Gygolite Expilion 500 User manual

CYGOLITE

1307-AEASTSAINTGERTRUDEPL.,SANTAANA,CA92705 USA

PHONE:(714)437-7752 FAX:(714)437-7962

www.cygolite.com

• Industry leading Cree LED Technology

• USB Rechargeable

• 7LightingModes(Med-Hi-Boost-Low-DaylightFlash-Walking-SOS)

• Quick Release Rechargeable Li-Ion Battery Stick

• Regulated Power Circuitry for steady brightness

• Smallest size in its class (only 130 g)

OPERATION MANUAL

CONTENTS

• Super Bright LED Headlight

• Quick Release Rechargeable

Li-Ion Battery Stick

• Wall Charger

• USB Charging Cable

• Handlebar Bracket

• Helmet Mount Kit (ExpiliOn500only)

•OperationManual

The ExpiliOn Series comes with a one year limited warranty, against any

defective part or craftsmanship. The battery is warranted up to 90 days

after the original date of purchase. If the unit is under warranty, Cygolite

will repair or replace defective components at no charge provided the

product has not been subject to misuse, abuse, or non-Cygolite authorized

alteration, modification or repair. Warranted products requiring service

must receive a Return Merchandise Authorization number (RMA#) from

customer service. The original receipt (INCLUDING DATE) is required on

all warranty repairs. Shipping costs inccurred from shipping warranty or

repair items from the customer to Cygolite are covered by the customer.

The headlight will not turn on.

· Make sure the power button was firmly pressed.

· Make sure battery is securely installed in the headlight and in the closed

position.

· Make sure the battery is fully charged.

All Cygolite products are backed by Cygolite’s warranty, providing quality,

craftsmanship and the assistance of our knowledgeable staff. If any

support is needed, we will assist with 48 hour turnarounds on parts and

service. For questions, problems, and/or authorized CYGOLITE parts

Congratulations on your purchase of the ExpiliOn High-Brightness LED

headlight system. Please refer to this guide to operate your ExpiliOn

safely and properly.

The ExpiliOn series is designed to be used on bikes in some of the most

extreme outdoor conditions. Over time, dust and dirt may hinder the

connections on your headlight. To prevent this from happening, ensure that

the headlight is clean after every ride.

Wipe the headlight with a damp cloth. Do not submerge the battery or

headlight in water. Remove all dirt around or on the plugs or jacks on the

headlight.

The High-Brightness LED has extensive life so bulb replacement is not

required.

Q: When should I replace the bulb?

· The LED bulb has extensive life so bulb replacement is not

necessary.

Q: When should I charge my battery?

· The battery can be charged any time, but we recommend fully

charging the battery every time you charge it.

Q: Can I use non-Cygolite parts for this unit?

· No, Cygolite parts are manufactured to specific quality

specifications. To ensure the quality of your lighting system,

only use Cygolite parts. Use of non-Cygolite parts will void the

warranty and may cause damage to the light.

Q: Can I leave my light charging for extended periods of time?

· Yes, the light is smart charging & will prevent from overcharging but

like all electrical appliances we recommend disconnecting the

headlight and charger when the light is fully charged.

Q: Can I use my other Cygolite batteries with the ExpiliOn?

· No, the ExpiliOn is only compatible with Cygolite’s Li-Ion

batteries used on the ExpiliOn systems.

Q: Will my charger for my other Cygolite systems recharge the

ExpiliOn battery?

· No, the ExpiliOn battery only works with the supplied charger.

Attempting to charge the battery with any other charger will

result in damage.

Q: Where can I purchase the compatible Li-Ion batteries for my

ExpiliOn?

· Compatible Li-Ion batteries can be purchased from the spare

parts section of our website or by contacting Cygolite

customer service.

Q: Can I use this light for activities other than cycling ?

· No, this light is specifically intended for bicycle use only.

Q: What should I do if moisture or water gets into my light?

· Immediately remove the battery from the light. Put the

battery aside and allow the light to dry completely before

continued usage.

Super Bright LED Lighting System

withUSBRechargeableLi-IonBatteryforCycling

If you have more questions that are not listed here,

visit the support page at: www.cygolite.com

CAUTION:

· Headlight may get hot during use. Use caution when handling.

· Unplug the headlight from charger when not in use.

· Unplug connectors by the plug, never by the cable.

· Do not modify or substitute any parts with Non-Cygolite parts.

· Do not open headlight case.

· Provide adequate airflow to the headlight to cool during use.

· If the light is on & stationary longer than 10 minutes, turn it off.

· Do not look directly at light.

· Do not operate or submerge under water.

· Do not operate the light unattended.

· Keep headlight away from combustible materials.

· Do not package headunit when hot or immediately after use.

· Carrying a flash light is recommended.

· This light is for bicycle use only.

Statelawsregardingflashingbicyclelightsmayvaryamongstates.Usetheflashingmodes

in accordancetoyourlocal state laws as well as federal law.

ExpiliOn 500/410

FEATURES

CONTENTS

WARRANTY

COMMITMENT

CARE

TROUBLESHOOTING

F.A.Q.s

Addfoampad

Helmet bracket (bottom view)

Charging Port

Rubber Cover

LOWBATTERYINDICATOR

The low battery indicator is in the power button. It shows a steady green light

when battery is fully charged. As the battery runs low, the green light will flash

quickly to indicate that you have approximately 10~15 minutes of power left.

