EnCase System Installation Instructions

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Tools & Supplies

Scissors
Razor blade
Lighter or heat gun

Mountain Bike Handlebars

The EnCase tools and storage sleeves were designed to fit in most flat bar and drop bar bikes. The rubber sleeves prevent the tools from rattling inside your bar. They fit most bars without any modification but they can be tailored to accommodate bars with a smaller internal diameter.

Place the tool inside the sleeve. For mountain bike handlebars the orientation doesn't matter.
Remove the bar end plug from your handlebar. Depending on which style grip you have this may involve prying a plug out of your handlebar or cutting an opening.
Insert the sleeve in the handlebar to test the fit. When properly fitted the sleeve should slide in when pushed with one finger.
If you feel any binding you can trim the flap along the ribs to reduce the diameter of the sleeve. We recommend trimming a little at a time until you get a perfect fit.
The fins near the end caps determines how tight the sleeves fit in the bar. If you feel excessive resistance or it is too difficult to remove the end caps you can use a razor blade to trim the fins.
If the inside of your handlebar is very rough you can apply a little bar soap, talc, or Vaseline to reduce friction. You should only need a small amount. (We do not recommend using other lubricants like chain lube, grease, or mineral oil since they may cause the sleeve material to swell).
We recommend installing the plugs with the beveled edge facing forward which helps them stay in place if you hit anything with your bars while riding.

Hidden Storage

The sleeves also have a hidden storage area in the aluminum bar plug. An internal o-ring creates a place to securely store a master link or presta-to-shrader adapter and presta valve core.

Road / Gravel / CX Bike Handlebars

The EnCase tools were designed with pivots that allow them to bend to match the contour of drop bars. As you can see in this cross section the tool and sleeve can flex to accommodate bars with significant curvature but they will not fit handlebars with extremely tight bends.

Place the tool inside the sleeve. For dropbars the tool needs to be oriented so the side that bends is away from the bar plug.
Insert the sleeve so the flap is facing down. This helps to prevent binding as the sleeve bends.
Make sure the tool is oriented in the sleeve so tool can bend to match the contour of your handlebar.
Insert the sleeve in the handlebar to test the fit. When properly fitted the sleeve should slide in when pushed with one finger.
If the inside of your handlebar is very rough you can apply a little bar soap, talc, or Vaseline to reduce friction. You should only need a small amount. (We do not recommend using other lubricants like chain lube, grease, or mineral oil since they may cause the sleeve material to swell).
Since road bars are nominally 1.6mm larger diameter than mountain bars we have included an optional Drop Bar Fit Kit. Use this kit if the sleeve is very loose or slides out while riding.
Cut off a 1/2 inch piece of heat shrink tubing. (There is enough heat shrink tubing for 4 sleeves so you can test the fit with or without the o-ring.)
Place the o-ring between the ribs at the base of the end cap.
Place a 1/2 inch piece of tubing over the o-ring and sleeve.
Use a lighter or heat gun to shrink the tubing over the sleeve.

Recommended Bar Tape Wrapping

The EnCase bar plug is designed to be used without bar tape tucked under the plug. If you cut a taper in the start of the bar tape and overlap the tape at the start of the wrap you will have a clean look that stays in place when you use the EnCase System.

Hidden Storage

The sleeves also have a hidden storage area in the aluminum bar plug. An internal o-ring creates a place to securely store a master link or presta-to-shrader adapter and presta valve core.