Changed my filter today and when putting the tank cover back on the back screw located under the W in Kawasaki pushed right in really easy so I look and the threads that were in the rubber went into I guess the frame? I cant see it and I tried to fish it out with a magnet, but I believe its lead or something. Is this area reachable by maybe taking the tank off or is it not going to cause me any problems and I can just get another one? I got the worst luck! Any help would be greatly appreciated!

WoHoo...now yer one o' the boys!I had to take my tank off and remove those silver covers there,then I could see it way back in the corner sitting there.Hassle...but I didn't want to take another's opinion that it "won't end up in the stacks".Gotta be extra careful starting that large bolt (as you found out).Can't push very hard to get er threaded.

* Last updated by: blue07 on 9/24/2010 @ 6:59 PM *

Dang Blue you have stepped up to the plate all week for me! Thanks man! Yea I just barely pushed and pop...there it went and the rubber was kind of screwed so I may have to get another one of those. Oh well...im getting more familiar with the machine. I looked at a pdf of the frame and saw those 2 covers there and had a sigh of relief and it feels better hearing you say been there done that. I was just worried that baby was going to be unreachable and cause me problems down the road. Looks like I will now get familiar with removing the tank. Looked at it in the maintenance manual and didnt look too bad. Anything I need to look out for while removing it like that nasty bolt that caused this :) Thanks again Blue!

Hey it's cool...I don't envy you having to learn so soon!But....you'll HAVE to eventually...unless ya wanna spend BIG DOLLAS for stuff you can do yerself!

Couple o things maybe for ya.When reinstalling that tank cover...make sure the metal tabs at the front there are horizontal to the ground.Then start the install by sliding that cover onto the tank keeping the rear facing "tips" in the center of the cover flush with the tank itself.Then slide it back over those tabs.If you bend them downwards any past the horizontal,the tank cover will obviously sit closer to the tank right there.Just don't "put the cover on" and then see a gap right there and push down on the cover.You've missed the tabs if you're getting a "larger" gap right there..should be almost flush,or very close to it.

Be gentle with that silver cover that's got the sensor connected to it.DON'T drop it or hit it with anything.

When you reinstall the fuel tank itself,be very careful that you are getting the fuel line AROUND the left hand side "post" in the frame (the bumper in the pan there).You'll see it when you lift the tank.When you reset the tank in position,that line will want to ride up over that bumper.If it does,your tank will be sitting "up" on the left rear end there,so just be aware of that..And DON'T yank on anything while moving the tank back to the side. Use something to kinda prop it up and away from the work area,but not so it might slip free and fall.Remember that fuel rail line is there as well...don't pull excessively with the tank.If you need some fuel line play to set your tank out of the way some,just gently pull back on the line that's coming through the frame ...you'll see it.And push it back forward when you reset your tank,with NO sharp bends or KINKS.I think you can get enough play by holding the tank free just above the motorcycle,then repositioning the tank BACK several inches so the front surface of the tank just clears those silver covers.That way,it won't fall off,and it'll be much safer than trying to twist it somehow sideways .Can't remember if I angled mine kinda sideways,I might have.You may have to as well.If ya do,just watch that fuel rail line,and don't collapse it by bending it.(it's right there under the frame)...made of plastic.So be cautious!It might be smart to lay a nice thick towel across the frame under your removed tank(get this within reach BEFORE you pick the tank up by hand!).You won't scratch the paint on the side areas of the tank that way(down along the bottom run).The subframe will scratch the tank if yer not watchin where yer resting the tank.

* Last updated by: blue07 on 9/25/2010 @ 12:37 AM *

I really appreciate it Blue! I think I had the tank cover on correct last time, but I will definitely make sure not to press on those tabs when I put it back on. Thanks for the heads up on that sensor....I will be really careful with it. I will get me a big comfy towel to rest that tank on and take my time not to mess any lines up. So I might be able to move the tank enough to reach those panels without actually having to disconnect any fuel lines? That would be a bit easier and less messy if its possible. Hope I see that thing and dont have to go looking for it. I priced me some more well nuts at Lowes so I can replace some of these when needed. I got to give it to Mama Kawi....they sure made it easy to check the air filters on these things. I learned alot about my cruiser tinkering on it and so I guess the same goes here. Im not the most mechanically inclined person I know, but I cant stand to pay for something I think I might be able to do myself. Once again Thanks Blue!

* Last updated by: motorpycho on 9/25/2010 @ 5:29 AM *

Ya...you shouldn't need to remove any fuel lines,just manipulate em so you can move your tank some.Might wanna run er down to nearly empty first though!Those well nuts for that tab are DIFFERENT than most.They have a thick "washer" built into em.Spaces the cover from the tab surface.You can use the right size well nuts without the spacer deal,but ya might want to buy a couple of rubber spacers and just put em on there before you crank the bolts in.Keeps the plastic tank cover edge in line with the tank surface so she sits flush with the tank.Esthetics ya know!

* Last updated by: blue07 on 9/25/2010 @ 2:24 PM *

Thanks Blue I didnt know that about the washers...yep Esthetics for sure. Have to grab some of those then. Do those well nuts just push (pop) in? I am having a busy weekend so the poor bike sits apart and broke until probably this week sometime. If I can keep the fuel lines on this should be a breeze. May even venture in there tomorrow evening. I went to a College football game today and all I could think about is getting my bike back rolling. Appreciate it Blue!

