Maximum integration is the stated goal of the Supernova Starstream Mini Lightbar. This component combines a handlebar and front light in one for ebikes. Especially for e-mountain bikes, which bicycle manufacturers often design without lights, this ingenious solution from Supernova and Ergotec appears to be a useful accessory. Its installation should be feasible for many of you at home.
1. Does the Supernova Starstream Mini Lightbar fit on your ebike?
2. What do you need to retrofit the Supernova Starstream Mini Lightbar?
3. Installation of the handlebar
1. Does the Supernova Starstream Mini Lightbar fit on your ebike?
Before you decide for or against the Supernova Starstream Mini Lightbar, there are three questions to answer:
- Is your ebike’s motor system compatible with this front light?
- Do you need the Ergotec stem – or a suitable alternative – on your ebike, or can you use the one you currently have?
- What is the diameter of the current handlebars on your ebike?
Is your ebike’s motor system compatible with this front light?
The Starstream mini headlight operates at a voltage of twelve volts and requires a peak power of eleven watts. Numerous common ebike systems meet these requirements. Nevertheless, it is better to check in advance whether this also applies to your ebike.
Do you need the Ergotec stem – or a suitable alternative – for your ebike, or can you use the current one?
Supernova recommends the Ergotec Bass SM stem. This is a stem for an Ahead headset, which is found on most ebikes today. The stem features a 35-millimetre-wide opening at the front, measures 45 millimetres in length and has a zero-degree angle. It is available for handlebars with a diameter of 28.6 millimetres and 31.8 millimetres. Its height at the steerer tube is 40 millimetres. If you have been using a higher stem, you may need additional spacers for the stem.
Regardless of the dimensions, the design of the stem also determines whether the Supernova Starstream Mini Lightbar can be mounted on your ebike. Units consisting of a stem and handlebars are generally not suitable – unless you want to remove them completely. Special stems, such as the e*thirteen Plus 35, are also unsuitable. They lock directly into the spacers below with small nipples and can only be replaced by a stem based on the same principle. Also consider whether you really want to replace a rather high stem with several degrees of positive rise. The riding position with the Ergotec Bass SM will be significantly lower and slightly more stretched out.
What is the diameter of the current handlebars on your ebike?
If it is 35 millimetres, for example, you may need different clamps for parts such as an ebike display or a smartphone holder. If, on the other hand, you already use handlebars with a diameter of 28.6 millimetres or 31.8 millimetres, everything can remain as it is.
2. What do you need to retrofit the Supernova Starstream Mini Lightbar?
If you’ve decided to swap your current handlebar for the Supernova handlebar with integrated light, you’ll need the following parts:
- Supernova Starstream Mini Lightbar
- Stem: either Ergotec Bass SM, a suitable alternative or your current stem
- Cable for connecting the front light to the ebike motor: either Supernova Power Connector Cable for Bosch Smart System or Supernova Power Connector Cable with open ends
3. Installation of the handlebar
The following description refers to a setup in which a current Bosch Performance Line CX from the Bosch Smart System is installed in the ebike. In addition, the stem and clamp for the ebike display must be replaced.
3.1 Switch off the ebike and remove the ebike battery
Whenever you replace or add hardware to the ebike system, it is advisable to switch off the drive and remove the battery. This ensures that you remain unharmed while working on the electronics.
3.2 Route the light cable through the frame and connect it to the ebike motor
Manufacturers such as KTM sometimes route a front light cable leading to the motor through the frame ex works. This should usually have open cable ends. Depending on the ebike system installed, you could connect this to the Power Connector Cable from Supernova.
If your ebike is based on a drive system from Bosch’s Smart System generation, a cable already in the frame is superfluous. However, you can still use it. After all, it is already laid. It therefore makes sense to use the cable as a useful aid and to feed the actual Supernova Power Connector Cable for Bosch Smart System through the frame with it. To do this, wrap one end of the cable in the frame with a flexible wire. The other end of the wire is also wrapped around the plug for connection to the ebike motor when you pull the cable from the stem to the motor through the frame. If you do the opposite, wrap the wire around the connection socket for the Supernova Starstream Mini Lightbar light plug.
