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  1. #1

    Join Date
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    Genesis Engine? Problem

    I have been working on two used 2002 Genesis Project skis. Original owner says they have been sitting for last two years. After replacing fuel pump, ski #1 is now up and running. Now moving to ski #2. I replaced the battery today and put in new plugs and fuel. When I tried to crank the engine smoke came from the batter wires and wires got extremely hot. Had to quick cut battery wire to stop smoke. After further examination I found that I cannot crank the engine by the hull shaft as I can in ski #1. It appears the engine maybe frozen.

    Can anyone suggests the steps I should take to trouble shoot this problem?


  2. #2
    polaristxi's Avatar
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    Oct 2007
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    Little Elm, TX
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    52
    Look at spark plugs. If any damage, remove the head and investigate.

    If no damage, try soaking the cylinder and pistons with oil. Than use a wrench on the PTO, rocking it back and forth. Had a Virage that was locked up, but found out it had been under water and the crank bearings were corroded. If it breaks free, it needs to turn smoothly or I'd be tearing the engine down.

    Or......... look at cylinders and pistons using a boroscope. If you don't have access to one, you will need to remove a head.

    Good luck with it.

  3. #3
    2&4strokepolaristech's Avatar
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    pull off the jet pump and make sure that it is not locked up. Isolate your problem.

  4. #4

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    Apr 2010
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    Pulled the cylinder head off and found no directly visiable damage. Tried to remove the cylinders. Cylinder #1 (towards front of ski) could be removed with little effort. Did not yet try cylinder #2. However, cylinder #3 will not budge.

    Does anyone have suggestions on how break the cylinder free without causing damage? I have about a 1/8 of oil sitting in the top of the cylinder to soak it.

    Thanks,
    Jeff

  5. #5
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by 2&4strokepolaristech View Post
    pull off the jet pump and make sure that it is not locked up. Isolate your problem.
    Quote Originally Posted by Jeffa15 View Post
    ...cylinder #3 will not budge...
    Did you remove the jet pump yet?

    If not, do that FIRST.

  6. #6
    ph2ocraft's Avatar
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    Quote Originally Posted by Jeffa15 View Post
    Pulled the cylinder head off and found no directly visiable damage. Tried to remove the cylinders. Cylinder #1 (towards front of ski) could be removed with little effort. Did not yet try cylinder #2. However, cylinder #3 will not budge.

    Does anyone have suggestions on how break the cylinder free without causing damage? I have about a 1/8 of oil sitting in the top of the cylinder to soak it.

    Thanks,
    Jeff
    Soak it in diesel fuel overnight, it will penetrate much better than an oil only.

  7. #7

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    Apr 2010
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    Orange County, CA
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    I have not yet removed the Jet Pump.

    I had thought I need an impeller removal tool to take out the Jet Pump. I was trying to look first at the items I could this weekend.

    Do you have a reference for good instructions on Jet Pump removal for a Genesis?

    Thanks,
    JEff

  8. #8
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by Jeffa15 View Post
    I have not yet removed the Jet Pump.

    I had thought I need an impeller removal tool to take out the Jet Pump. I was trying to look first at the items I could this weekend.

    Do you have a reference for good instructions on Jet Pump removal for a Genesis?

    Thanks,
    JEff
    No special tools required for jet pump removal.

    Instructions have been posted in many threads.

  9. #9

    Join Date
    Apr 2010
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    Orange County, CA
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    Thanks for the input.

    I found the instructions after replying to your post. I will pull of the pump and post the results.

    Thanks again,
    Jeff

  10. #10

    Join Date
    Apr 2010
    Location
    Orange County, CA
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    26
    Need more advice.

    I removed the housing from the Jet Pump as described in the service manual. However, the impeller assembly will not budge. The service manual says that I should just be able to work it out with an orbital motion. However, it is stuck on solid.

    Any suggestions for removing this assembly?

    FYI - When I remove the nozzle assembly I found a fair amount of sand inside.

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