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Replacing Earlier Light Power Controller With Updated Version

While unplugging/plugging in the controller connections is simple, installing the additional headlight wire and light power wire used with the new controller requires the removal of the internal battery. Removing the battery can be an involved process that also requires the removal of other components (such as the handlebar and One Button) to access wiring connections. If you are not confident servicing your own bike, it is recommended that you seek a qualified bicycle mechanic. For instructions on how to remove the battery from your LeMond bicycle, see the included Replacing Internal Battery Instructions. Once the battery has been safely removed from your LeMond bicycle, follow the instructions below to install the updated light power controller:

Identifying Different Versions of the LeMond Light Power Controller

LeMond bicycles built prior to the end of 2021 were assembled with an
earlier version of our light power controller. This version can be identified
by the two outermost wires which run the full-length to the headlight and
light power supply on the battery.
Updated versions feature connections near the controller with separate
wires running to the headlight and power supply. Please refer to the
pictures below for further assistance distinguishing between versions.

Steps 1

  • Note how the wiring is run along the top of the battery and held in place by tape. You will replicate this later as it makes it easier to slide the battery and wiring back into the frame.
  • Remove any tape attaching the wiring to the battery.

Steps 1

Steps 2

  • Unplug the remaining wire running from the power controller to the light power
    supply connection on the battery. (Note: The headlight wire and two taillight wires were unplugged from the power controller prior to removing the battery)

Steps 2

Steps 3

  • Connect the wire labeled “Power” included with your new controller to the light power supply connection on the battery (the connection unplugged in Step 2) making sure to align the arrows on the side of each plug.

Steps 3

Steps 4

  • Connect the other end of the “Power” wire to the power controller, again making sure to align the arrows on the side of each plug.

Steps 4

Steps 5

  • Connect the new wire labeled “Headlight” to the power controller, aligning the slot on the female end with the ridge on the male end.
  • With both new wires attached to the power controller you should have two plugs remaining in the middle. These are the connections for the taillights which will be plugged in after installation of the battery back into the bike.

Steps 5
Steps 5

Steps 6

  • Run wires along top of battery (side opposite the mounting holes) as noted during Step 1. The power controller should be about 2 inches beyond the
    battery to provide enough slack for tucking it into the bike after installation. At the opposite end, the light wire should extend as far beyond the battery as possible.

Steps 6

Steps 7

  • Keeping wires along top center of the battery, secure with masking tape in multiple spots while making sure to not cover the mounting holes on bottom. Battery is now ready for install. Refer to the Replacing Internal Battery Instructions (Step 16 and on) for guidance on install.

Steps 7