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  1. #1
    ctmaloney's Avatar
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    1996 SLT 780 Rebuild

    The guy I got it from burned up #1 and #3 right after he had the top end rebuilt. They didn't burn all the way through, so I don't think any bits made it down to the crank. I know it was bored when it was rebuilt. I think it is 0.5 over as the pistons have 0.5 stamped on the top? Would that be correct?

    Pics to come.


  2. #2
    I'm addicted to Polaris PWC ghostinstallations's Avatar
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    Glad to see you ended up picking that ski up. Trailer should be nice! Cant wait to see more detailed pictures.

  3. #3
    ctmaloney's Avatar
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    Quote Originally Posted by ghostinstallations View Post
    Trailer should be nice!
    I think the trailer got in a fight with a guard rail at some point. It pulls fine, but it's a little messed up. Nothing some tweaking can't fix.

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    Quote Originally Posted by ctmaloney View Post
    The guy I got it from burned up #1 and #3 right after he had the top end rebuilt. They didn't burn all the way through, so I don't think any bits made it down to the crank. I know it was bored when it was rebuilt. I think it is 0.5 over as the pistons have 0.5 stamped on the top? Would that be correct?

    Pics to come.
    Sounds like he got the high speed jets incorrectly set, almost like he used the '97 780 settings. If you read the manual wrong you can totally screw things up. The '96 used #110 jet size in all 3 carbs and then had different HS needle settings on each. In '97 they switched to HS needles all turned out 1/8 and then jets of Mag=125 CEN=122.5 PTO=130.

    If you had #110 jets ('96 config) with '97 HS needle config it would run and the CEN piston would probably be just about right. Unfortunately the MAG and PTO would be very lean. So, that's one possibility.

    The other possibility is both the front and rear crank seals are bad and that caused them to both go lean and burn down.

    KJ

  5. #5
    She likes the bike. But the ski gets her wet!!!! xlint89's Avatar
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    Yes you have that coorect. .5 stamped on piston is .5mm oversized.


    He may have rebuilt the top end because the carbs/fuel system are in need of service. If not remedied, it will happen all over again.... (which may have happened)


    Persoanlly, i would also budget in the fuel system update.

  6. #6
    ctmaloney's Avatar
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    Quote Originally Posted by xlint89 View Post
    Persoanlly, i would also budget in the fuel system update.
    I am definitely thinking the same. So, from what I have read here, I would rebuild the carbs and just rebuild, not replace, the fuel pump since it already has the better one.

  7. #7
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    Quote Originally Posted by ctmaloney View Post
    I am definitely thinking the same. So, from what I have read here, I would rebuild the carbs and just rebuild, not replace, the fuel pump since it already has the better one.
    Definitely open up the carbs and see what they need. If all of the rubber parts are soft and flexible, with no signs of drying or cracking a good cleaning may be all you need. Verify that you have all of the proper jetting and needle settings in your carbs. Check your inlet needles and seats as well. Do a rebuild on your fuel pump. The biggest thing is to do a leak down test on the engine when its all put back together. If you have no air leaks you should be good to go.

  8. #8
    She likes the bike. But the ski gets her wet!!!! xlint89's Avatar
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    Quote Originally Posted by ctmaloney View Post
    I am definitely thinking the same. So, from what I have read here, I would rebuild the carbs and just rebuild, not replace, the fuel pump since it already has the better one.
    Correct. However, I would still replaces the fuel hoses, oil hoses, and fuel selector valve due to age alone.

  9. #9
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    Pictures...

    MAG:
    Click image for larger version. 

Name:	MAG.jpg 
Views:	88 
Size:	88.0 KB 
ID:	263113

    CEN:
    Click image for larger version. 

Name:	CEN.jpg 
Views:	89 
Size:	131.9 KB 
ID:	263112

    PTO:
    Click image for larger version. 

Name:	PTO.jpg 
Views:	96 
Size:	118.8 KB 
ID:	263111


    Click image for larger version. 

Name:	Overview.jpg 
Views:	102 
Size:	102.2 KB 
ID:	263110

  10. #10
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    Looks like you need a top end

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