05 Kawasaki STX-12F Fuel Tank Question

[BigDog9721]

Does anyone know the part number for the styrofoam that fits underneath the fuel tank? Or any suggestions on how to configure one?

[steve45]

To my knowledge, that is not available through normal channels.

I have several Ultra LXs and discovered that my 2013 was missing some foam flotation material in the back on one side, but the 2010 model had it. I contacted my dealer and they called an engineer at Kawasaki who looked it up by HIN. He said that my 2013 was not supposed to have foam on both sides, only one. I asked if I could order it for the 2010 and install it myself, but they wouldn't sell it to me. Have your dealer call Kawasaki and ask.

That said, I have a 2004 STX-15F that I will be parting out one of these days. I can probably get that foam out and send it to you. I'm not sure if it can be removed in one piece without splitting the hull. The engine and tank would obviously have to be removed first. I wasn't planning to work on that 'Ski just yet, but maybe it's time. My wife is tired of looking at it.

[BigDog9721]

Steve45, knowing what i know on getting to that foam, that would be a major undertaking just for me... I've already called Kawasaki, and they don't have a part number on that either... so... with that in mind, what alternative would you use to replace it? I threw the old one away because it smelled of gas and oil and was useless in keeping (dangerous too!). I was thinking just going and making foam inserts but in pieces... I couldn't just make one to fit... that would be impossible. You would think(?) Kawasaki would have a part number so I could search on eBay, etc... .

BTW, do you have the dash gauge display cluster off of that 15F? I have another 2008 15F that my son also got me roped into to rebuild... I've learned a WHOLE lot rebuilding these engines, hopefully the 2nd one will be alot easier(?). Hopefully the 1st one runs smoothly!

[steve45]

The foam is a flexible closed-cell foam. If you were to try to make one from Great Stuff canned foam, or similar product, it would be brittle and would deteriorate quickly. That would be a mess. You may be able to find a source for the correct foam mix on the internet. I'd place a sheet of plastic in the hull, then lift the tank and wrap a plastic trash bag around that, then spray the foam mix in there and gently lower the tank so that it's well supported by the foam while it cures.

There are a number of parts that Kawasaki considers to be hull components that are not available separately. One that really pisses me off are the old plastic HIN plates that are essentially designed to break. Sure can make life difficult if you encounter a law enforcement officer and don't have a hull number plate. Kawasaki refuses to provide replacements, even to dealers with proof of hull ownership.

I don't mind pulling the foam for you, but it will be a while. No charge, but you'll have to pay shipping.

Sorry, I don't have a display. All mine will be used in my engine conversions.

If you have a display that needs help, contact Performance Design at 407-790-5642, text only. Also, there are several YouTube videos that explain how to take the display apart.

EDIT: This may help you with foam: https://www.wifoam.com/foam/closed-c...yethylene-foam

[K447]

Waterproof foam intended for landscaping of waterfalls and such seems appropriate for use as in-hull floatation foam.

Years ago another GH member recommended it when he re-worked the battery tray, which was molded foam from the factory. I think it was a minimal expanding type of foam, aerosol pressurized can.

It is available in black and perhaps some other colors.

https://www.greenhulk.net/forum/personal-watercraft-performance-skis/polaris-pwc-performance/polaris-how-to-faqs/17870-battery-improvement#post627493

That was a killer tip, one thing I noticed, if you don't leave the wax paper flat and it has folds and wrinkles the foam gets in there and holds the paper.
… what I used for foam and worried about it acting like a sponge.

I used an exterior Polyurethane Sealant called Touch 'n Foam (in black).
It says it's "ideal for ponds and waterfalls", "superior adhesive for landscaping projects", "expands and fills voids".

[BigDog9721]

Steve45, the key is finding the correct source for correct foam mix ... I pulled the tank out already... it was filled with rust and crud.... it was better to pull and clean versus cleaning while still in the hull. After cleaning it looks great! Now i know the gas will be clean & pure...

No I don't have a display at all... I'll keep checking ebay, etc...

[BigDog9721]

K447, thanks for your input! I went to Amazon and found XCEL Extra Large Marine Roll for $39.95 that I think(?) will do the trick... your feedback would be great!

[steve45]

When shopping for a display, make sure you get the correct part number, 25031-3754. There were several variations in the early years with SLO mode, etc.

[BigDog9721]

Steve45, will do!

[steve45]

I looked at the foam under the tank on one of my -15's today. It looks like there are 3 pieces: one on each side of the tank, and one underneath it. It really doesn't look hard to change after you pull the engine out.

[BigDog9721]

I did the Amazom XCEL Extra Large Marine roll... it worked perfectly... lots of sticky on one side and when tank is weighted down on it along with straps, it did the trick...