capped star lock washer. Use a small painters knife to protect the plastic first hammer the knife in between the dome and the plastic, then hammer a large flat blade screwdriver in between the dome and the knife. Work from one side than the other to "walk" the dome up and off the shaft. There may be a second plain star washer under the Dome you can use a small screwdriver to "walk" that up and off too.
Note it is best to open and repair one side at a time, so your moving and flexing one side of the handle does not dislodge parts in the other side. The hubs and disks are mirrors of each other and not interchangeable the locking rods are interchangeable. Bugaboo designate the side with the brake lever as left, the Bugaboo parts will have an "L" after their serial numbers. 2/. Check the hubs for wear. If too badly worn or damaged you will have too much movement in the locked position. You can fix this by cutting a 20 mm section of a 3 to 4 mm house nail drilling a hole the same as the nail in the damage hub wall next to the pin then epoxy it in. 3/. There are three parts in the hub, a plastic disk and two aluminum-locking rods. The disk has two plastic pins that move the locking rods in and out of cannels in the inner hub. Why Bugaboo use plastic for this vital component is a mystery to me? If you need to repair the disk you can try drilling out the pin stumps and using a cut down 4 mm cap bolt. Or (my preferred choice) have a new disk fabricated that will last a lifetime. The locking rods if broken can only be replaced, either by ones salvaged from another frame or new laser cut or 3D printed copies. I prefer the copies as they have been cut / printed from stainless steel. I sell both metal $30.00 and plastic $10.00 disks, and the stainless steel locking rods $16.00 each direct from <shapeways.com/shops/bugabooparts> Shipping is only $6.00 to USA $9.50 EU and $20.00 for the rest of us 8-( If you are in Australia or New Zealand contact me directly [email protected] for better shipping direct from New Zealand 3/. Reassemble handle locking hub and check operation. If wire rods seem to be in the incorrect position try pulling the handle up to it\'s full extension, if that does not work loosen the top plastic fittings where the handle extends from by removing the small self-tapping screws (note I\'m now finding some frames now have pop rivets, drill them out and replace with self tappers) and wiggle things into alignment. (I use a small amount of the silicon grease used for taps to give a smooth action) If all is working well fit the new capped star lock on the hub shaft and tap home. To protect the dome finish I use a large socket from my socket set and an old rubber washer from a toilet cistern. Repeat operation on the other side if necessary. Once repaired, I can\'t empha enough, the need to keep Bugaboo hubs well lubricated. They have to endure incredible forces from the handle. To give you some idea, a crow bar of the same length can pull six-inch nails out of hard wood! If you have further questions or require other parts you can contact me

The bugaboo handle fault is caused either by two small plastic pins shearing of a plastic disk that actuates two metal locking rods or broken locking rods.Why bugaboo uses plastic for the disk and aluminum for the locking rods is beyond me!They are critical components with a history of failing and should be made in stainless steel.

1/.Remove the capped star lock washer.This is the hardest part of the job.Most people try to leaver this off in the hope of re using.First problem with this is you will mark or damage the surrounding plastic second is star locks are not intended for reuse and will never hold as well as when first used, so best find a new replacement.A hardware store should be able to source some for you.Quickest way to remove a capped washer is to carefully cut a slot in the dome with an angle grinder and then use a large screwdriver to carefully prize one side up so you can fit another screwdriver under the starlock.Note the walls of the aluminum hub axel are thin and easily distorted, make sure you only lever the capped star lock and not hub axel.Use one screwdriver as a support and another to lift off the capped star lock.Note it is best to open and repair one side at a time, so your moving and flexing one side of the handle does not dislodge parts in the other side.The hubs and disks are mirrors of each other and not interchangeable the locking rods are interchangeable.The side with the brake lever is left The Bugaboo parts will have an "L" after their serial numbers.

2/.The lock mechanism is very simple; a wire rod rotates a plastic disk.Check the hubs for wear.If too badly worn or damaged you will have too much movement in the locked position.The Frog, Gecko and Chameleon use the same plastic hub so find another frame to salvage hubs from.They are held in by a single aluminum rivet.
The disks have two plastic pins that move the locking rods in and out of the inner hub. Locking into and out of the outer hub.You need to either repair the disk by drilling out the pin stumps and finding a replacement metal screw you can fit / glue in.Or (my preferred choice) have a new metal disk fabricated that will last a lifetime.The locking rods can only be replaced, either by ones salvaged from another frame or new laser cut copies.I prefer the copies as they have been cut from stainless steel.


