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  1. #1
    Budman's Avatar
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    Engine troubles on 2000 Genesis--Need help

    I noticed last week that my 2000 Genesis was getting water in the hull. Yesterday it started sounding louder than usual. It then died in the middle of the lake and would not restart. After towing it back to the boat ramp It restarted but had no power. Again very loud under the seat. When I got home I did a compression test and all three cylinders are at 120 lbs just as the last time I checked it. I started it up. (Started very easily) It was load in the engine compartment and exhaust smoke was coming out from around the engine. If the exhaust sections are coming apart will water come out into the hull? The exhaust manifold has a U bend and then goes into a separate section. The section after the U is very loose and can be moved around easily. Is this normal? There is a small hose that goes into the elbow. Is this a water line? I can't download the service manual because of computer problems. Anyone have a pic or drawing of the exhaust system?
    Thanks
    Budman


  2. #2
    Click avatar for tech links/info, donation request K447's Avatar
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    The exhaust manifold and large pipe does have a water jacket, and water is also injected into the exhaust stream.

    The exhaust system should be tightly bolted together - no loose sections.

    If you are leaking exhaust into the hull, the engine will be starved for fresh air, so power will be down.

    The attached picture might help you figure out what has come loose.

    Water injection is items 2 and 3, which are connected with a small hose.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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  3. #3
    Budman's Avatar
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    Thanks K447, That is the pic I was looking for. Item # 12 is the one that is very loose. Hopefully the clamps # 6 have just came loose and it will be an easy fix.
    Thanks
    Budman

  4. #4
    Budman's Avatar
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    I slid the exhaust pieces together and tightened the clamps. It ran fine for about 3 minutes and it came apart again. I turns out that parts # 14 and 15 are missing. Does anyone know what size bolt this is? Is it something I can get at the hardware store?
    Thanks,
    Budman

  5. #5
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by Budman View Post
    ...turns out that parts # 14 and 15 are missing...
    I would expect the missing parts are still there, in the bottom of the hull somewhere.

    Parts like to hide under the engine, and down by the drain plugs

    Ball up and stuff an old T-shirt under the engine, and push it through to the other side. See what comes out with the shirt

    Then stuff it under from front to back, use a stick to push it along...

    Get a small mirror and a good light, and peak in all the nooks and crannies towards the rear of the hull, around and under the battery, and so on.

  6. #6
    Budman's Avatar
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    Well its worse then I thought. I removed the water box and exhaust pipes. I found the the missing bolt and washers. The bad part is that the bolt broke off in the exhaust manifold. So i will have to remove the exhaust manifold to try to get the rest of the bolt out. I need to know about the manifold. Is there a gasket or just silicone? What is the torque specs for the bolt? If I ever find time to set up my new computer I will download the manuals. Until then I will have to tap you guys for info.
    Thanks for all the help!!
    Budman

  7. #7
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by Budman View Post
    ...I need to know about the manifold.

    Is there a gasket or just silicone?

    What is the torque specs for the bolt?...
    Do you have a buddy that could download the manual and put it on a CD for you?

    Torque specs
    Exhaust Manifold Bolts 8mm - 22 ft-lbs (Loctite 242 or 243)
    Exhaust Manifold to pipe bolts 12mm - 45ft-lbs (Loctite 242 or 243)

    "...Apply Ultra Copper™ silicone, making sure surfaces are clean and free from burrs. Torque evenly in three steps, as shown, to specification..."

    Torque chart is in attached PDF file

  8. #8
    Budman's Avatar
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    Thanks K447,
    You have been a great help.
    Budman

  9. #9
    Budman's Avatar
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    I have the genesis put back together now. Do I have to wait 24 hours before I can start it so the ultra copper can cure? I really want to start it to see if it works. I can't believe how fast polaris got the stainless bolt to me. I went to the dealer on monday afternoon and had the bolt on thursday morning.
    Thanks
    Budman

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