ZUMIKE
09-16-2010, 04:45 PM
So I found here http://www.provoscooter.com/genuine-yamaha-handle-bar-caps-set.html (http://www.provoscooter.com/genuine-yamaha-handle-bar-caps-set.html) under zuma 125 parts some nice yamaha bar ends. So I got them today and they are very nice, but dont fit without a 2 hour ordeal. I started on the left side, well the second I cut a hole in my grips I have to finish this project. The bar ends are about 2 mm too big. So I had to turn down the end on a grinder for a while, checking abck and forth until it went in.
Now for the nightmare. The throttle side. First mine has a solid 3 inch long slug welded into the bar. About 80% weld so I had to go through a few sizes drill bit, then finally 3 different unibits to cut away enough of the slug to punch it down into the bars. No way I could get it out. After that since I had unibited the pipe slightly bigger by accident the bar end went in without any grinding. But what a ordeal to do this. Turned out perfect but I think maybe a note in the product description about the bar ends wont fit in without grinding or possibly opening up the handlebar tube. Since I selected a zuma 125 in the search they came up, but im guessing they may come up in a generic search. Only reason I got them was they were factory yamaha ends for scooters and I was assuming they would fit in without any fuss.
Here is the finished pic, turned out great
http://i117.photobucket.com/albums/o56/mikegigabyte/Zuma/125/ends.jpg
Now for the nightmare. The throttle side. First mine has a solid 3 inch long slug welded into the bar. About 80% weld so I had to go through a few sizes drill bit, then finally 3 different unibits to cut away enough of the slug to punch it down into the bars. No way I could get it out. After that since I had unibited the pipe slightly bigger by accident the bar end went in without any grinding. But what a ordeal to do this. Turned out perfect but I think maybe a note in the product description about the bar ends wont fit in without grinding or possibly opening up the handlebar tube. Since I selected a zuma 125 in the search they came up, but im guessing they may come up in a generic search. Only reason I got them was they were factory yamaha ends for scooters and I was assuming they would fit in without any fuss.
Here is the finished pic, turned out great
http://i117.photobucket.com/albums/o56/mikegigabyte/Zuma/125/ends.jpg