3/.Reassemble handle locking hub and check operation.If wire rods seem to be in the incorrect position, loosen the top plastic fittings where the handle extends from by removing the small self-tapping screws (note I'm now finding some frames now have pop rivets, drill them out and replace with self tappers) and wiggle things into alignment. (I use a small amount of the silicon grease used for taps to give a smooth action)If all is working well fit the new capped star lock on the hub shaft and tap home. To protect the dome finish I use a large socket from my socket set and an old rubber washer from a toilet cistern.Repeat operation on the other side.

I can't emphasize enough the need to keep Bugaboo hubs well lubricated with silicon spray.They have to endure incredible forces from the handle.To give you some idea, a crow bar of the same length can pull six inch nails out of hard wood!

I do have parts available: laser cut metal disks with stainless steel pins, replacement-locking rods in stainless steel and capped star lock washers. You can contact me at [email protected]

The bugaboo handle fault is caused either by two small plastic pins shearing of a plastic disk that actuates two metal locking rods or broken locking rods.Why bugaboo uses plastic for the disk and aluminum for the locking rods is beyond me!They are critical components with a history of failing and should be made in stainless steel.

1/.Remove the capped star lock washer.This is the hardest part of the job.Most people try to leaver this off in the hope of re using.First problem with this is you will mark or damage the surrounding plastic second is star locks are not intended for reuse and will never hold as well as when first used, so best find a new replacement.A hardware store should be able to source some for you.Quickest way to remove a capped washer is to carefully cut a slot in the dome with an angle grinder and then use a large screwdriver to carefully prize one side up so you can fit another screwdriver under the starlock.Note the walls of the aluminum hub axel are thin and easily distorted, make sure you only lever the capped star lock and not hub axel.Use one screwdriver as a support and another to lift off the capped star lock.Note it is best to open and repair one side at a time, so your moving and flexing one side of the handle does not dislodge parts in the other side.The hubs and disks are mirrors of each other and not interchangeable the locking rods are interchangeable.The side with the brake lever is left The Bugaboo parts will have an "L" after their serial numbers.

2/.The lock mechanism is very simple; a wire rod rotates a plastic disk.Check the hubs for wear.If too badly worn or damaged you will have too much movement in the locked position.The Frog, Gecko and Chameleon use the same plastic hub so find another frame to salvage hubs from.They are held in by a single aluminum rivet.
The disks have two plastic pins that move the locking rods in and out of the inner hub. Locking into and out of the outer hub.You need to either repair the disk by drilling out the pin stumps and finding a replacement metal screw you can fit / glue in.Or (my preferred choice) have a new metal disk fabricated that will last a lifetime.The locking rods can only be replaced, either by ones salvaged from another frame or new laser cut copies.I prefer the copies as they have been cut from stainless steel.


3/.Reassemble handle locking hub and check operation.If wire rods seem to be in the incorrect position, loosen the top plastic fittings where the handle extends from by removing the small self-tapping screws (note I'm now finding some frames now have pop rivets, drill them out and replace with self tappers) and wiggle things into alignment. (I use a small amount of the silicon grease used for taps to give a smooth action)If all is working well fit the new capped star lock on the hub shaft and tap home. To protect the dome finish I use a large socket from my socket set and an old rubber washer from a toilet cistern.Repeat operation on the other side.

I can't emphasize enough the need to keep Bugaboo hubs well lubricated with silicon spray.They have to endure incredible forces from the handle.To give you some idea, a crow bar of the same length can pull six inch nails out of hard wood!

I do have parts available: laser cut metal disks with stainless steel pins, replacement-locking rods in stainless steel and capped star lock washers. You can contact me at [email protected]

The handle is prone to failure. Quite often it will either lock up in one position and not move or it won't lock at all and the handle becomes floppy. You have two options if your Bugaboo is out of warranty. Buy a new frame, this is around a third of the cost of a new Bugaboo but will add value to your resale price (as you'll get the newer handle extension lever system and the red brake lever) or repair it. Cost varies depending on what parts you need to repair or replace. Worse case scenario of all the parts in a hub being broken would cost around $100 to fix that one hub vs $400 for a new chassis with an added $200 to resale value.
Here's my How to fix a Bugaboo Handle instructions if you are not a handy person type, take these instructions to you local Bicycle Mechanic or Small engineering shop.

The bugaboo handle fault is caused either by two small plastic pins shearing of a plastic disk that actuates two metal locking rods or one or both locking rods breaking. Why bugaboo uses plastic for the disk and aluminum for the locking rods is beyond me! They are critical components with a history of failing!

