InstallationP

Drill,
- 1" Hole Saw Bit,
Center Punch,
Razor or Utility Knife,
2 Large Crescent Wrenches,
Channel Locks, or 1/2" Drive Ratchets with 1 1/16-1 1/8" sockets.
Marker or pencil.
light Grease or petroleum lubricant
Locktight thread locking compound

(1) velcro boot covering,
(1) urethane tow pad,
(1991 -'95WR3 models:
- one stainless Bracket assembly & one stainless bottom plate;
‘96-'99WR3 and Wave Venture:
- one Stainless Bracket assembly and one urethane top plate,
- one stainless and one urethane bottom plate;
1999 and 2003 model XL, XLT, SUV, FX and GP hulls:
- one stainless bracket assembly, one urethane, and one stainless bottom plate each);
(2-4) 3"x 3/4"-10 Stainless bolts,
(2) 2.5"x 3/4"-10 bolts,
(10-12) flat fender washers,
(6-7) spring lock washers,
(5-6) 3/4"-10 nuts,
(2) 3/4"-10 Jamb Nuts, (2-4) aluminum bow eye bushings.

1. You will need to drill one to four 1" diameter holes. To do this, remove all stock plastic tail bushings or squirt nozzle fittings(if any are found within the center of pwc rear step). The existing holes may need to be slightly reemed out to fit aluminum bushings in the holes.

Your hitch assembly comes preassembled. When disassembling the components for installation take careful observations as to how it was assembled as this is the fashion in which you will be installing the hitch to your pwc.

Disassemble the nuts and bolts from the lower portion of the hitch bracket assembly, the bottom urethane and/or stainles plates, the aluminum bushings (if any) are included, and the top urethane plate (if any) is included with your particular hitch.

Place top stainless bracket hitch assembly ( and top urethane plate if 1996 & later WR3 or Wave Venture hulls) on top of stern step, locate and mark the position for the holes needed to be drilled. Remove the assembly temporarily and Drill holes. (A center punch sometimes helps with guiding the drill bit when starting the hole.)

After drilling holes, clear out debris. Place the aluminum bushings in the two outside holes that you just drilled (Not used in 1999 and later models). With a razor blade or utility knife, trim away rubber mat from around bushing for a flush mount fit on the pwc hull. Tighten the aluminum bushings.

2. Place 3/4" x 3.0" (1991-1996 WW3, 1999- XL, SUV, FX and GP hulls) or 3.5 and 4.0"(1997-2000 XL 760) Bolts and fender washers provided through the holes on the Stainless hitch bracket assembly. Then place the top urethane plate(1996-1999 WR3 and WVenture models only )through the bolts.

Run the bolts through the holes in the velcro boot making sure that the velcro is facing up. Place the entire assembly on the stern area of the PWC, passing the remaining thread through the aluminum bushings.

3. Once you have placed the top part of hitch assembly on the pwc stern and located the bottom match plate(s), fender washers, lock washers and nuts,pass the bolts through the aluminum bushings. Apply a generous amount of Locktight thread locking compound to the nut and bolt threads before tightening hardware down. This compound provides two important features: one, it keeps the nuts from loosening from vibration and two, it protects the metals from oxidizing and seizing in the harsh saltwater environment so that they can be removed at a later date.

(You will probably need to loosen up on the double nut feature on the triangular hitch bar to get enough play to mount the sled for the first time. After the sled is mounted, tighten up the double nut feature so that there is very little up and down slop and enough play to allow side to side motion.

Align the entire assembly, apply some locktight, and tighten down all the nuts and bolts. To mount sled, have one person raise the tail end of the sled above the nose end and have a second person guide the front of the sled towards the triangular hitch bar remove the cross pin, lightly grease the cross pin, and locate the sled up to the hitch (the bottom of the sled at the nose area rests on top of the urethane rubber tow pad overhang. The urethane tow pad overhanging portion does not rest on the deck surface of the sled) To reintall the lightly greased cross pin, with one hand supporting the sled up by a front hand grip and the other hand holding the cross pin, slide the cross pin through the first hole, line up the triangle hitch bar tube, slide the cross pin through the triangle hitch bar tube, and line up the sled to slide the pin through the remaining hole, fasten lynch pin to end of cross pin.

After the first couple of uses the double nut feature loosens up. 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. Fold velcro boot over and fasten to sled. You're good to go! (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.