Tools Needed:

• Drill,
  • 1" Hole Saw Bit,
• Center Punch,
• Razor or Utility Knife,
• 2 Large Crescent Wrenches,
• Channel Locks, or 3/4 Drive Ratchets with 1 1/16-1 1/8" sockets,
• Silicone Seal

You will need to drill one to three 1" diameter holes. To do this, remove all stock plastic tail bushings and squirt nozzles. Temporarily place OEM style aluminum tail bushings in holes already provided by PWC Manufacturer.

1.)(1998-2001 ZXi, Ultra Hulls) Your stainless hitch assembly comes preassembled. Do not dissassemble connected parts on upper half of elevated stainless bracket! Look closely and notice how the lower assembly bolts and nuts are loosely assembled, as well as the order in which the bottom stainless plate and hitch boot covering are placed. Dissasemble the lower bolts, nuts, washers, and bottom stainless plate from the hitch assembly. Place top hitch bracket assembly on top of stern step and position the center hole on the bracket plate over the existing hole in the pwc hull (ZXi-look underneath and you will see the hole; Ultra-there are no holes, you will have to find the midline on the pwc stern step, locate the bottom plate underneath, and mark the holes where the assembly will match up and where you will need to drill.) Mark hole locations. Drill Holes.

After drilling holes, remove the top hitch assembly. Clear out debris. There are not any aluminum bushings in this application for covering holes.

2.)Place the top hitch assembly along with the hitch boot covering back on the stern step and locate it over the holes just drilled (making sure that the velcro is facing up, so that when it is folded over the hitch assembly the velcro is facing down and it can fasten to the velcro piece attached to the front of the sled).

Place 3/4" x 2" Bolts and fender washers provided through the holes on the bottom stainless plate. Position them underneath the stern and run the bolt through the pwc hull, the hitch boot covering holes, and the elevated stainless hitch bracket assembly.

3.) Once you have done this, locate the fender washers, lock washers and nuts (some pwcs require someone to stand on assembly, for weight, to help get enoughbolt thread for the first time). Align the entire assembly, and tighten down all the nuts and bolts.

To mount sled, remove the cross pin, locate sled upto hitch, reintall cross pin, fasten lynch pin to end of cross pin. Fold velcro boot over and fasten to sled. You're good to go! (Loosening the double-nut feature on the hitch triangle may be required to attach the sled for the first time. Once it is attached retighten the assembly so that there is some side-to-side movement but zero slop.

(Approximate assembly time: 30-45 minutes.)

Periodically, you will need to adjust and retighten the play in the double nut feature. Also, you will need to periodically retorque the rest of the nuts on the hitch. Even though the nuts are torqued on with spring washers, vibration tends to loosen the nuts slightly over a period of a few months. So, as a precaution, check the fastening hardware at every pre-op and post-op.