1/ Remove the capped star lock washer. This is the hardest part of the job. Most people try to leaver this off in the hope of re using. First problem with this is you will mark or damage the surrounding plastic, second is the star lock is not intended for reuse and will never hold as well as when first used, so best find a new replacement. A hardware store should be able to source some for you. Quickest way to remove a capped washer is to carefully cut a slot in the dome with an angle grinder and then use a large screwdriver to carefully prize one side up so you can fit another screwdriver under it. Note the walls of the aluminum hub axel are thin and easily distorted, make sure you only lever the capped star lock and not the hub axel. Use one screwdriver as a support and another to lift off the capped star lock.
Note it is best to open and repair one side at a time, so your moving and flexing one side of the handle does not dislodge parts in the other side. The hub and disks are mirrors of each other and not interchangeable. The locking rods are interchangeable. The side with the brake lever is left side. The Bugaboo parts will have an "L" after their serial numbers.

2/. The lock mechanism is very simple; a wire rod rotates a plastic disk. Check the hubs for wear. If too badly worn or damaged you will have too much movement in the locked position. The Frog and Chameleon use the same plastic hub find another frame to salvage hubs from. You may also get the disks and rods from it. The hub is held in by a single aluminum rivet.
The disk has two plastic pins that move the locking rods in and out of the inner hub into and out of the outer hub. You need to either repair the disk by drilling out the pin stumps and finding a replacement metal screw you can fit / glue in. Or (my preferred choice) have amore robust metal disk fabricated.


3/. Reassemble handle locking hub and check operation. If wire rods seem to be in the incorrect position, loosen the top plastic fittings where the handle extends from by removing the small self-tapping screws and wiggle things into alignment. (I use a small amount of silicon grease used for taps to give a smooth action) If all is working well fit the new capped star lock on the hub shaft and tap home. To protect the dome finish I use a large socket from my socket set and an old rubber washer from a toilet cistern. Repeat operation on the other side if necessary.

I have parts available both laser cut metal disks with stainless steel pins and replacement locking rods made in stainless steel. Also capped star lock washers if you can't find them. You can contact me at [email protected]

Not sure what you mean by can't stand anymore? The Bugaboo is made up of three shaft sets coming of a central hub. The front wheels are one set the back wheels another, they lock in place by the seat unit locking into the central hub. This is very robust and rarely fails. The third set is the handle and this is not very robust and prone to failure. Quite often it will either lock up in one position and not move or it won't lock at all and the handle becomes floppy.
You have two options if your Bugaboo is out of warranty. Buy a new frame, this is around a third of the cost of a new Bugaboo but will add value to your resale price or repair it. Here's my How to fix a Bugaboo Handle instructions Cost varies depending on what parts you need to repair or replace.

If you are not a handy person type, take these instructions to you local Bicycle Mechanic or Small engineering shop.

The bugaboo handle fault is caused either by two small plastic pins shearing of a plastic disk that actuates two metal locking rods or one or both locking rods breaking. Why bugaboo uses plastic for the disk and aluminum for the locking rods is beyond me! They are critical components with a history of failing!

1/ Remove the capped star lock washer. This is the hardest part of the job. Most people try to leaver this off in the hope of re using. First problem with this is you will mark or damage the surrounding plastic, second is the star lock is not intended for reuse and will never hold as well as when first used, so best find a new replacement. A hardware store should be able to source some for you. Quickest way to remove a capped washer is to carefully cut a slot in the dome with an angle grinder and then use a large screwdriver to carefully prize one side up so you can fit another screwdriver under it. Note the walls of the aluminum hub axel are thin and easily distorted, make sure you only lever the capped star lock and not the hub axel. Use one screwdriver as a support and another to lift off the capped star lock.
Note it is best to open and repair one side at a time, so your moving and flexing one side of the handle does not dislodge parts in the other side. The hub and disks are mirrors of each other and not interchangeable. The locking rods are interchangeable. The side with the brake lever is left side. The Bugaboo parts will have an "L" after their serial numbers.

2/. The lock mechanism is very simple; a wire rod rotates a plastic disk. Check the hubs for wear. If too badly worn or damaged you will have too much movement in the locked position. The Frog and Chameleon use the same plastic hub find another frame to salvage hubs from. You may also get the disks and rods from it. The hub is held in by a single aluminum rivet.
The disk has two plastic pins that move the locking rods in and out of the inner hub into and out of the outer hub. You need to either repair the disk by drilling out the pin stumps and finding a replacement metal screw you can fit / glue in. Or (my preferred choice) have amore robust metal disk fabricated.


