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Repair and Battery Upgrade for Gen 1 Tyre Pressure Monitoring Sensors

Eddie Green

Tricycle
Forum Subscriber
My tyre mechanic did it again, properly broke the sensor case, circuit board and valve stem! These are the 1st generation sensors with a battery that is replaceable and I wanted to keep these alive rather than fit 2nd gen sensors.

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As you can see, the positive terminal is broken away on the board, I've re-engineered a solder point for the positive rail on the board.

I'm posting my modifications to the sensor which I have just completed. This comprises of a replacement battery holder that does not require soldering the battery, and a robust nylon enclosure closely matching the shape of the original.

The width of the enclosure has been increased from 23.6mm to 28.3mm to accommodate the size of the battery board and also to provide a 2mm wall thickness for added strength.

It's designed as a repair or an upgrade to the OEM sensor module, where the original board, if it's still functional, is removed and the battery terminals on the board are de soldered and replaced with 24AWG flexible silicone wire with ring terminals to attach to the battery holder. The enclosure lid is held down by screws that also anchor the two circuit boards and complete the battery circuit. The original sensor standoff and spring are required for re-fitting to the wheel.

This is the battery holder:

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The following images show components and the assembly detail:

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The components required are in production at the moment. I've ordered enough 3D prints and circuit boards to make six units so will have spare sets to make available to people who would like to perform the upgrade.

I'm also waiting on 8.3mm right-angled valve stems which will complete the project.

I'd be interested to know whether it is worthwhile producing these as a kit, so let me know your views.
 

Tim R

Moderator
Staff member
Member
If it were mine, I would send it to Fred Harmon. He sells the maintenance tapes/Disk. He has the equipment to make sure the sensor is working after battery replacement. And it is worth it to me anyways to just send it to him. Quick turn around on my 1st gen sensors. Sorry guys I don't think he is doing the 2nd gen sensors.

I think I would find another mechanic. When I have tires changed I remind the shop these have sensors just like the Goldwing's do. They always go Ahhhhh.
 

jwh360

Member
Member
Looks good Eddie. The right angle valve stems would be a major improvement as well. Do you have an idea on pricing for the kit?
 

TireguyfromMA

Member
Member
Impressive work there! Just curious...do you know how many grams one of these weigh with the right angle valve stem on it?
 

Conrad

Street Cruiser
Forum Subscriber
If it were mine, I would send it to Fred Harmon. He sells the maintenance tapes/Disk. He has the equipment to make sure the sensor is working after battery replacement. And it is worth it to me anyways to just send it to him. Quick turn around on my 1st gen sensors. Sorry guys I don't think he is doing the 2nd gen sensors.

I think I would find another mechanic. When I have tires changed I remind the shop these have sensors just like the Goldwing's do. They always go Ahhhhh.
Have you examined what Eddie has done above? I believe that he's a bit beyond what Fred does here.
 

Tim R

Moderator
Staff member
Member
Yes, I saw that. Eddie has come up with a good plan but is still in development. But in the mean time Fred is most likely available to make repairs and knows more about the sensors than most think or know. Fred has the equipment to make sure the sensor is transmitting. I would hate to go through getting a sensor off the wheel fix it and reinstall. Then find out there was something else that caused the sensor to fail.

A while back I managed to hit a rather deep pot hole. It took both sensors out and I thought I had bent a front wheel. Turns out I threw a wheel weight and Fred got both sensors working again.
 
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