I'm moving this to the "general" section so more people might see it. I got a new wellnut from Kaw. 2 problems right off the bat. #1 No "bump out" in the middle, so it fits loose in the hole and spins freely. #2 Because it isn't squished in the middle, it's also longer. That means the bolt doesn't reach the threads with 2 panels in between. So now the wellnut spins freely in the hole, and the bolt doesn't reach the threads no matter how hard you push. There's no way to tighten it! I wrapped some electrical tape arount it so it fit tight, but the bolt still can't catch the threads. After an hour of trying to hold the back of the nut and squish it far enough for the bolt to catch I gave up that idea. Next I shave off as much plastic from the black battery cover, and try again. Still no go, so I shave some rubber off the wellnut flange, and the bolt FINALLY touches thread. 3 hours to replace 1 @^%*^$ wellnut!

Venting is nice sometimes. I think the worst part of wrenching on the 14 is taking off the plastics. I never had that problem when I had the zrx.

Plastics suck.....if they didn't cut the wind as well as they do I'd turn my bikes into streetfighters

I too hate it when all that time is wasted on small stuff like that.

And you get on websites (like this one) and people say things like 'removing flies is a half an hour job'?

SAY WHAT?

:))

* Last updated by: faz on 9/30/2009 @ 5:51 PM *

blue07; You're right, sorry. Meant the foreman grill.

The well nut will fatten up after you tighten it the first time, i think. If the flange on the outside is big enough to keep it from falling through the hole in the airbox, you have the right wellnut. I think it was 6mm, but can't say for sure.

Your problem is not that the wellnut is too deep; the screw you had in there is too short. The screws I have that go on the back corner of the tank fairing into the airbox wellnut are much longer than they need to be. They are ~1 1/2 long. That is one reason you don't need to tighten them much. Even if they did get loose (which they won't) they still wouldn't fall out. I'd go to the stealer and tell him they sold you a bike with screws that are too short. Doesn't sound like your bike was fitted with the proper ones. You will need to take the formans off a lot so you should get the right screw.

* Last updated by: Rook on 9/30/2009 @ 10:20 PM *

if they didn't cut the wind as well as they do I'd turn my bikes into streetfighters

Oh geeze, did somebody go and cut wind??

Rook; bolt on the other side is same length, and yes, about 1.5 inches. The bolt fits fine with the old wellnut because of the bulge. Yes, that happens when you tighten, and stays after being that way for months/years. Problem is, how do you start it without the bulge shortening the nut? The factory probably put the tank on last, and could hold the nut from the backside. I can't believe I'm the first/only one to replace a wellnut, and have this problem!

I agree guys. I stripped the ZX-11 a few times, and it was easy. This thing is ridiculous. Why they think they need so many different sizes and types of fittings I can't figure out.

* Last updated by: alg8er on 9/30/2009 @ 10:54 PM *

I'm sure you have plenty enough common sense to have tried everything possible to get the screw in there. Sounds like you have the right screws, too. I wonder if you got a malformed wellnut? I hope it works better after it is squeezed for a while because you will most certainly be taking it off again.

First I've ever heard of having this problem. Lots of people split that one but never heard of having a prob with the replacement.

I PUT a dab of superglue on the back side of the flange

alg8tr, the screw that goes into the airbox well nut has ~ 3-4x longer threads than any other large well nut used to hold down fasteners. If that is what you have, it is probably the correct one. Well nut must be too deep if it wount grab threads.

hyped; That wouldn't work since the bolt doesn't reach the threads it would just spin inside the wellnut.

Rook; The next problem will be if I can get the bolt back out, and then in again. I would love to talk to the guy that thought this piece of crap was a good idea for this situation. I'm thinking of buying another wellnut and bolt so I can have a compressed one in the bin hoping it will hold it's shape when I need it. I suppose I could try to find a 1/4" longer bolt that looks decent.

* Last updated by: alg8er on 10/1/2009 @ 12:10 PM *

^^Those are good ideas. I really think you have something that is the wrong part. It would be a good idea to reorder a screw and a wellnut. What a PITA for such a simple problem. That is an important fastener though and as we have all found, you don't want to have it screwed in improperly.

Your pre-compressed wellnut idea gave me a thought -- maybe you could try threading in the screw without the plastics on there so it will reach the nut. That should compress the rubber into shape and maybe it would be short enough to work with the plastics on. I suppose you already tried that.

Just a little FYI for those with the well nut problems and the hardware that goes with them,,,,,

The local ACE hardware by me sells metric allen screws in stainless steel that almost exactly match the oem hardware for only $.70 each. They also carry the little plastic washers. It's gotta' be cheaper and it's definitely easier than dealing with the dealer for something stupid like hardware.

* Last updated by: Beondwacko on 10/2/2009 @ 5:49 AM *

Beondwacko: My local ACE doesn't have them, SAE or Metric. NAPA has SAE 1/4" , so I could re-tap, BUT....since this is the first time I've replaced a wellnut, and since the other end is the airbox, I wanted OEM to make sure it was right. I bought 6mm wellnuts at 70 cents ea online, but the outer flange was thinner, and I was worried it would tear too easily.