3/. Reassemble handle locking hub and check operation. If wire rods seem to be in the incorrect position, loosen the top plastic fittings where the handle extends from by removing the small self-tapping screws and wiggle things into alignment. (I use a small amount of silicon grease used for taps to give a smooth action) If all is working well fit the new capped star lock on the hub shaft and tap home. To protect the dome finish I use a large socket from my socket set and an old rubber washer from a toilet cistern. Repeat operation on the other side if necessary.

I have parts available both laser cut metal disks with stainless steel pins and replacement locking rods made in stainless steel. Also capped star lock washers if you can't find them. You can contact me at [email protected]

You have two options if your Frog is out of warranty. Buy a new frame, this is around a third of the cost of a new Bugaboo but will add value to your resale price or repair it. Here's my How to fix a Bugaboo Handle instructions Cost varies depending on what parts you need to repair or replace.

If you are not a handy person type, take these instructions to you local Bicycle Mechanic or Small engineering shop.

The bugaboo handle fault is caused either by two small plastic pins shearing of a plastic disk that actuates two metal locking rods or a broken locking rod.Why bugaboo uses plastic for the disk and aluminum for the locking rods is beyond me! They are critical components with a history of failing!

1/.Remove the capped star lock washer.This is the hardest part of the job.Most people try to leaver this off in the hope of re using.First problem with this is you will mark or damage the surrounding plastic second is star locks are not intended for reuse and will never hold as well as when first used, so best find a new replacement.A hardware store should be able to source some for you.Quickest way to remove a capped washer is to carefully cut a slot in the dome with an angle grinder and then use a large screwdriver to carefully prize one side up so you can fit a screwdriver.Note the walls of the aluminum hub axel are thin and easily distorted, make sure you only lever the capped star lock and not hub axel.Use one screwdriver as a support and another to lift off the capped star lock.
Note it is best to open and repair one side at a time, so your moving and flexing one side of the handle does not dislodge parts in the other side.The hub and disks are mirrors of each other and not interchangeable.The side with the brake lever is left The Bugaboo parts will have an "L" after their serial numbers.

2/.The lock mechanism is very simple; a wire rod rotates a plastic disk.Check the hubs for ware.If too badly worn or damaged you will have too much movement in the locked position.The Frog and Chameleon use the same plastic hub find another frame to salvage hubs from.They are held in by a single aluminum rivet.
The disk has two plastic pins that move the locking rods in and out of the inner hub into and out of the outer hub.You need to either repair the disk by drilling out the pin stumps and finding a replacement metal screw you can fit / glue in.Or (my preferred choice) have a new metal disk fabricated that will last a lifetime.


3/.Reassemble handle locking hub and check operation.If wire rods seem to be in the incorrect position, loosen the top plastic fittings where the handle extends from by removing the small self-tapping screws and wiggle things into alignment. (I use a small amount of the grease used for taps to give a smooth action)If all is working well fit the new capped star lock on the hub shaft and tap home. To protect the dome finish I use a large socket from my socket set and an old rubber washer from a toilet cistern.Repeat operation on the other side

I have parts available laser cut metal disks with stainless steel pins, replacement locking rods in stainless steel and capped star lock washers you can contact me at [email protected]

I answered a similar question only yesterday. The sliver cap is a Capped Starlock do a google to find out more. They are a one use item and trying to remove them for reuse will mark the plastic hubs and make a weak repair. Here's my How to fix a Bugaboo Handle instructions

If you are not a handyperson type, take these instructions to you local Bicycle Mechanic or Small engineering shop.

The bugaboo handle fault is caused either by two small plastic pins shearing of a plastic disk that actuates two metal locking rods or a broken locking rod. Why bugaboo uses plastic for the disk and aluminum for the locking rods is beyond me! They are critical components with a history of failing!

1/. Remove the capped star lock washer. This is the hardest part of the job. Most people try to leaver this off in the hope of re using. First problem with this is you will mark or damage the surrounding plastic second is star locks are not intended for reuse and will never hold as well as when first used, so best find a new replacement. A hardware store should be able to source some for you. Quickest way to remove a capped washer is to carefully cut a slot in the dome with an angle grinder and then use a large screwdriver to carefully prize one side up so you can fit a screwdriver. Note the walls of the aluminum hub axel are thin and easily distorted, make sure you only lever the capped star lock and not hub axel. Use one screwdriver as a support and another to lift off the capped star lock.

