Boogie Actuator Repair Guide

Fixing a Loose Magnetic Encoder Disc

The Boogie uses a 24V actuator for steering. Inside the actuator is a motor, gearbox, and a magnetic encoder. While generally reliable, a few units have developed issues over time—most commonly, the magnetic disc on the encoder comes loose. This can cause calibration failures or drifting during operation.

Fortunately, the fix is straightforward and only requires basic tools and some 2-part epoxy.

Tools Required

• Phillips screwdriver

• 10mm socket

• 4mm Allen key

• Flat-head screwdriver

• Isopropyl alcohol wipes

• 2-part epoxy

Removing and Opening the Actuator

1. Open the zip of the Boogie fully.

2. Remove the 10mm bolt from the end of the actuator.

3. Undo and remove the barrel nut connecting the actuator to the steering arm.

   Do not remove or loosen the steering arm itself.

4. Lift the actuator out of the Boogie and place it on a towel.

5. Remove the three Phillips screws at the rear of the actuator.

6. Use a flat-head screwdriver to carefully separate the rear section of the case only.

Securing the Magnetic Disc

1. Check for movement in the magnetic disc by gently rotating it with your fingers.

   If it moves, this is likely the source of the problem.

2. Use the 10mm socket to gently press the disc fully onto the shaft.

   The disc is brittle—press evenly and carefully to avoid damage.

3. Clean the disc and shaft using isopropyl alcohol wipes.

4. Prepare the 2-part epoxy according to the instructions.

5. Apply a small amount of epoxy to bond the magnetic disc securely to the shaft.

6. Ensure the sensor is correctly aligned—it should not be bent and should sit close to the disc.

Reassembly and Testing

1. Reassemble the actuator, reversing the steps above.

2. Once the rear cover is secured with the three screws:

   • Turn on the Boogie

   • Confirm the issue is resolved and the actuator calibrates correctly.

3. Optionally, mark the piston’s center position, steer left and right several times, and verify it returns to center without drifting.

4. Reinstall the actuator into the Boogie.

   Do not overtighten the 10mm bolt.