1. By following these FREE DIY BYO plans you agree to not operate this pedal power generator around small children or any individual who might stick their fingers in the wheel, chain, sprocket, or belt while it is moving.

2. You also agree not to allow anyone near this bike generator with long hair or loose clothing that could possibly get it stuck and pulled in to the belt / chain / wheel assembly while being operated and cause injury or death.

3. Also, By following these steps, you assume all liability and responsibility for owning and operating you own pedal power bicycle generator.  You also agree to have a licensed electrician check over your assembled unit to make sure you have not wired up something up incorrectly BEFORE you hook it up to any kind of high power devices such as battery packs or lead acid batteries.  Also, before you charge a Powerpack with your pedal power bicycle generator, you will read and understand the safety section of the owner's manual. 

4. You also agree to send me a photo of your final project to share with others on this web page.

MOUNT THE BLOCKING DIODE

• Remove wire box from PMM permanent magnet motor / generator housing

• Remove two knock out punches on wire box.  (see video)

• Install cord grip fitting

• Install blocking diode and loosely tighten locking ring

• put wire box back onto PMM / Generator housing

• Tighten retaining ring

• Use wire not to connect the Anode of the blocking diode to the positive output from the PMM / generator

• Route negative wire from PMM / Generator out of the wire box through the cord grip connector

• Install the lid on the wire box

MOUNT GENERATOR ASS.

 This step will involve you mounting your pm motor / generator assembly to the trainer adapter plate.

WIRING PART 1

Solar Panel Input Box                         Diversion Load Output Box

• Mount the diversion load box and the solar power input box and the NC25A Charge Controller

• Use crimpers to crimp  a 3/8 ring terminal onto the Negative Generator Output Wire

WIRING AND CRIMPING PART 2

• Route and form the red wire from the solar panel power input box behind - up - and over to the charge controller

• Trim this wire to the correct length, strip it, and insert it into the far left terminal on the NC25A charge controller with the label "Power connections INPUT +"

• Use a flat screwdriver that has a width of 1/8" to tighten the screw terminals

• Make sure and do the tug test on the wire to make sure it does not slip.  It is better to find out now that you have a bad connection instead of later. 

• Grab and combine three ring terminals connected to the three black wires onto the negative bolt stud. Put the star washer in between two of the terminals.  one wire is coming from the negative side of the generator, the other wire is coming from the solar power input box, and the third wire is coming from the diversion load box.

• Expose 1/2 of thread on the negative lug bolt.  Screw the lug bolt into the pre-drilled and tapped hole located at the end of the bike trainer adapter plate.

• Once 1/2" of the lug bolt has entered, use a 9/16 wrench to tighten the first jam nut against the adapter plate. It should be very tight so that you can't move the bolt with your fingers. 

• Now back down the 2nd jam nut so that it compresses the 1st jam nut, and use the 9/16 wrench to tighten very snug. 

• Remove the resistance training wheel off of your Bell Motivator or Ascent  trainer stand.

• Mount the trainer adapter plate in the same spot where you took off the resistance wheel.

REMOVE REAR TIRE

• Remove the air from your rear tire by using a pressure relieve style pressure gauge or using a small screw driver or nail (see video). 

• Release your rear brake cable so that the break pads open up wide and allow you to remove the rear wheel.

• Now that the tire is completely flat and removed from the frame, use the tire levers to remove the rear tire from the rim.  (see video for more details)

• Remove the tube and the thin rubber band that runs all around your rim covering the ends of your spokes.  If you don't take this off, it will break and get tangled in the pedal power bike generator drive belt.

• Now that the rear tire is off of the rim,  install the rear wheel back onto your bicycle frame. 

INSTALL REAR WHEEL RIM

After your tire is off and your rear wheel is mounted back onto the bike frame, mount your bike into the trainer stand.  (see video)

INSTALL PULLEY & POWERTWIST BELT

• Turn the shaft of the permanent magnet motor / generator until you find a flat spot.  This is where the set screw of the pulley must land and be tightened.

• Before attempting to slide the pulley onto the shaft, look through it at a light and verify that the set screw is fully backed out and not protruding.  If it is sticking out in the slightest, it may catch on the end of the generator shaft and keep you from sliding it on.  Use an allen wrench to back the set screw out.

• Now install the pulley mentioned above.  Do so without tightening the pulley set screw too tight so that you can adjust the pulley position later in the procedure.

• Next you need to install the red adjustable length  V-belt shown to the left. If you order from Grizzly hardware through Amazon.com , you will need two of these belts because one belt is only 5 feet long which is not going to be sufficient for your needs.   The first thing to do is to combine the two adjustable V-belt Powertwist  belts into one belt that will be 10 feet long.   Then wrap the belt around the rear wheel and then around the pulley of the generator.  Estimate a length of the belt that will provide proper drive tension.  Use a pair of needle nose pliers to gently twist the little tab located at the end of the particular link that you have chosen as your belt break point.  Once you twist the tab on the end of the link, it will slide out of the notch that it is residing in and you will be able to re-attach it so that it forms a nice belt that goes around your rear wheel and generator pulley. 

SET CHARGE CONTROLLER VOLTAGE

 TESTING YOUR GENERATOR SYSTEM