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Thread: 96 SL780

  1. #1
    cajunup's Avatar
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    96 SL780

    Hello all! I am new to the forums, and ready to soak up as much knowledge as I can. I recently purchased a 96 SL780 not running with a new engine, blown CDI and wiring, and am in the process of rebuilding. I was over at pwctoday, they said to check the pop-off on the carbs and i was wondering if anyone else had any input on the most efficient way of making this thing a reliable machine. I removed the engine from the hull yesterday. Anything else i should replace or check while i have the engine out? Thanks!

    PS: These are a few pics before i yanked out the engine..









  2. #2
    Moderator beerdart's Avatar
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    Welcome to the Hulk.
    There is lots of info in the tech section including manuals.
    Any questions just ask.

  3. #3
    Click avatar for tech links/info, donation request K447's Avatar
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    Welcome to the Hulk!

    For Polaris PWC, this is the place you need to be.

    Do a search here for Fuji engine, as most 1992-1997 Polaris models (SL, SLT) have similar maintenance and upgrade issues.

    Be sure to download the 67MB POLARIS PWC SERVICE MANUAL (link found in the Tech section). There is an newer, cleaner PDF version of this manual in the works, but it is not quite finished yet.

    Common items for your era Polaris inlcude;
    Replacing all the original fuel lines, including those inside the tank
    Carb disassembly and cleaning

  4. #4
    100 MILES OF HEAVEN AND I AM SMACK IN THE MIDDLE KEYZBUM's Avatar
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    WELCOME TO THE FORUM
    there is no better place for info,parts,PEOPLE
    this will be the last place you will ever need
    ohhh and nice pics --(you will fit in here well)
    mattman

  5. #5
    cajunup's Avatar
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    thanks, besides the regular carb work and fuel lines, what else should i replace that maybe doesnt have a very long life span? also, where can i order the bumper and trim pieces for my ski? does anyone produce aftermarket in diff colors?

  6. #6
    ph2ocraft's Avatar
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    Hi cajun, I'd also like to say WELCOME to the Green Hulk Forums!!!
    If you do a quick search there are a few guys parting out body parts for the SL's.
    Check with zigler as I'm pretty sure has them as well.
    The 780 is a pretty hard machine to kill and other than replaceing the usual fuel lines the rest of the boat is pretty tough to kill.

    Check impeller pump bearings for roughness.
    Check pulse line to fuel pump.
    Check oil supply lines.
    Check and replace fuel lines.
    Check for cracks around the fuel cap and cap filler neck.
    I'm sure others will throw a few more ideas your way.

  7. #7
    Click avatar for tech links/info, donation request K447's Avatar
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    Did the 1996 780 already have the triple outlet fuel pump?

    If it is still the single outlet pump, many have upgraded to triple output fuel pumps to ensure adequate fuel delivery.

    Do you want to restore your SL780 to stock form, or are you looking forward to more power and speed, handling, or perhaps better acceleration?

  8. #8
    Moderator beerdart's Avatar
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    780 already has the high volue three outlet fuel pump.

  9. #9
    ph2ocraft's Avatar
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    96 already has the good pump.
    If you want to make some small gains, just copy the SLX CHANGES.

  10. #10
    cajunup's Avatar
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    well seeing as it isnt running right now, i think that me getting it running and in the water will make me happy for now...then maybe see what i can do as far a power mods....

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