Note it is best to open and repair one side at a time, so your moving and flexing one side of the handle does not dislodge parts in the other side. The hub and disks are mirrors of each other and not interchangeable. The side with the brake lever is left The Bugaboo parts will have an "L" after their serial numbers.

2/. The lock mechanism is very simple; a wire rod rotates a plastic disk. Check the hubs for ware. If too badly worn or damaged you will have too much movement in the locked position. The Frog and Chameleon use the same plastic hub find another frame to salvage hubs from. They are held in by a single aluminum rivet.

The disk has two plastic pins that move the locking rods in and out of the inner hub into and out of the outer hub. You need to either repair the disk by drilling out the pin stumps and finding a replacement metal screw you can fit / glue in. Or (my preferred choice) have a new metal disk fabricated that will last a lifetime.

3/. Reassemble handle locking hub and check operation. If wire rods seem to be in the incorrect position, loosen the top plastic fittings where the handle extends from by removing the small self-tapping screws and wiggle things into alignment. (I use a small amount of the grease used for taps to give a smooth action) If all is working well fit the new capped star lock on the hub shaft and tap home. To protect the dome finish I use a large socket from my socket set and an old rubber washer from a toilet cistern. Repeat operation on the other side

I have parts available laser cut metal disks with stainless steel pins, replacement locking rods in stainless steel and capped star lock washers you can contact me at [email protected]

Regards

Steve

This is a far to common fault with Bugaboo's If it's less then two years old Bugaboo will replace it. If older you can buy a new one around $400 if yours is the older wing nut version you will improve your resale value with the newer lever version. Or you can fix it for around $100 a side. Depends on what parts are broken.

How to fix a Bugaboo Handle

If you are not a handy-person type, take these instructions to you local Bicycle Mechanic or Small engineering shop.

The bugaboo handle fault is caused either by two small plastic pins shearing of a plastic disk that actuates two metal locking rods. Why bugaboo uses a plastic disk for this critical component is beyond me! Or a broken locking rod

1/. Remove the capped star lock washer. This is the hardest part of the job. Most people try to leaver this off in the hope of re using. First problem with this is you will mark or damage the surrounding plastic second is star locks are not intended for reuse and will never hold as well as when first used, so best find a new replacement. A hardware store should be able to source some for you. Quickest way to remove a capped washer is to carefully cut a slot in the dome with an angle grinder and then use a large screwdriver to carefully prize one side up so you can fit a screwdriver. Note the walls of the aluminum hub axel are thin and easily distorted, make sure you only lever the capped star lock and not hub axel. Use one screwdriver as a support and another to lift off the capped star lock.

Note it is best to open and repair one side at a time, so your moving and flexing one side of the handle does not dislodge parts in the other side. The hub and disks are mirrors of each other and not interchangeable. The side with the brake lever is left The Bugaboo parts will have an "L" after their serial numbers.

2/. The lock mechanism is very simple; a wire rod rotates a plastic disk. Check the hubs for ware. If too badly worn or damaged you will have too much movement in the locked position. The Frog and Chameleon use the same plastic hub find another frame to salvage hubs from. They are held in by a single aluminum rivet.

The disk has two plastic pins that move the locking rods in and out of the inner hub into and out of the outer hub. You need to either repair the disk by drilling out the pin stumps and finding a replacement metal screw you can fit / glue in. Or (my preferred choice) have a new metal disk fabricated that will last a lifetime.

3/. Reassemble handle locking hub and check operation. If wire rods seem to be in the incorrect position, loosen the top plastic fittings where the handle extends from by removing the small self-tapping screws and wiggle things into alignment. (I use a small amount of the grease used for taps to give a smooth action) If all is working well fit the new capped star lock on the hub shaft and tap home. To protect the dome finish I use a large socket from my socket set and an old rubber washer from a toilet cistern. Repeat operation on the other side

I have parts available laser cut metal disks with stainless steel pins, replacement locking rods in stainless steel and capped star lock washers you can contact me at [email protected]

Regards

Steve

How to fix a Bugaboo Handle

If you are not a handyperson type, take these instructions to you local Bicycle Mechanic or Small engineering shop.

