2003 STX-12f

[leejax01]

I started at the pump and went both ways. Took the air box out to get to what all I could. On hoses connecting to where I could not reach, I was able to blow and assure free flow. Only blockage I found was at the waterbox and did check the whole system a few times. I believe the manifold is the culprit. Maybe a hole is corroded allowing cooling water in the exhaust. Found a few holes so far with 2 in the waterbox neck and 1 in the exhaust manifold under the blue hose coupler. That leads me to think there may be more in the exhaust manifold. I don't mind helping to get it going, but knew it may end up going this route and don't want to be the fall guy in case other issues arise down the road. I tried to fix what I could, but time for him to buy a few parts. Thanks again for all the help guys and will check the cooling system again in case I did miss something

[smokeysevin]

If there are more holes its worth Pulling the Intake manifold to check the cooling log under it. Kawi replaced the part with a new one and the early ones are known to rot and flood the ski.

Sean

[Shuswap]

Sounds like this thing could be rented out as a mobile power sprinkler.

I'd yank the intake manifold and the entire exhaust system, pressure test each and have a real good look at that problematic pipe (or cooling log as Smokie calls it) under the intake manifold....where you may find a significant problem with the water nipple corroded to the point where it leaks or blocks flow. Kawasaki makes a new one that doesn't corrode the same way.

If you check your email address (that I sent something to the other day) you'll find a picture of the pipe....er "cooling log"

[leejax01]

Thanks for the info guys. I already checked the cooling system and that water rail has flow through it with no leaks at this point. Will try another exhaust manifold and waterbox as well as testing the fuel pressure. Thanks again.

[leejax01]

Ok, have a donor ski to get the gauge and whatever else we need. Question. Is the 12f and 15f exhaust manifold the same and will fit? Looks a little different at a glance.

[Shuswap]

Perhaps go to Kawasaki's site and see if the part numbers are the same?

[smokeysevin]

The physical manifolds are the same but they use different sealing rings.

Sean

[leejax01]

Thanks. So I will need new exhaust gaskets and sealing rings. Thanks.

[meangreenman]

Is the 12f and 15f exhaust manifold the same and will fit? Looks a little different at a glance.

YES, the 12F and 15F use the EXACTLY same exhaust system parts as following:

Exh Manifold P/N 590813741
Gasket for Exh Manifold P/N 110613713
4-1 Exh Collector Pipe P/N 180883723
Gasket for 4-1 Pipe P/N 110613714
Sealing Rings P/N 130031383 x 2

When you install the Rings, make sure you apply a little piece of paper tape (like masking tape) to secure the Rings in the groove. More than often, the Rings get pushed out of the groove and hot exhaust gas leaks out, burning the connecting rubber tube. The masking tape will burn out and disappear.

[leejax01]

Thanks. Will definitely get it going soon. Got a new fuel pump, gauge and exhaust manifold/ waterbox. Will double check the cooling lines again.