If there is no cable pre-installed in the frame, wrapping one end of the Supernova Power Connector Cable can still make your work easier. The wire is more likely to find its way through tight spaces than the thicker cable. If the wrapping holds, you can then carefully pull the cable through.
Once everything is perfectly in place, plug the blue connector of the Supernova cable into the matching blue-rimmed light port on the motor.
3.3 Remove the existing handlebars
Before removing the stem, it is advisable to remove the handlebars. To do this, remove the handlebar grips, shifters, brake levers, seat post levers and similar parts. Then loosen the screws on the stem cap and pull out the handlebars. If simply loosening the screws is not enough, remove the cap completely.
3.4 Remove the existing stem
You have removed the previous handlebars. Now, in our case, it is time to remove the existing stem. To do this, loosen the stem bolts and then remove the screw from the top cap. Now the stem can be pulled off the steerer tube.
3.5 Fitting the new stem
Now fit the new Ergotec stem onto the steerer tube. As mentioned above, you can also use a suitable stem from another manufacturer. The height at which the stem sits on the steerer tube depends on whether you place spacers above or below it and, if so, how many. In the end, the spacers or stem should protrude two to three millimetres above the steerer tube. This ensures that the top cap has the necessary hold in the star nut or expander plug. Once the distance is correct, insert the top cap screw and tighten it by hand. Do the same with the stem bolts. The final adjustment is made after the handlebars have been installed.
3.6 Inserting the new handlebars
To insert the Supernova Starstream Mini Lightbar, remove the cap from the stem or loosen it until the Supernova handlebars can be easily inserted. When tightening the cap, you can already align the handlebars with the headlight so that the light cone falls as centrally as possible in front of the front wheel. We will activate the light later for fine adjustment. Before doing so, you can first reattach the components removed from the previous handlebars, such as handlebar grips, shifters, brake levers, etc.
In our case, switching to Supernova handlebars also requires replacing the clamp for the ebike display. Previously, the Bosch Purion 400 was mounted on handlebars with a diameter of 35 millimetres. Its clamp is now significantly too large. Fortunately, Bosch offers the clamps individually, so we only need a new mounting bracket that fits the 31.8-millimetre diameter and do not need a new display.
3.7 Finally connecting the handlebar to the ebike system
Now you have reached the point where the headlight can be connected to the ebike system. To do this, plug the headlight’s light cable into the Power Connector Cable connected to the motor. Make sure that the plug and socket are aligned centrally with each other. Otherwise, the gold contact in the plug could bend. You definitely want to avoid this.
After you have reinserted the battery into the ebike and activated the system, in some cases the light will come on immediately. If this is not the case, press the corresponding button on the display or the control unit.
3.8 Aligning the headlight
One of the most important points when mounting the headlight is to align it correctly with the road. Supernova provides precise recommendations for this so that no road users are dazzled by the headlight. To make the correct adjustment, proceed as follows:
- determine the distance from the top edge of the headlight to the ground
- permitted height between 400 millimetres and 1,200 millimetres
- subtract 70 millimetres from the measured height
- mark the result on a wall two metres away from the headlight
- position the bicycle so that the wall is illuminated at a 90-degree angle and the correct distance from the wall is maintained
- loosen the stem cap slightly until the handlebars can be turned
- align the upper light-dark edge of the headlight with the mark by turning the handlebars
- tighten the stem cap in this position
3.9 Tighten all screws on the handlebars, stem, levers, grips, etc.
Finally, all that remains is to check that all parts on the handlebars and stem are in the desired position and securely screwed back in place. It is best to use a torque screwdriver or torque wrench for this. Manufacturers usually have precise specifications for which screw should be tightened to which torque.
Parts for installing the Supernova Starstream Mini Lightbar
Pictures: Elektrofahrrad24 GmbH; Supernova Design GmbH; Bosch eBike Systems