The install steps shouldn’t be too involving. It will be comprised of 4 components, these being:
- Headlamp with 3 wire conductor to a BLS housing.
- Handlebar momentary switch with 2 wire conductor to a BLS housing.
- Handlebar battery pack with a 2 wire conductor to a BLS housing.
- BLS housing jumper.
I’ll need to make a few modifications to the headlamp and battery pack. The jumper will need to be made. The handlebar switch will be the easiest part of it, all I need to do is put a BLS connector on it. Here’s a detailed breakdown of what needs to be done.
- Handlebar momentary switch is mounted already, all that needs to be done is crimp a BLS housing on the 2 wires from the switch.
- The handlebar battery pack will need to be attached to the handle bars somehow. I envision it being underneath the stem bar that mounts the handlebars in place. It will be least noticed there and should help it keep dry. I’ve got the usual options of velcro, electric tape, or zip ties to choose from for fastening it in place. I’ll need to replace the current 2 wire conductor and put a BLS connector on the end.
- The headlamp will need to be modified. This means I’ll need to solder 3 wires to the circuit board housed inside the headlamp. The headlamp circuit board is different, so I’ll need to verify that the switch is grounded. I’ll also need to install a 3 wire conductor with a BLS housing on the end. Lastly, I’ll be wrapping the front of the lamp with black electric tape. The reason for this is to help cut down on glare to other riders.
- The jumper housing will just be a way to connect the BLS housings from the above 3 devices. This will then be heat shrunk to protect it from moisture and to make it look better.
Once everything is in place, loose wires will be taped to surrounding cabling and wiring to tidy up the look. If all goes well, toggling the switch will cycle the headlamp through its various operating modes.
Next up, installation of the new system.