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DIY Plug-In Hybrid Car

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Step 4: Remote Start

One neat feature on this generator is that it has a REMOTE CONTROL PANEL connection on it. That panel is an option for this generator, which allows you to turn the generator on and off from the front of the RV. It also supports an "ON" indicator light and an hours meter.

However, I didn't want to spend money on a special order RV part, (you wouldn't believe how much money they want for it....) and I really just need to be able to kick the generator on.

Fortunately, the repair manual has the schematic for the remote control cable.

By grounding the proper pin on the remote cable, the generator will kick on the starter.

I ran a 14 ga wire from the spice off the ignition to a 12V relay. The leg opposite of that goes to ground (the car body.) When I turn the key the relay is activated. The other two pins on the relay are the wire from the remote cable, and also the ground. When the relay connects the remote cable wire is grounded, and the starter is remotely activated.

A new battery power cable needs to be run to the generator for the electric start. This will provide the 12V+ cranking power for the starter. The 12V negative is through the frame of the generator to the frame of the car, and back to the 12V accessory battery.
The cable needs to be heavy enough to support the amperage required for starting. Since this is only a 220cc single-cylinder engine, I can use lighter cable than would be required for a typical car engine. I looked at the cable on the generator that goes from the starter solenoid to the starter. It was 6 gauge. I used the same weight cable to run 12V power from the battery in the front of the car to the rear of the car, up through one of the drain plug holes in the spare tire well (through a rubber grommet) and to the starter solenoid.

Another great thing about this generator, is that it has a 12V charging circuit. After the generator is running, it charges the 12V battery used to run the starting motor. In my application, this is really handy. On my EV conversion, there is NO ALTERNATOR to charge the battery (because there is not engine to run the alternator.) Nor is there a DC/DC Converter - a device that converts one level of DC electricity to another - for example, 72 volts from the main battery pack to 12V for the headlights, radio, etc. Instead, I simply had a small 12V charger right on the battery. It would trickle charge the 12V battery while the car was plugged in. Most of the time, this was fine. But in cold, dark, winter weather, the 12v battery didn't always perform as well as I would want it to. (For example, dimmer headlights than I would want.)

Now, the generator will take care of the charging the 12V battery. 
 
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