General Engines Co. Sewell NJ.
Cycle Chair Manufactured 1970   ?   ¿

Home Page   |   Bottom   |   December 21   |   December 22   |   December 23   |   December 27
photo01

The image above and the text below, have been copied without permission from the internet.
Unedited.

That is a General Engines Cycle Chair from the 1970s. They were heavily advertised in the back of Popular Mechanics magazines. Here is one of their ads. The Cycle Chair's electric motor is 24 Volts and although the Watts of the motor is not mentioned by the manufacturer or written on the motor itself, by looking at it (we have a couple of them here in our shop) I can tell from its size and lack of ventilation holes that it is around 500 Watts continuous duty. It would be safe to use a 24 Volt 500 Watt controller on it for continuous use. A 24 Volt 1000 Watt controller could also be used with it as long as the tricycle was not used going up hills at full power all of the time. With a 1000 Watt controller more power could be had from the motor for momentary uses such as getting up steeper driveways and ramps, however I would not recommend a 1000 Watt controller for full power use going up long hills, as it might overheat the motor. If the trike will just be used at around walking speed on mostly flat ground then a 1000 Watt controller will be fine though. Either way, with a 500 or 1000 Watt controller the trike will run great though.

The images below and the information included is the result of my rebuild and reconstruction of the Cycle Chair I found on Kijiji and was lucky enough to purchase.
December 21 2022

photo02

December 21 The Cycle Chair in the barn where I first seen it.

photo03

This is a view from the side, very rusty and had been exposed to moisture for several years.

photo04

December 22 photo taken at my home where I intend to refurbish the Cycle Chair.

photo05

Logo on the side of the chair.

photo06

Front wheel drum brake. No brakes on the back wheels.

photo07

December 22 Logo on the front of the tree.

Home Index Page   |   Bottom   |   Top
photo08

The 12 volt sealed beam headlight will be replaced with a LED style I purchased many years ago.

photo09

The seat back rest cushon is still there but the seat cushon is missing.

photo010

The steering handle has the speed control and the front brake lever.

photo011

Below the seat on each side are the battery boxes.

photo012

The tail light and the back cover are missing.

photo013

December 23 The Cycle Chair Logo on the seat back.

Home Index Page   |   Bottom   |   Top
photo014

December 23, now in my work area where I will disassemble and start the rebuild process. The trike is flipped upside down for better access to components.

photo015

I wanted to remove all the wiring, switches, control box and relays without disconnecting.

photo016

The black box mounted on the side is the speed controller and the relay is the foward and reverse controller.

photo017

The 24 volt DC motor belt drive to the jack shaft.

photo018

Battery box on the right and the driver motor on the left.

photo019

Here you can see the driver motor pulley driving the larger pulley on the jack shaft. It appears to me the motor pulley is a "B" width and the belt is an "A" . The pulley on the motor is a 2 ¼ " and the larger pulley on the jack shaft is a 9 ".

Home Index Page   |   Bottom   |   Top
photo020

All wiring and controls have been removed.

photo021

The motor has been removed. Next is to remove the rear axels and the differental, there is a split collar on the hub that holds a ¼ " spring pins .The axel shaft has a hole the matches the hole in the hub of the differental, this is unique, simple but yet efficient.

photo022

Here is the removal of the spring pin which allows the differental hub to connect to the axel, there are shimms to align the differental between the axel bearings.

photo023

A photo of the drive belt JASON 4L - 380 38" and ½ wide. you can see I had flipped the belt over to show the condition how the belt is worn and cracked. December 29 2022 purchased replacement V bely from Peavey Mart $4.39 plus 15% taxes.

photo024

A 60 tooth number 35 roller chain sprocket bolted to the differental and the spacers tied with a wire so I dont loose them. The smaller sprocket on the jack shaft is a 15 tooth.

photo025

flipped over you can see how the sprocket is bolted to the differental also spacers attached by wire so I dont loose them. The sprocket is in excellent shape showing very little wear

Home Index Page   |   Bottom   |   Top
photo026

The bolts that hold the battery boxes in place were carrage bolts and rusted so badly I used my Dremel to cut the threaded portion then cut the but so it could be split and removed.

photo027

December 27 All wiring, relay, control box, light have been removed but still intact so if necessary I can trace back the circuits if needed.

photo028

All three rims are rusted badly and the metal pitted, I will sand the best I can then paint the rims. December 29 2022 Purchased Grey Paint Peavey Mart 946 ml $34.99 plus 15 % taxes.

photo029

This is a close up view, The rims are heavy metal and sturdy but the chrome is almost all gone.

photo030

This decal is on the floor close to the front and explains the operating procedure.

photo031

The same decal but the right hand side explaning the charging procedure.

