How to fix a Bugaboo Handle
If you are not a handyperson type, take these instructionsto you local Bicycle Mechanic or Small engineering shop.
The bugaboo handle fault is caused by two small plastic pinsshearing of a plastic disk that actuates two metal locking rods. Why bugaboo uses a plastic disk forthis 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 reusing. First problem with this isyou will mark or damage the surrounding plastic second is star locks are notintended for reuse and will never hold as well as when first used, so best finda new replacement. A hardwarestore should be able to source some for you. Quickest way to remove a dome washer is to carefully cut aslot in the dome with an angle grinder and then use a large screwdriver tocarefully prize one side up so you can fit a screwdriver. Note the walls of the aluminum hub axelare thin and easily distorted, make sure you only lever the Domed Star Lock andnot hub axel. Use one screwdriveras a support and another to lift off the Domed Star lock.
Note it is best to open and repair one side at a time, soyour moving and flexing one side of the handle does not dislodge parts in theother side. The hub and disks aremirrors of each other and not interchangeable. The side with the brake lever is left The Bugaboo parts willhave an "L" after their serial numbers.
2/. The lockmechanism is very simple; a wire rod rotates a plastic disk. Check the hubs for ware. If too badly worn or damaged you willhave too much movement in the locked position. The Frog and Chameleon use the same plastic hub find anotherframe to salvage hubs from. Theyare held in by a single aluminum rivet.
The disk has two plastic pins that move the locking rods inand out of the inner hub into and out of the outer hub. You need to either repair the disk bydrilling 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/. Reassemblehandle locking hub and check operation. If wire rods seem to be in the incorrect position, loosen the topplastic fittings where the handle extends from by removing the smallself-tapping screws and wiggle things into alignment. (I use a small amount ofthe grease used for taps to give a smooth action) If all is working well fit the new star dome on thehub shaft and tap home. To protect the dome finish I use a large socket from mysocket set and an old rubber washer from a toilet cistern. Repeat operation on the other side
I have available kits with two (left & right) laser cutmetal disks with stainless steel pins fitted and two new star dome washers. Cost is $150 New Zealand plusshipping. If you like a set, youcan contact me [email protected]
Regards
Steve
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