Before working on your Optibike always turn off the main power switch located on the battery.
Tools in this guide
- 2.5mm Allen/Hex Wrench
Components in this guide
- M3 x 35mm Bolt (3x)
- M3 x 16mm Bolt (4x)
- Blank Cover, 1/4″ ID (4x)
- Mounting clamps (2x)
- Headlight back shell
- Headlight main body
- Adapters for smaller bars [needed on some handlebars only] (2x)
Install back shell and clamps
Depending on which handlebars you have, you may need the adapters to fit the smaller bar diameter.
If the back shell isn’t a snug fit on the bar you’ll need to fit the adapters to the handlebar first. You can do this by pulling the adapter apart and fit it over the handlebar.
Place the back shell on your handlebars with the half-circle holes on the bottom, and use the clamps and bolts to lightly secure it for now.
Insert connectors and route wires
The connectors are push-fit into the housings with a small amount of force. There is text on the circuit board indicating what each connector is used for.
- THR – Throttle, located on the handlebar
- Display – Display, located on the handlebar
- Speed – Speed Sensor, located on the front fork
- Tail – Taillight wire, follows the large main cable into the frame
- Other connections are for future use, and are not used now.
Wire routing is meant to cross over to make it easier to assemble (photos below showing an example).
Orient the headlight body roughly how it will mount on the bike to get an idea of how the cables will run, it’s easy to tangle the cables up so spending a minute to familiarize yourself helps a lot.
Start with the large 15-pin connector first.
Then add the other smaller connectors, and seat the grommets into the cutouts.
Finished connections. You can install the blank covers now, or wait until later.
Assemble main body to back shell
Take the main body, and starting with seating the grommets at the bottom, mate to the back shell of the headlight.
Bolt the main body to the back shell using the longer bolts. These do not require much force to tighten.
Check on the bottom that none of the grommets have shifted and fallen out.
If you waited to install the blank covers, you can do that now, they snap in easily.
Check alignment and tighten
When sitting on your bike the headlight should be aimed straight forward, flat with the ground. This will give you a decent starting point that you can tweak after a test ride.
Once adjusted tighten the clamps on the handlebars, these don’t need much force to tighten down. If you notice the headlight shifting while riding you can tighten the clamps more.
When tightening the clamps check the gap on the bottom and top of the clamps, it should be a similar gap size.