PNW Components 31.8 Drop Bar Lever Kit Installation Guide

31.8 Drop Bar Lever Kit

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Product Information

Specifications:

• Product Name: Drop Bar Lever Kit – 31.8
• Compatibility: Fits handlebars with a diameter of 31.8mm
• Tools Needed: 3mm allen wrench, cable cutters
• Package Includes: Flexible cable housing, Barrel Adapter

Product Usage Instructions

1. Position the hinged lever clamp on the handlebar without
   interfering with the front shifter. Tighten using a 3mm allen
   wrench to a maximum of 2nm.

2. Insert the end of the cable noodle with the rotary ferrule into
   the lever until fully seated.

3. Thread the cable originating from the dropper post through the
   rotary ferrule and housing to the lever.

4. Insert the barrel nut into the round floating center blade of
   the lever, ensuring it is placed correctly in the curved portion.
   Use a 2mm and 3mm allen wrench to tighten.

5. Pull the cable through the lever and barrel nut until tight.
   Securely tighten the barrel nut using both allen wrenches.

6. Test by pushing the lever 5-10 times to ensure proper seating
   of the cable housing and check for any play in the cable. Make
   adjustments as needed.

7. Slide the cable into the guide under the lever, trim excess
   cable with cable cutters leaving about 10mm, and crimp the cable
   end in place.

8. Reassemble any removed bar tape after completing
   installation.

Frequently Asked Questions (FAQ)

Q: What should I do if the lever isn’t returning after

installation?

A: Check the cable routing to ensure it is correctly installed.
If needed, loosen the barrel nut with both allen wrenches, pull the
cable tight again, and make micro adjustments using the rotary
ferrule on the cable housing.

Q: How do I prevent cable fraying during installation?

A: It is important to use proper cable cutters to trim excess
cable, leaving about 10mm to crimp securely in place. This will
prevent fraying and ensure a reliable connection.

Q: Can I modify my frame to install this kit?

A: No, do not drill or modify your frame in any way as it will
void the warranty and may result in frame failure leading to
serious injury or death. Follow the provided installation
instructions carefully without any modifications.

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INSTALL MANUAL
DROP BAR LEVER KIT – 31.8

DROP BAR LEVER KIT – 31.8 INSTALL MANUAL

TOOLS NEEDED:
· 2mm, 2.5mm, 3mm, 4mm hex wrench · Cable cutter · Cable crimp or needle nose pliers

PACKAGE INCLUDES:

· Dropbar lever · Lever bolt · Shifter cable · Crimpable cable end · 600mm length of
flexible cable housing

· Rotary Ferrule · Cable Housing · Housing Ends · Shifter Cable End
Barrel Adapter

WARNING: DO NOT DRILL OR MODIFY YOUR FRAME IN ANY WAY. DOING SO WILL VOID THE WARRANTY. MODIFICATION OF YOUR FRAME IN ANY WAY MAY RESULT IN FRAME FAILURE WHICH MAY RESULT IN SERIOUS INJURY OR DEATH.

DROP BAR LEVER KIT – 31.8 INSTALL MANUAL

1. Position hinged lever clamp on bar to not interfere with front shifter and tighten with 3mm allen wrench to maximum 2nm.*
2. Insert end of cable noodle with rotary ferrule into lever until the cable noodle is completely seated.
3. Insert cable originating at dropper post through rotary ferrule and through the housing to the lever.**
4. Insert barrel nut into the round floating center blade of the lever. It is crucial that the barrel nut is placed into the curved portion of the floating center blade. Note: The barrel nut that will be inserted into the lever has a hole for the cable to slide through and is tightened using a 2mm and 3mm allen wrench.
5. Pull the cable through the lever and hole in the barrel nut until the cable is tight.
6. Tighten the barrel nut with a 2mm allen wrench on one side and a 3mm allen wrench on the other side. Note: You may have to back off the 2mm side to open the hole in the barrel nut.

7. Push the lever 5-10 times to make sure the cable housing is fully seated and to check for play in the cable. Note: If the lever isn’t returning, check cable routing to ensure proper installation of the cable. If there is play in the lever/cable, loosen barrel nut with 2mm and 3mm allen wrenches and pull cable tight a second time. For micro adjustment, use the rotary ferrule on the cable housing.
8. Slide cable into the guide under the lever. Trim excess cable with cable cutters with enough room to place cable end, approximately 10mm. It is important to use proper cable cutters to prevent the cable from fraying.
9. Crimp cable end in place. Push lever. Drop post. Get rad.

*Remove bar tape to expose bare handlebar and cable housing / wiring for proper clamp placement.

**Insert cable originating at dropper post through rotary ferrule and through the housing to the lever.

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