The bugaboo handle fault is caused either by two small plastic pins shearing of a plastic disk that actuates two metal locking rods. Why bugaboo uses a plastic disk for this critical component is beyond me! Or a broken locking rod

1/. Remove the capped star lock washer. This is the hardest part of the job. Most people try to leaver this off in the hope of re using. First problem with this is you will mark or damage the surrounding plastic second is star locks are not intended for reuse and will never hold as well as when first used, so best find a new replacement. A hardware store should be able to source some for you. Quickest way to remove a capped washer is to carefully cut a slot in the dome with an angle grinder and then use a large screwdriver to carefully prize one side up so you can fit a screwdriver. Note the walls of the aluminum hub axel are thin and easily distorted, make sure you only lever the capped star lock and not hub axel. Use one screwdriver as a support and another to lift off the capped star lock.

Note it is best to open and repair one side at a time, so your moving and flexing one side of the handle does not dislodge parts in the other side. The hub and disks are mirrors of each other and not interchangeable. The side with the brake lever is left The Bugaboo parts will have an "L" after their serial numbers.

2/. The lock mechanism is very simple; a wire rod rotates a plastic disk. Check the hubs for ware. If too badly worn or damaged you will have too much movement in the locked position. The Frog and Chameleon use the same plastic hub find another frame to salvage hubs from. They are held in by a single aluminum rivet.

The disk has two plastic pins that move the locking rods in and out of the inner hub into and out of the outer hub. You need to either repair the disk by drilling out the pin stumps and finding a replacement metal screw you can fit / glue in. Or (my preferred choice) have a new metal disk fabricated that will last a lifetime.

3/. Reassemble handle locking hub and check operation. If wire rods seem to be in the incorrect position, loosen the top plastic fittings where the handle extends from by removing the small self-tapping screws and wiggle things into alignment. (I use a small amount of the grease used for taps to give a smooth action) If all is working well fit the new capped star lock on the hub shaft and tap home. To protect the dome finish I use a large socket from my socket set and an old rubber washer from a toilet cistern. Repeat operation on the other side

I have parts available laser cut metal disks with stainless steel pins, replacenment locking rods in stainless steel and capped star lock washers you can contact me at [email protected]

Regards

Steve

How to fix a Bugaboo Handle Locking Mechanism

If you are not the handyperson type, take these instructions to you local bicycle mechanic or small engineering shop.

The cause of the Bugaboo handle fault is due to two small plastic pins shearing off a plastic disk inside the plastic hub. This disk activates two metal locking rods. Why Bugaboo uses a plastic disk for this critical component is beyond me. The disk’s two plastic pins move the locking rods in and out of the inner hub engaging and disengaging the outer hub. You need to either repair the disk by drilling out the pin stumps and finding a metal screw you can fit / glue in or replace with a new metal disk fabricated to last a lifetime.


The lock mechanism is very simple; a wire rod rotates the plastic disk that moves the lock pins. Before replacing the disk, check the hubs for wear. If too badly worn or damaged you will have too much movement in the locked position. Both the Frog and Cameleon use the same plastic hubs so you can find an old frame and salvage replacement hubs. A single aluminum rivet holds them and this is easily drilled out.

1/ Remove the domed star lock. This is the hardest part of the job and most people try to lever this off in the hope of reusing. The first problem is you mark or damage the surrounding plastic, the second is the star lock isn’t intended to be reused and will not hold as well. It is best to find a new replacement - normally sourced from a hardware store on indent.

The quickest way to remove a domed star lock is to carefully cut a slot in the dome with an angle grinder and then use a large screwdriver to gently prise up one side high enough so you can fit a second screwdriver underneath without marking the plastic. Note. The walls of the aluminum shaft the hub rotates on are thin and easily distorted, make sure you only lever the domed star lock and not the shaft. Use the first screwdriver to support the second screwdriver as per photo.





Note it is best to open and repair one side at a time, so the moving and flexing one side of the handle does not dislodge parts in the other side. The hub and disks are mirrors of each other and not interchangeable. The side with the brake lever is left; the Bugaboo parts will have an “L” after their serial numbers.



2/ Reassemble handle locking hub and check operation. If the wire rods seem to be out of position, loosen the top plastic fittings where the handle extends from by removing the small self-tapping screws and wiggle things into alignment. (I use a small amount of the grease used for taps to give a smoother action) If all is working well fit the new star dome on the hub shaft and tap home. To protect the dome finish I use a large socket from my socket set and an old rubber washer from a toilet cistern. Repeat operation on the other side.

I have available kits with (left & right) laser cut metal disks with stainless steel pins and two new star dome locks. Cost is $150 New Zealand plus shipping. If you would like a set, my contact email address is below.



Regards

Steve
Email: [email protected]