Tutorial: How to Easily and Quickly Mount Lights on Your Ebike

Here’s how to mount two ebike lighting on a full-suspension electric mountain bike.

1. Installing the headlight to the right of the stem cockpit
2. Headlight connection
3. Stripping the cables
4. Connecting the taillight

For the taillight, we chose the Busch & Muller “µ E (Mü) model. Of course, other taillight models, as well as the headlight, can also benefit from this tutorial. The latter comes with various brackets and parts, as it can be attached in different locations. We mount it on the seat stay. We have a suitable bracket, adhesive tape, a screw and nut, and two cable ties at our disposal. We only use one. The position of the light on the seat stay is important. On this KTM Macina Kapoho Master, we position the bracket where the lighting cable exits the frame.

For the headlight, we chose the IQ-XM High Beam. With its compact size, powerful illumination, and high beam, it’s a popular choice. Off the bike, we first prepare the light by pre-mounting it on the bracket. On the handlebars, we place it to the right of the stem. Thanks to the curved bracket, the light continues to shine in the center of the bike.

1) Installing the headlight to the right of the stem cockpit

The headlight and taillight are now mounted on the bike. Let’s move on to the connection. The headlight cable can be set aside for now. We’ll come back to this later. Before that, let’s determine the best location for the front light remote. Of course, the ideal is to position it as close to the handlebar as possible, so you can reach the button at any time without having to take your hand off the handlebars. But there may already be a lot of other things there, such as a control unit, a remote for the seat post, the brakes, etc. Therefore, you may need to modify your current setup a little. In our case, it’s still fine, maybe it’s the same for you.

To prevent the cables from tangling, we use spiral wrap and place the remote cable around the brake cable. It’s a little more elegant.

2) Headlight connection

We’re done with the cockpit. Now let’s lay the front light cable. To do this, we have to remove the stem from the KTM Macina Kapoho. As with many modern ebikes, a large portion of the cables run inside the frame. Access to the head tube is only possible with the stem removed. But it’s not that complicated. While you’re routing the cable through the head tube, you can hold the stem and handlebars in your other hand. Once the cable is routed, replace the cap, check the headset, and continue.

Once the battery is removed, you can see if the manufacturer has already installed lighting cables inside your ebike. We’re lucky because KTM prepares its bikes really well. Here, the cables are already in the frame, which makes our job much easier. All we need to do is estimate the length needed for the lighting cable.

3) Stripping the cables

Once this is done, you can start stripping the cables.

• To do this, separate the two terminals, including the sheath.
• The insulation is most easily removed with special pliers. In our case, these are Knipex wire strippers. But other manufacturers also offer them.
• Next, place two heat-shrink tubes on the separated terminals. These are very important, as we’ll need them in a few moments.
• Repeat the stripping process on the cable coming from the motor, then carefully twist it.
• Then simply bend them back slightly with your fingers and connect them to the rest of the cable.
• Now comes the heat shrink tubing mentioned above. Slide it over the new connection. Then place a lighter underneath and light it briefly so the area heats up and the heat shrink tubing securely surrounds everything.

When routing the new cable into the frame, it’s important to work neatly, as care must be taken not to trap any cables. On modern ebikes, there are solutions for routing cables neatly. On KTMs, there’s even a complete cover that neatly separates all the battery cables. Finally, simply place the battery back in the compartment, replace the cover, and you’re done.

For the usual function test, press the light button on the LED Remote. You can also test the separate button for the high beam.

4) Connecting the Taillight

All that’s left is to connect the taillight.

• To do this, let’s first remove the rear wheel. It’s much more convenient to work this way, as everything is much more accessible. Regarding the taillight, the same question arises as for the headlight: How far has the manufacturer of your ebike planned for the installation of lights? Let’s hope they’ve planned as far ahead as KTM.
• In our case, the cable is already in the frame. These are bare wires, so we still need connectors for the connection. The cable leading from the taillight already has male clip terminals at the ends, so all that’s left to do is plug in the corresponding female clip terminals. Using the special pliers, strip the cable insulation again and then place the female clip terminals on the exposed terminals using crimping pliers.
• Before connecting the male and female clip terminals, remember to use heat shrink tubing. This is also necessary here; one tube per terminal must be used.
• Once you’ve clipped the cable ends together, close the connector and slide the heat shrink tubing over it.
• Briefly heat the corresponding area with the lighter. If you remember to, check the taillight first.
• Now carefully put the cables back in the frame. Not only is the cable better protected from the elements, but it’s also less likely to fall off while you’re riding and potentially be damaged.
• Now let’s perform our check and press the LED remote’s illuminated button.

Everything should work. If it doesn’t, feel free to ask us any questions in the comments.

You may want to watch our video tutorial: