HULL AND BODY
7.18
2004 Four Stroke PWC Service Manual
Top Deck / Hull Repair
The hull and top deck are manufactured using Fiberglass Reinforced Compound (FRC).
Repair kits are available through Polaris Industries. Detailed instructions regarding material preparation, setup
and cure times are included with each kit. However, sound knowledge of FRC repair is required when working
with these kits. Polaris recommends that a dedicated marine--fiberglass repair facility inspect or be consulted
with prior to attempting any repairs.
Footpad Removal
1. Peel off the footwell pad that is to be replaced. Use a
heat gun to soften the adhesive.
W ARNING: Use the heat gun on its lowest heat setting.
Do not heat the footwell pad or hull for more than a second.
W aiving the heat gun back and forth once is sufficient to
soften the adhesive. Prolonged heating will permanently
damage the hull.
2. With the footwell pad removed, apply Goo Gonet and
remove all old adhesive from the hull. If scraping is
required, only use a soft plastic material.
3. Remove Goo Gonet with mild detergent soap. Wipe
surface with acetone. Allow Acetone to completely
dry.
Footpad Application
4. Peel a small portion of backing material away from the
new footwell pad, and immediately apply to deck.
5. Work the pad with your fingertips until the entire pad is
pressed onto the deck surface. Constant pressure
activates the adhesive and works out any air bubbles
out from under the pad.
6. Allow for 24 hours for adhesive to cure.
NOTE: Do not allow the pad temperature to exceed 80°F,
or below 60°F for at least 24 hours. Always cover the wa-
tercraft when exposed to direct sunlight for long periods
time.
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