Home Index Page   |   Bottom   |   Top
photo32

The Cycle Chair logo on the side of main body frame.

photo033

Pedal Power Electric logo on the front steering tree.

photo034

Close up of General Engine Co. information.

photo035

I don't believe the company is still in business.

photo036

This is a close up of the rear axel bearing, (GENBERCO) there are 4 and are press fit into the rear axel housing. Outer flange is 1 ½" outside Diameter 1 3/8" with a inner race diameter of ¾"

photo037

A photo of the large 60 tooth sprocket the differential the locking pin and the split locking collar. The ¾" axel will fit into the hub on the differental then slip the pin through the collar and shaft then place the split locking coller over the pin and hub and tighten the allen cap screws, very simple method.

Home Index Page   |   Bottom   |   Top
photo038

A photo of the bearing and flange that secure the jack shaft to the side walls of the frame. These are off the shelf replaceable items. 2 bearings and 4 flanges all in good shape.

photo039

This pulley fits on the motor shaft ½" bore and 2 ¼ O.D. its a B should be a A width. The drive V belt ia an A width.

photo040

The differential felt a little stiff so I thought I would check the grease.

photo041

The grease was dried up and stiff like peanut butter.

photo042

This is a close up, a little blurred but I think you get the idea.

photo043

After cleaning and washing the gears and shaft everything looked very good shape and little wear. I was very happy to see the condition, I replaced the grease with silicone teflon high temperature and will not run, drip, or leak.

Home Index Page   |   Bottom   |   Top
photo044

The motor ready for painting, the day, month, year ? . or month, day, year, any way the cycle chair is supposed to be a 1970 so 86 would be the year. bearings are good, I did not take it apart for inspection.

photo045

The original pulley was a "B" size which let the belt ride a little lower in the scheeve . I replaced the pulley with a "A" width pulley.

photo046

The Aluminum frame with all decals, dirt and paint removed.

photo047

.

photo048

.

photo049

.

Home Index Page   |   Bottom   |   Top
photo050

.

photo051

.

photo052

I installed the motor and drive components.

photo053

.

photo054

This is a close up of the split collar that hold the drive pins in place.

photo055

I cleaned and lubricated the original number 35 roller chain.

Home Index Page   |   Bottom   |   Top
photo056

I didn't notice this before ? a serial number stamped into the frame.

photo057

Rather difficult to read so I wrote it on with pencil 35 72 853. It may mean the unit was built March 5 1972 and was the 853 unit built.

photo058

This piece of ½" plywood will go under the battery in the battery box.

photo059

I needed a box to place the electronic speed controller, so I carved out the inside of this Dremel case.

photo060

The components ready to be secured in place.

photo061

I installed the double pole single throw switch as a total power disconnect switch, top left hand corner.

Home Index Page   |   Bottom   |   Top
photo062

This is component box is 6" by 2" by 2" and mounted on the handle bar.

photo063

A schematic drawing of the electrical layout.

photo064

I ran a 24 conductor cable through the frame tubing from the Dremel box to the steering tree. This will protect the cable from being damaged.

photo065

The handle bar control box. I made a laminoid plate to identify the switches and controls.

photo066

The under side of the control box. Ya, I know there are too many switches but I installed them anyway.

photo067

The speed controller is all connected to the handle bar control box. The RED and BLUE wires are the connection between the two batteries as a series connection, now connected with a bolt, there will be a fuse installed here

Home Index Page   |   Bottom   |   Top
photo068

From Left to Right, Key lock switch, difficult to see in this photo, Rocket Launch, ON = OFF, IGNITION , ON = OFF, LIGHTS, ON = OFF, FORWARD, NEUTRAL, REVERSE, and HORN push Button. The speed control potentiometer is on the Right, difficult to see.

photo069

The first TEST RUN, and everything works, GREAT. January 12 2023 in front of our home.

photo070

Rear fenders not installed yet.

photo071

.

photo072

The circumference of the rear tire is 66" and the RPM at full speed while on jack stands was 190 RPM, this may be faster than original because I changed the drive pulley on the motor from a B width to an A width, the belt rides higher on the pulley.

photo073

The two 12 volt batteries are used ones I had sitting around, they hold a charge but will be replaced with new in the spring.

Home Index Page   |   Bottom   |   Top
photo074

The back cover and tail light were missing, however I made a new cover and will install a headlight and tail light later.

photo075

.

photo076

.

photo077

.

photo78

.

photo079

.

Home Index Page   |   Bottom   |   Top
photo080

.

photo081

.

photo082

.

photo083

.

photo084

.

photo085

.

Home Index Page   |   Bottom   |   Top
photo086

.

photo087

.

photo088

.

photo089

.

photo090

.

photo091

.

Home Index Page   |   Bottom   |   Top
photo092

.

photo093

.

photo094

.

photo095

.

photo096

.

photo097

.

Home Index Page   |   Top