Ya...the wellnuts just slide into those tabs.You could just to be on the safe side...get the wellnut started just a couple of threads,then push it in there....that way you won't need to push on the bolt while tryin to match the hole up.Long as you don't run the bolt in there more than a couple of turns,it will still retain it's round profile enough to get it in there.Do Not Push excessively when yer tightening that bolt...just let the bolt thread in without any pushing.It will.And don't crank down hard at the final snugging...that cuts wellnuts to shreds.

* Last updated by: blue07 on 9/25/2010 @ 5:30 PM *

Ok Blue I will do just that and not go crazy tightening them. I believe the previous owner or mechanic might have put some UMPH into it because the rubber on the one I lost is screwed. Thank you very much man!

Hi guys,
Interesting topic as the same happened to me. Is it neccessary to remove the grommet from wherever it went to ? If it is not removed, will it cause problems ? Do not really want to go the tank removal way so thought I can learn from you guys !!

Deon ( South Africa )

You can see on that factory well-nut,it has a thick "spacer" molded into the outer side of it.That prevents it from falling inward and into your airbox when you install the bolt(it also keeps the cover flush with the tank right there).IF you've broken(torn) that factory well-nut,and just replaced it with a same size well-nut,without the thick spacer part,you will again end up pushing it through into the airbox if you aren't REALLY gentle when installing the bolt.You start pushing on that bolt,the nut's gonna slip through before she threads....and there ya go...again.

You will see the thick part of the factory well-nut when ya remove the cover and side panel.Part of the problem with those is when tightening,they can be cut easily by being too tight in that metal tab.The body begins to tear away from the "spacer" part,eventually falling free...inside the airbox when ya go to remove the bolt.So buy the same part number from Kawasaki...install normally,and don't overtighten.The side panel(foreman grill) "hole" sits on top of the spacer part,then the tank cover hole.Screw in but don't force.If the well-nut is turning with the bolt,which it might,just push firmly on the tank cover at the "hole" area with your fingers to put pressure on the nut "spacer" part right there while turning.Once you've tightened her down a few times,she'll hold the desired shape in the tab there.The bolts are the long bolts...not the short ones.Hope that helps!

* Last updated by: blue07 on 10/6/2010 @ 1:34 AM *

Thanks Blue,
Do I need to remove tank & recover the one that has fallen in or could I just fit new grommet & tighten up ? Will the one that has fallen in cause any problems ? I guess what I am asking is whether the one that fell in, fall into the airbox or is it in the frame ?
Deon

* Last updated by: Deon on 10/6/2010 @ 1:31 AM *

No Deon...it's IN the airbox sorry to say.Probably sitting in the rear corner back there.Gotta remove the tank now to remove it.I can't say IF it would somehow get sucked into the stacks...but I wasn't willing to find out...it's up to you.Like I said,IF you just replace with a simple well-nut that fits in that tab,you're running the real risk of having to "fish" another one out cause you pushed it through without realizing it when you installed the bolt.The thick spacer will prevent that from happening.I would...Fish it out...then replace the well-nut with another of the same design.You MIGHT be able to find one similar enough to use at a fastener store around there somewhere.You won't have to worry about it for a long time then.As long as ya don't crank down on that well-nut.Just snug...that's all.

* Last updated by: blue07 on 10/6/2010 @ 1:48 AM *

Thanks for the assistance Blue. Will take tank off & fish it out. Also not willing to take risk.
Deon

Try to just remove the tank fasteners and then slide your tank backwards,just enough to clear ONE of those covers there..either one.Remove cover...go for it.Hold yer tank with one hand,fish the grommet out with a coathangar and some sticky thing on the end.Should be fairly simple.Just don't crush or pinch your fuel line at the "support tower" in the lower part of the frame when you reinstall.Don't yank on the line coming from the throttlebody fuel rail on the other side of the frame in the engine area...it's plastic,so if ya need some slack,pull it back CAREFULLY while watching the connector at the rail..you can see it in there.

The line from the fuel pump goes around the tank support tower ...not OVER it.

* Last updated by: blue07 on 10/6/2010 @ 2:11 AM *

Thanks Blue. Will get stuck into it this evening. Need to get her ready as we are going to a rally in Cape Town on Friday. All this came about only to change a front indicator globe !!!!!!
Deon

Hi Blue,
Just to let you know, I managed to get the little bugger out without too much fuss ( tank lifted high enough so that I could get cover off - grommet was lying right next to stack ). Thanks once again for your advice. Ride hard but ride safe my brother !!!!!
Deon

Awesome Deon.Glad it worked good for ya.I trust she's runnin fine now?

Yep !! Back to normal. All this fuss just to change a indicator (turn signal) globe !!!! I am almost sure that if this had to happen at a dealer (here in SA), they would've just fitted another grommet without taking the fallen one out of the airbox. Those stacks are not so high & I am sure the chances are good that the grommet can get into buttefly. Anyway, now I've learnt something from you guys that I can pass on to my buddies who ride the same bikes.

* Last updated by: Deon on 10/7/2010 @ 1:03 AM *