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.
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.
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 $160 New Zealand plus shipping. If you would like a set, my contact email address is below.
Email: [email protected]