Question about Bugaboo Cameleon Jogger

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I cant fold my bugaboo cameleon chasis. how can i open the silver cap on the side to take it apart?

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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.

I cant fold my bugaboo cameleon chasis. how can i - macnutz_20.jpg

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.
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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.I cant fold my bugaboo cameleon chasis. how can i - macnutz_22.jpgt operation on the other side

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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

Posted on Nov 23, 2010

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hi
i would advise against you doing this yourself as they are starlock caps and are easily damaged

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