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1996 Polaris SLT 780

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  • 1996 Polaris SLT 780

    Ok, here we go.. First time PWC owner.. I'm so used to mercruisers, johnson/envinrude/mercury... But my first time with a pwc. This thread will be a single thread, containing all my questions, I will have a lot of them. I am 100% ignorant when it comes to pwcs. So here we are...
    PWC is on a trailer...
    Is there a manual online anywhere for one of these?
    What are the round holes in the back of it by the drive?
    Anything I need to check or do before trying to see if this thing starts?

  • #2
    Is there a manual online anywhere for one of these?
    Might be, check at Green Hulk site, they would know. Can be found for around 25

    What are the round holes in the back of it by the drive?
    Would be best to take a pic, but one is the jet output, one would be the connection when a hose is used to run it on land. The third should exhaust or cooling water exhaust

    Anything I need to check or do before trying to see if this thing starts?
    The ski uses oil injection, so make sure you have oil in the tank unless someone has by passed it and your now mixing oil with the gas
    94 Formula 27PC Custom 509MPI MEFI3 , B3 XR
    95 Rinker 232 w/ 7.4L Carb 0F425011 B1 0F486471
    07 SeaDoo GTX
    Raw Water Pump Maintenance
    Merc Adults Only
    G-Dad always said "First Liar doesn't stand a chance"

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    • #3
      Hole

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      • #4
        Also, I need a battery.. Does not have one in there. Anyone know what size, type, brand?

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        • #5
          This is where the drain plug went. Someone has removed the hole drain plug assembly. Search for watercraft drain plug and find one that looks something like this. You can use a different type but it will take some modifications. There should be one on each side

          Click image for larger version

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          Search for "1996 polaris slt 780 battery" and it will come up with several listings. They typically use motor cycle batteries. If you get it all going good, I would recommend using an AGM battery when the next battery is needed
          94 Formula 27PC Custom 509MPI MEFI3 , B3 XR
          95 Rinker 232 w/ 7.4L Carb 0F425011 B1 0F486471
          07 SeaDoo GTX
          Raw Water Pump Maintenance
          Merc Adults Only
          G-Dad always said "First Liar doesn't stand a chance"

          Comment


          • #6
            Thanks. I only see 1 hole

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            • #7
              make sure that your motor is in perfect tune and the center carb isnt running lean (common problem on the 780's) if the center carb runs lean, you destroy the center piston in very short order.
              1988 Cruisers Rogue 2420 -VP 290 DP now powered by custom 468 - http://forums.iboats.com/forum/owner...988-rogue-2420

              Past Boats
              1970 Wooster Hellion - Merc 9.8
              2002 SeaRay 190BR - 5.0 - A1G2 - "Cheasheads in Paradise"
              1984 Avanti 170DLI -3.0 stringer- "Ship Happens"

              What’s behind you doesn’t matter.Enzo Ferrari

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              • #8
                Pump was trashed. Have new one but the housing has all this on it.. how to hone it?
                Attached Files

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                • #9
                  Not a Polaris guy but all the pumps I've worked on have a wear ring which is installed. If it uses a wear ring also then no need to hone

                  94 Formula 27PC Custom 509MPI MEFI3 , B3 XR
                  95 Rinker 232 w/ 7.4L Carb 0F425011 B1 0F486471
                  07 SeaDoo GTX
                  Raw Water Pump Maintenance
                  Merc Adults Only
                  G-Dad always said "First Liar doesn't stand a chance"

                  Comment


                  • #10
                    I thought that, but this appears to be one solid piece.. Looking through the service manual, they are just calling it a pump housing.. saying if excessive wear, etc.. place pump housing
                    Last edited by SaveTexomaBeaches; August 1st, 2017, 01:50 PM.

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                    • #11
                      The cone doesn't look like the parts in the breakdown



                      Does look similar but not like a part. Item 24 is the wear ring
                      http://www.polarispartshouse.com/oem...lt-780-i964588
                      Click image for larger version

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                      94 Formula 27PC Custom 509MPI MEFI3 , B3 XR
                      95 Rinker 232 w/ 7.4L Carb 0F425011 B1 0F486471
                      07 SeaDoo GTX
                      Raw Water Pump Maintenance
                      Merc Adults Only
                      G-Dad always said "First Liar doesn't stand a chance"

                      Comment


                      • #12
                        Yes, part 24.. Pump housing extension/wear ring. That is one solid piece though right? Because what Im finding, it places want 150+ for that

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                        • #13
                          Your right my bad. Looks like Polaris doesn't use a wear ring, they use an aluminum extension housing. Most others use an aluminum housing and a plastic wear ring which fits inside the housing. So if those nicks are not that bad I wouldn't even hone it. If you hone it then your removing material further away from the impeller. The further the impeller gest away from the housing the less power it has to push the ski
                          94 Formula 27PC Custom 509MPI MEFI3 , B3 XR
                          95 Rinker 232 w/ 7.4L Carb 0F425011 B1 0F486471
                          07 SeaDoo GTX
                          Raw Water Pump Maintenance
                          Merc Adults Only
                          G-Dad always said "First Liar doesn't stand a chance"

                          Comment


                          • #14
                            well they arent really nicks.. they are parts from the other impeller melted/slung against it.. i took a pick and was able to pop off alot of them, smooth under it. almost like if you tried to weld onto galvanized metal without grinding it first. you'll get a nice bead, but 0 penetration/welding.. weld will knock right off and still have smooth under it

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                            • #15
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                              Ok, so I tried sanding and honing.. nada.. tried to be gentle.. was not happening. so I got the air grinder out and knocked all those suckers off and polished up the inside, slide it over the impeller and smooth fit. no scraping -- got the pump put all back together, greased and installed. Went around and lubed up all my cables and moving parts. Tomorrow, drain gas

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