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  1. #1
    jackofalltrades's Avatar
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    Smile 2002 Polaris Genesis intake grate removal

    I put my previous post in the wrong area so here goes again. I have a broke bar on the intake grate and want to replace it. I took the screw out and got it loose from the hull but cant get it to come out of the ride plate. Am I missing something or do I just need pry harder Thanks for any info you can provide.


  2. #2
    Click avatar for tech links/info, donation request K447's Avatar
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    Are you pulling the intake grate forward to remove it from the ride plate?

    Is there sealant holding it in place?

    Do you have the replacement intake grate on hand?
    If so, you can see how it is shaped to fit into the ride plate.


  3. #3
    jackofalltrades's Avatar
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    Smile

    I finally got it off there. Had to take a tie down strap and pull it out. The sealant was holding it in there good. I ordered a good used one so once that gets here I will be good to go. Any particular type of sealant I need to re-install. I was going to use dow corning grey RTV sealant, seems to be simular to what was on it. Thanks.

  4. #4
    Lake Mead Bum & BTLS Mark starflight's Avatar
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    I would recommend using 3M 4200 marine sealant/adhesive. It's almost as good as 5200, but cures faster and comes off easier if you need to remove it later.

  5. #5
    jackofalltrades's Avatar
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    Thumbs up

    Here are a couple pics of the ski. Picked it up for $400 with the trailer. Couldnt turn it down. Waiting for the emm to come back from DFI then its off to the lake. One other thing that made the deal a little sweeter was it has a new rebuilt SBT engine with about 15 hrs on it! How did I do?
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  6. #6
    Click avatar for tech links/info, donation request K447's Avatar
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    While you are waiting for the EMM to come back, take the time to go over everything else.

    If you have not done so yet, remove the jet pump and check the bearings. Check, or even better, replace the seals in the through-hull bearing. Check the drive splines, impeller clearance. Lubricate the steering and reverse cables, steering shaft, throttle cables, and so on.

    Don't assume anything is good until you have checked it.

    My signature links will give you some pointers. Start at the back of the hull, and work your way forward, inside and out, checking every fitting, nut, bolt, hose and clamp...

  7. #7
    This is how I run a jetski shop in the desert nmpeter's Avatar
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    Quote Originally Posted by jackofalltrades View Post
    How did I do?
    lot better then the guy who thought I was going to give him $300 for an old tigershark with a rusted motor on a trailer.

    that's a fine looking ski

    you get your emm back after the rest of _mine_ come back ( three this month!)

    my tip:

    Use an AGM battery

  8. #8
    jackofalltrades's Avatar
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    Thanks for the tips. The jet pump and impeller was serviced when the motor was replaced to include new bearings and seals. I just checked the clearance and it is well within specs. As for the rest, I been looking it over hard the last week or so. I am going to change the fuel lines from the original factory grey ones since they feel a bit soft and go with a SAE J1527 B1 as you talked about in another post. Also, he mentioned that the nipples on the fuel pump had broke off twice before so I plan to brace the fuel line so it dont flop around between the fuel pump and #1 injector. Once I get the emm back, I plan to check the fuel pressure and make sure its working properly and the reg hasnt fallen off. I just hope it fires up when the emm is repaired. If not, I will R2 the start/stop module that I found hanging when I took off the access panel in the front compartment. I also found that the battery was bad so I ordered the Odyssey PC625 to replace it, should be here tomorrow.

  9. #9
    jackofalltrades's Avatar
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    Dang Pete, that why they wont answer the phone, you go them tied up with repairs

  10. #10
    jackofalltrades's Avatar
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    I am happy to say that my emm just came back from DFI and it cranked right up. Lots of smoke when you hit the gas but I figure thats normal since its not in the water. Those guys at DFI are great and have good customer service.

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