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Discussion Starter #1 (Edited)
I ordered my bar end weights from Babbitt's on-line store. There are three parts to the stock bar ends, plus the bolt:

1. The weighted cylinder (steel)
2. The bushing that fits into the weighted cylinder
3. A clip that holds in the bushing

Kawasaki has made the bushings too large to fit into the cylinders or the cylinders diameter is not large enough for the bushing. The size difference between the two parts is probably less than or equal to 1 mm, but nevertheless I have not been able to fit them together correctly, and one needs the bushing to drop into the cylinder so that the clip may be clipped into the weight's groove and so that the bolt can screw with enough torque into the handlebar end to make the weighted bar ends flush with the handlebars. I've tried oil and thermally changing the parts, but have had no success in correctly getting the parts to fit together. This problem has been the case now on two weighted ends, so I know that it's not simply one bad weight out of the production manufacturer. One of the bar ends I have hammered away at but have gotten it stuck halfway in now--with not enough leverage to unseat the bushing and not enough torque using the bolt to pull the bushing on through (to seat it). I will try a press if I can find one, but I suspect that the press will fracture the hard rubber in the bushing. The shop tells me that they replace them with weights with the bushing prepared into the weights. All they have to do is take off the old ones and bolt in the new weights.





 

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I'm trying to figure out why you'd want to take the stock weights apart...crash damage?nice pics, though.
 

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FWIW: I put Zeta hand guards on WITHOUT bar-end weights. Work FINE for me.
 

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I have strong aluminium frame handguards which bolt on to the outside end of the existing bar-end weights. The weights now don't have the flexible rubber mounting, it is bolted up solid.
I have serious vibration on some extreme road surfaces which made my fingers so dead one day I couldn't take my ear-plugs out because I couldn't feel them. I never had it that bad before on any bike. A bit worrying.
I am looking for a rubber bar-mounting kit now, anyone know of one at a sensible price?
Ted.
 
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