I bought a pair of them from the dealer and they went it and tightened up fine. Maybe the ones you got from the online source were a little off?

OEM wellnut replacement here too and no problems.

I ordered a couple from my dealer, and they just came in. I'll pick them up this week and see if they're different.

The OEM part # IS...92015.There's TWO different 6 mm wellnuts.The airbox BOLT is like three times as long as the BOLT that goes just below that one on the lower bolt hole in the foreman.They are NOT the same length(the bolts).Looking at the parts fiche-it's EASY TO GET THE WRONG items by looking at the diagram(the BOLT is pictured on the TANK COVER diagram in the same window).On the TAB in the FUEL TANK diagram,that's where the wellnut is pictured).The correct wellnut+the long bolt-it will fit perfect.It'll grab and thread right in there.NO problemo!The thin flanged one-that's what Alg8r's got(or had I should say now?)-plus he's using the short bolt!!I did the exact same thing.The LOWER bolt is-Part #92153D-6X14(FRAME FITTINGS)(SHORT).The UPPER BOLT is 92153C-6X30(FUEL TANK)(LONG).The black plastic washer goes between the bolt head and the Tank Cover hole.You don't need any glue or anything else to hold it tight in there-as rook said-just don't crank down on the bolt and she'll last a LONG TIME.

* Last updated by: blue07 on 10/5/2009 @ 3:51 AM *

I've owned motorcycles for 40 years. I've rebuilt motors, and done most of my own maintenence and parts ordering the whole time. I'm using the correct bolt, same on other side and longer than other bolts. I'm not even using the plastic washer. I ordered part # 92015-1692 online. Bag is "genuine parts" and Kawasaki. Wellnut fits loose in the hole. About 1/16" play, and bolt threads are short of nut threads by about 1/16" with plastics between. I called my dealer and only told them I needed the wellnut that's inserted in the tank. They ordered part # 92015-1692. I picked it up today, and it's EXACTLY the same as what I got online. Fits too loose in the hole, and bolt doesn't reach the threads through the plastics. Correct bolt, correct wellnut, correct hole, and it DOES NOT FIT TIGHTLY! I have no clue what you guys are getting that works fine. In fact after tightening the bolt as much as it would tighten, I can stick a finger under the plastics and pull the wellnut right out without even loosening the bolt. Mainly because it's impossible to tighten the bolt because the wellnut turns in the hole. I tried a dab of glue, but it cracked loose as soon as I tried to tighten it. I'm just going to get a 1/4" longer bolt, and use that. I don't even care what it looks like at this point. I've never worked so hard to get something this stupid to work at doing something this simple.

blue07; By the way, I did NOT overtighten the wellnut. The first time I ever took the bolt out, I couldn't thread it in because the wellnut was torn. Previous owner, or mechanic before me. Let's try this a different way. Maybe Kawasaki has changed their source for the wellnut, and I am getting the new replacement. My old wellnut has a bulge in the middle (9/16") that makes it fit tight in the hole, about 13/16" long, the small end is about 1/2", and the threads are about 9/16" down. The new wellnuts are all straight with NO bulge about 1/2" wide, 13/16" long, and the threads are 5/8" down. Both say "WELLNUT D-1420" on them, but the old one has "96", and the new one has "D25" imprinted on the flange too. Slight changes but enough to make a difference.

I'm NOT saying you tightened it too tight(that's unimportant).The NEW wellnut WILL NOT HAVE A BULGE IN THE MIDDLE UNTIL YOU TIGHTEN IT IN PLACE.IT WILL SLIDE INTO THE TAB.You can take the bolt-put it in the wellnut without tightening(except to get it started on the brass threads in there)-then insert WITHOUT THE BODYWORK-into the tab-tighten it down good-get the center threads moving up the rubber piece inside of the wellnut,THEN remove the bolt and it should sit firmly(or somewhat snug)in the tab.DOES YOUR WELLNUT HAVE A THICK ROUND FLANGE ON THE ONE END?(where you insert the bolt).You say"my old wellnut"-that's the damaged one,right?They are the right ones my man.Gotta tighten em like I said.Forget the numbers and lettering on there-that doesn't matter.The part # IS CORRECT.I have the same ones!!!!IF your wellnut has a THIN,FLIMSY looking flange on the one end-IT"S NOT THE CORRECT ONE.This flange is thick,like maybe about 3 nickels thick.It doubles as a spacer in there.

* Last updated by: blue07 on 10/6/2009 @ 12:31 AM *

My flange is the thick one, same as the damaged original. I tried that method during my 1st ordeal. Started the bolt, tightened enough to be bulged, shoved into the hole. I had to tighten it quite a bit, while holding the wellnut flange to keep it from turning, before the wellnut was secure. Took an hour break. Loosened the bolt, and tried again, but same thing. The wellnut basically fell out on it's own. The bulge doesn't stay, and without the bulge it's not tight enough. I can hear the wellnut squeaking as the bolt is tightening, but it's turning and never tightens enough to be secure. I'm beginning to wonder if it's possible that the hole is bigger than normal!