WARNING: Charge the battery with the supplied charger or USB cable

only. Using any other charger or USB cable to charge the battery may

result in damage. The charger is for indoor use only.

Power

Button

RubberPad

INSTALLINGBATTERY

1. Line up the arrow on the back of the battery and the arrow on the back

of the headlight that reads “O”. Insert battery into light as shown.

2. Lock battery into the headlight by turning clockwise as shown.

3. CYGOLITE should read straight horizontally when locked and the arrow

on the battery lines up with the arrow on the headlight that reads “C”.

REMOVINGBATTERY

1. Unlock the battery from the light by turning counter-clockwise until

arrows on the battery and headlight align into the open position.

2. Once battery is unlocked from light, pull battery out.

Charging Indicator

Flashing Green = Charging

Steady Green = Battery Charged

BATTERY CHARGING - continued

1. Lift the RIGHT side of the rubber cover to reveal the charging port.

STEP 2 VARIES DEPENDING ON CHARGINGMETHOD.

2A. (Wall charging) Connect the charger to the wall outlet.

2B. (Computer USB charging) Connect the USB charging cable to your

computer’s USB port.

3. Insert charging cable into the USB charging port.

4. The charging indicator on top of the light will flash green when charging

then have a steady green when fully charged.

5. Allow approximately 5 continuous hours to fully charge a drained

battery. (Charging times may vary depending on charging method)

1. Attach handlebar spacers to inside of handlebar bracket for standard

sized handlebars. Remove spacers for oversized handlebars.

2. Swing thumbnut out from thumbnut slot to open bracket.

3. Attach rubber pad to handlebar spacer (or handlebar bracket). First

remove paper from rubber pad to reveal adhesive side, align rubber pad

holes to handlebar spacer plugs and join together.

1. Add foam pad to bottom of helmet bracket to cushion against helmet.

Peel away paper to reveal adhesive and fasten to the helmet bracket.

2. Weave the 12” long velcro strap up through one hole of the helmet

bracket, then down through the outer hole on the other side. Pull the

strap until the plastic loop prevents the strap from moving further.

3. Position helmet bracket over vent holes on the front top of the helmet.

4. Insert velcro strap downward through the vent hole then up through the

opposing vent hole. Thread the velcro strap through the velcro strap loop

and pull to tighten. Then fasten the velcro strap to itself, making sure the

helmet bracket is secured in place.

5. Sliding backward, insert the headlight into the helmet bracket until it locks

in place. To remove headlight, press the bracket tab down and slide the

headlight forward.

SPECIAL MODE (Walking - SOS)

1. While the headlight is in the off

postition, press and hold the power

button for 2 seconds to activate the

special modes.

2. Press power button to scroll through

the 2 special settings. Press and

hold power button for 2 second to

turn the light off.

Attachspacers

(forstandard size bars)

The ExpiliOn features a BICYCLE MODE with 5 brightness settings, and a

SPECIAL MODE with 2 special settings. The settings are controlled by the

power button on the top of the headlight. The top button also functions as

the low battery and charging indicator. The diagram and instructions below

indicate where these features are located on the headlight and how to use

them.

CAUTION: The light may get hot during use. Handle with care and turn

light off if stationary for more than 10 minutes.

BICYCLE MODE (Med-High-Boost-Low-Daylight Flash)

1. Press power button to turn light on. The light will turn on in the Medium

setting and the top green indicator will illuminate. Press power button

again to scroll through the different settings and daylight flash.

2. Boost mode is the brightest setting in bicycle mode. The green

indicator on top will blink slowly to show when boost mode is on.

3. Hold the power button for 2 second to turn the light off.

Low

Battery

Indicator

4. Wrap bracket around handlebar and return thumbnut into slotted space.

5. Twist thumbnut clockwise until tight.

6. Slide headlight back into the bracket until headlight clicks into place.

TO REMOVE HEADLIGHT FROM THE HANDLEBARS

Press the release tab down on the bracket and slide headunit forward.

TO ADJUST THE SIDE-TO-SIDE BEAM DIRECTION

Swivel the headlight left to right to adjust the side-to-side direction. If side

swivel becomes loose, tighten the swivel screw on the top of the bracket

with a philips screwdriver.

Thumbnut

Open

HEADLIGHTOPERATION

MOUNTINGONHANDLEBARS

123

MOUNTING CONTINUED

456

INSTALLINGBATTERY

1 2 3

BATTERY CHARGING

12B

RUNTIMES

HELMETMOUNT (Expilion500only)

1345

High

2:15

2:30

Medium

3:15

4:00

Low

15:00

17:00

Boost

1:30

2:00

DayFlash

19:00

22:00

BicycleModes SpecialModes

Walking

38:00

44:00

SOS

38:00

44:00

Model

EXPILION500

EXPILION410

REINSTALLING USB COVER:

1. Insert the left inner edge of the

USB cover into the recharging port.

2. Apply pressure diagonally inward to

the right side of the cover until the

USB cover is fully inserted.

Thumbnut Release Tab