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My theory is that the leads of the peizo cell (if not soldered snugly) will stretch. Or the retaining sides rub against the housing which wears them down. The net result is the same. Eventually the metal cube sticks against the outer housing.

The fix is simply to unsolder the cube leads, snug them up making sure the cube does not protrude past the side retainers. You may also choose to use a small grinder to grind off a small part of the metal cube that is touching. That's it.

If you do this be very careful not to damage any of the circuit. But more importantly when you remove the whole black plastic sensor from the metal band that holds it to the wheel be very careful bending the metal tab that holds the sensor in place.

Bend it just enough to clear the tab. Do not bend the band itself. Just the little tab on the band. Also, I used a bit of loctite on the screw that holds the band in place just to make sure it does not loosen up.



To begin with, notice the white powdery substance in the plastic sensor housing. This is pulverized black plastic.Note the scored or scraped pattern



This is the top of the power generating unit.It is a plastic housing with a metal cube in

the middle. The metal cube is attached to a peizo cell. This cube is intended to vibrate between the two black plastic retainers as you drive..

The problem occurs when the metal cube moves far enough down between the two black retainers to make contact with the outer housing (see photo 1) to touch.

When the metal cube touches the outer housing (photo 1)  then the movement is restricted resulting in a failure to build enough stored energy in the cap to send the RF signal.The above photo shows the part that rubs on the right. The part on the left does not touch.

Here you can see that one side of the metal cube does not touch.

Here is a good shot of the top which clearly shows that part was rubbing.

Again another shot of the top showing the part that rubs.

Author: Scott Fabre
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