Want to bring your ebike with the DJI Avinox system to the next level and retrofit it with a front and tail light? No problem! This option is available for the Avinox M1 and Avinox M2 motors as well as for the new Avinox M2S motor. This upgrade is particularly useful for brands that, in contrast to Amflow, do not fit their models with lights as standard. There’s no need to visit a workshop. With a bit of DIY know-how and the right components, you can easily carry out this project in your own garage. Here you’ll find everything you need to know about the installation and which details make all the difference with your Avinox system.
1. What lighting system do you need?
2. Single front light with Higo plug
3. Front and tail lights with open cable ends
4. How to operate the lighting system on the DJI Avinox system
5. Conclusion on installing the lighting system on the DJI Avinox system
1. What lighting system do you need?
Before you order a lighting system, you should quickly check what hardware you actually need. If you only want to install a front light, an Avinox headlight or a model from another manufacturer with a Higo plug will suffice. You can find such models from brands such as Supernova, Lupine, Litemove or Busch + Müller.
Do you also want to install a tail light? Then you’ll need a light cable from Avinox with open ends to connect both lights.
Regarding your ebike’s drive system, there are two requirements to bear in mind to ensure the electronics are not damaged: Firstly, the entire system must not exceed a maximum power of 30 watts. And secondly, it must be compatible with a voltage of 12 volts. If the ebike system meets these requirements, nothing stands in the way of your project.
2. Single front light with Higo plug
If you have decided on a new front light, we recommend a headlight with a so-called Higo connector. In our example, we are using the Supernova M99 Pro 2 headlight. Not only does it provide fantastic light, but it can also be programmed perfectly within the power limits mentioned earlier.
The first step to a successful installation is to securely attach the headlight to your handlebars. Once the light is firmly in place, you can connect it directly to the display on the top tube using the 50-centimetre Avinox light cable.
To do this, loosen the two screws on the Avinox Control Display, remove the protective cap from the plug and plug in the cable. Any excess length of the light cable can be easily stowed away in the frame. Make sure that the cable is not kinked too sharply. Otherwise, there is a risk of the cable breaking.
3. Front and tail lights with open cable ends
If you prefer a complete lighting solution with front and tail lights, you’ll need the Avinox light cable with open ends. In our example, we have chosen the Herrmans Nordic Extreme front headlight. This requires a power output of just 16 watts in high beam mode. This means it operates within the system’s limits. This leaves you with plenty of additional leeway to implement a complete lighting system on your ebike using the Avinox system.
We use the Litemove TSV as the matching tail light. This requires less than one watt of power and also features open cable ends. In this configuration, the entire system meets the technical requirements. The front and rear lights operate at a voltage of no more than twelve volts and together consume less than 30 watts.
Step 1: Routing the rear light cable
Before you switch on your new lighting system, first find a suitable spot on your ebike to mount the tail light. The challenge here is often routing the tail light cable through the frame, past the motor, and up to the display. On models like the Amflow PL Carbon, this isn’t as straightforward as it sounds. There are only a few openings in the frame through which you can pull the cable. Take a look at the point where the brake line runs along the motor towards the rear. We were able to squeeze the light cable through there.
Sometimes it helps to lift the motor slightly to route the cable neatly. To do this, simply remove the chain from the chainring and loosen the two motor bolts to lift the motor slightly. You can now pull the tail light cable through the frame up to the display using a binding wire. Then tighten the motor bolts again to the correct torque of 30 Newton-metres.
Step 2: Mounting the front light
Next, we’ll fit the front light. We’ll attach the Nordic Extreme to a standard handlebar mount. Its light cable also needs to be routed through the frame. On our Amflow PL Carbon, we’ll remove the small cable plug from the head tube and run the cable through it into the frame.
Step 3: Connecting the tail light
The cables from the tail light and front light now meet at the top tube. In the next step, connect these two to the Avinox light cable on the display. To do this, remove the display from its frame. This gives you more room to work.
The Avinox light cable has four colour-coded wires. You only need the red and black wires for the connection. To be on the safe side, insulate the green and blue wires with heat-shrink tubing. Then insert each of the red and black wires from all the cables involved into two corresponding Scotch-Lock connectors and crimp the connectors together using pliers. This creates a secure connection for your entire lighting system.
Before tucking all the excess cable into the frame, it is advisable to carry out an initial test. Switch on the ebike and activate the lights. If both the front and tail lights are working, you can carefully stow all the cables in the frame, refit the display and return the motor to its original position.
2. How to operate the lighting system on the DJI Avinox system
Once the hardware is installed, the final digital setup is carried out via the Avinox Control Display. The system allows you to customise the controls entirely to your liking. Simply navigate to the settings and select the “Customise” sub-menu. There, you can select any button on your remote unit and assign it the “Lighting system on/off” function. From now on, a quick press of a button will turn night into day while you drive.
5. Conclusion on fitting the lighting system to the DJI Avinox system
Fitting a lighting system to an ebike with the DJI Avinox system represents a significant upgrade in terms of safety and visibility on the road. Thanks to the well-designed system integration, the installation is also technically flawless. Whether you opt for the minimalist version with just a headlight or choose the full package with front and tail lights – the system remains flexible. With the right components, you can save yourself a trip to the workshop and enjoy even greater convenience on your ebike.
Our tips:
- If you only need a front light, go for a headlight with a Higo connector – it saves time.
- If you’re going for a setup with front and tail lights, make sure you get the Avinox light cable with open ends.
- Use low-power lights to leave some leeway for other electrical components.
Pictures: Elektrofahrrad24 GmbH
