Question about Bugaboo Cameleon Jogger
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 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!
1/. Remove the domed 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 dome washer is to carefully cut a slot in the dome with an angle grinder and then use a large screwdriver to prize off.
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.
2/. The lock mechanism is very simple; a wire rod rotates a plastic disk. 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 ether 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. (I use a small amount of the grease used for taps to give a smooth action) If all is 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.
4/. Repeat operation on the other side. Note the disks are mirror images of each other and are not interchangeable. Bugaboo calls the side with the brake lever “LEFT” the disk will have a serial number that ends with “L”. I have had metal disks laser cut and stainless steel pins fitted. Cost of a disk with a new star dome washer is $75 New Zealand. If you like one or a set, you can contact me firstname.lastname@example.org
Posted on Aug 01, 2010
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Posted on Jan 02, 2017
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