PNW 24MM Drop Bar Lever Kit Installation Guide
- September 7, 2024
- PNW
Table of Contents
PNW 24MM Drop Bar Lever Kit
Product Information
Specifications:
- Product: Drop Bar Lever Kit – 24MM
- Tools Needed: 2.5mm allen wrench, 2mm allen wrench, 3mm fallen wrench, cable cutters
- Package Includes: Flexible cable housing, Barrel Adapter
Product Usage Instructions
- Remove bar tape to expose the bare handlebar and cable housing for clamp placement.
- Identify the two types of housing included: flexible shorter section and longer standard section.
- Position the lever on the bar and clamp in place using a 2.5mm allen wrench.
- Insert the end of the flexible cable housing into the lever and run it along the handlebar.
- Insert the cable originating at the dropper post through the rotary ferrule into the lever.
- Insert the barrel nut into the lever ensuring it is placed correctly in the floating center blade.
- Pull the cable through the lever and tighten the barrel nut with a 2mm and 3mm allen wrench.
- Check cable housing seating and cable tension by pushing the lever multiple times.
- Slide the cable into the guide under the lever, trim the excess cable with cable cutters, and crimp the cable end in place.
FAQs
Q: Can I modify my frame to install this product?
A: No, modifying your frame in any way will void the warranty and may result in serious injury or death.
Q: What tools are needed for installation?
A: You will need a 2.5mm allen wrench, 2mm allen wrench, 3mm allen wrench, and cable cutters.
Q: How do I adjust cable tension after installation?
A: To adjust cable tension, loosen the barrel nut with 2mm and 3mm allen wrenches, pull the cable tight, and retighten the barrel nut. For micro- adjustments, use the rotary ferrule on the cable housing.
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.
INSTALLATION
- Remove bar tape to expose the bare handlebar and cable housing/wiring for proper clamp placement.
- Identify the two types of housing included with your dropper lever. The shorter approximately 600mm length of housing is more flexible than the longer section of housing and does not have or require cable ends. This shorter more flexible section of housing will be installed at the lever under the bar tape and connected to the longer standard housing that will run to the post via the included rotary ferrule.
- Position the lever on the bar and clamp it in place with a 2.5mm allen wrench to a maximum of 2nm.
- Insert the end of the flexible cable housing into lever until the housing is completely seated and run the housing along the handlebar, securing it with tape.
- Insert cable originating at the dropper post through the rotary ferrule and the housing to the lever.
- Insert barrel nut into the round floating center blade of the lever. The barrel nut must be 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.
- Pull the cable through the lever and hole in the barrel nut until the cable is tight.
- 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.
- 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 the barrel nut with 2mm and 3mm allen wrenches and pull the cable tight a second time. For micro-adjustment, use the rotary ferrule on the cable housing.
- Slide the 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.
- Crimp cable ends in place. Push lever. Drop post. Get rad.
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