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Download Polaris VIRAGE W005197D User's Manual
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VIRAGE Model #W005197D INT’L VIRAGE Model #W005197I Rev. 01 E 2000 Polaris Sales Inc. PARTS MANUAL PN 9915581 and MICROFICHE PN 9917173 11/00 TABLE OF CONTENTS VIRAGE W005197D and INT’L VIRAGE W005197I Parts Manual B F BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . B10 BILGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . B13 C CARBURETOR . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT and PISTON . . . . . . . . . . . . . CYLINDER & MANIFOLD . . . . . . . . . . . . . . . H HULL and BODY . . . . . . . . . . . . . . . . . . . . . A7-8 C6 B11 C3 C5 C4 D M MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . C8 O OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . C7 OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . A14 P DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A10 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . B3 E ELECTRICAL BOX . . . . . . . . . . . . . . . . . . . . ENGINE AIR INTAKE/HULL AIR INLET . . . . ENGINE FOGGING SYSTEM . . . . . . . . . . . . ENGINE MOUNTING . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . FUEL/WATER SEPARATOR . . . . . . . . . . . . . C10 PROPULSION . . . . . . . . . . . . . . . . . . . . . . . B4 R REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . B5-6 C1-2 B14 C11 B9 B7-8 F FRONT STORAGE COMPARTMENT . . . . . . A9 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . A12 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . A11 S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHROUD . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR . . . . . . . . . . . . . . . . . . . STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . T A13 A5-6 C9 B1-2 TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . C12 W WATER INLET . . . . . . . . . . . . . . . . . . . . . . . B12 The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly. 2000 VIRAGE WATERCRAFT SPECIFICATIONS CAPACITIES Fuel Tank Reserve Fuel Tank Injection Oil Reservoir ENGINE 17 US Gallons (64.26 l) N/A 6 Quarts (5.68 l) Regular Unleaded 87 Octane or 89 Octane Oxygenated 1-40mm Diaphragm Type Carburetion Idle Speed 1350 50 RPM COOLING Cooling System Type Water Cooled, Thermostat Pop off Overheating Warning Warning Light/RPM Limit Number of Cylinders 131.1² (330.5 cm) 2 700cc Compression Ratio Effective 6:8 Maximum Power (approx.) 95 HP Maximum Torque (approx.) 69.2 @ 6500 RPM RPM Limiter Operation 7200 RPM 100 PROPULSION Transmission Height, Overall 39² (99.06 cm) Impeller Diameter Hull/Deck Material Polaris TC-W3 or Injection Displacement Minimum Water Level for Jet Pump Load Limit Oil Injection 68mm 49.3² (125 cm) 650 lbs. (295 kg) Water Cooled/Injected Stroke Width, Overall Dry Weight Case Reed 81mm Jet Pump Type 1-4 Persons Polaris Marine 700 Bore Propulsion System DIMENSIONS Length, Overall Exhaust System Oil Type Carburetor Type and Number Number of Passengers Induction Type Lubrication CARBURETION Gas Type Engine Type Impeller Jet Drive Axial Flow, Single Stage Direct Drive 2 feet (60 cm) 5.83² (14.80 cm) 3 Blade, Slim Hub 600 lbs. (273 kg) Deck - FRC, Hull - SMC ELECTRICAL Alternator Output Ignition System 8.5 amps/60 watt at 4500 RPM CDI Spark Plug Type NGK BPR8ES Spark Plug Gap .028² (0.7 mm) Starting System Electric Starter Ignition Timing; BTDC @3000 RPM Battery 23° 12V, 19A Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice. 2000 POLARIS VIRAGE PUBLICATION NUMBERS MODEL MODEL # OWNER’S MANUAL PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS VIRAGE INT’L VIRAGE W005197D W005197I 9915574 9915574 9915581 9915581 9915589 9915589 9915597 9915597 SHROUD VIRAGE W005197D and INT’L VIRAGE W005197I 1 2 4 3 4 6 5 E 2000 Polaris Sales Inc. 7 47 8 46 9 10 34 43 17 42 41 11 12 14 36 35 17 18 19 38 37 15 16 13 39 40 45 44 32 34 33 25 26 17 20 27 21 24 23 17 20 A5 22 31 28 29 30 SHROUD VIRAGE W005197D and INT’L VIRAGE W005197I Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 3280339 5411738 8450070-190 7041931 2632234 2201593 3280342 5433709-311 7041754 5521478 7546705 5811783 7516609 5211865 7517668 7556055 7555874 5411557 5411558 2631973-070 2631972-070 7546804 7080926 7546704 7555839 Qty. 1 1 1 2 1 1 1 1 1 1 2 1 2 1 4 2 8 1 1 1 1 4 1 2 2 Description Gauge, MFI, Analog/Digital Gasket, MFI Line, Pitot, Formed End Spring, MFI Mounting Asm., Console Latch Kit - MFI Button Replacement Bezel, MFI, Overlay Lid, Console Spring, Torsion, Console Seal, Console Lid Nut Pad, Console Screw Plate, Hook Screw Washer, Lock Washer, Flat Gasket, Mirror, LH Gasket, Mirror, RH Asm., Mirror, RH (Incl. 18) Asm., Mirror, LH (Incl. 18) Nut, Hex Cable, Choke Nut, Nylok Washer Ref. Part No. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 7541931 5244673 7516717 5411664 2690151 5433210-070 ------2690150 7710517 7516805 7552613 7556094 5433589-311 5812076 2080004 2080005 5244670 7555837 7517818 7512045 5811552 5433266 5333698 5433384 Qty. 2 1 2 1 1 1 1 1 2 6 8 6 1 1 1 1 1 2 2 2 1 1 1 1 Description Nut Bracket, Support, Shroud Bolt Grommet, Deck, Wire Harness Strap, Tool Kit, Lower Cover, Wire, Shroud Kit, Tool (See Tool Kit Pg. C12) Strap, Tool Kit, Upper Ring, Retaining Screw Washer, Lock Washer Shroud, Steering Bumper, Door/Shroud Knob, Choke Screw Plate, Latch, Receiver Washer, Flat Screw Screw Gasket, Console Hook Hook, Console Pin, Hinge Hinge, Console 1/01 A6 HULL and BODY VIRAGE W005197D and INT’L VIRAGE W005197I Bulkhead 1 6 5 2 32 31 30 29 28 3 33 35 30 31 8 10 27 34 7 8 8 10 9 8 13 12 26 4 29 8 25 10 24 14 13 23 22 19 11 12 21 15 20 18 14 15 16 17 A7 13 HULL and BODY VIRAGE W005197D and INT’L VIRAGE W005197I Ref. Part No. 1 5811915-070 2 5811913-070 5811914-070 3 5811911-070 5811912-070 4 5811909-070 5811910-070 5 5411158 6 5411658 7 7516807 8 7556094 9 5433671 10 7546704 11 5411758-070 12 7621511 13 5431994-070 14 7542133 15 7555839 16 7555870 17 2670150 Qty. 1 1 1 1 1 1 1 2 1 2 14 1 8 1 31 29 4 12 2 1 Description Ref. Part No. Pad, Boarding Platform Pad, Footwell, Rear, LH Pad, Footwell, Rear, RH Pad, Footwell, Center, LH Pad, Footwell, Center, RH Pad, Footwell, Front, LH Pad, Footwell, Front, RH Grommet Grommet Screw Washer Plate, Seat Tongue Nut Bumper, Front Rivet Plug, Bumper, Rear Nut, Nylok Washer Washer, Dish, Rubber Strap, Bow 18 5521568-070 5521569-070 19 5811440 20 5432272-070 5432273-070 21 7515198 22 7517320-070 23 7555836 24 5811918 5811919 25 5433531-070 26 1060125 27 7511882 28 2632218 29 7517644 30 7555846 31 7542454 32 5020753 33 5433474-070 34 7552607 35 5433473 Qty. 1 1 10 1 1 10 2 2 1 1 1 2 4 1 6 2 2 1 1 1 1 Description Rail, Rub, Side, LH Rail, Rub, Side, RH Washer Sponson, LH Sponson, RH Bolt Bolt Washer Pad, Heel, LH Pad, Heel, RH Bumper, Rear Plug, Bilge Screw Hook, Tow Screw Washer Nut Plunger, Latch Handle, Grab Washer, Lock Bucket, Rear Storage 4/00 A8 FRONT STORAGE COMPARTMENT VIRAGE W005197D and INT’L VIRAGE W005197I 1 2 10 11 12 13 7 14 8 9 3 6 19 5 15 20 4 16 17 21 22 18 22 23 Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 2653012 5433710-311 1013282 7555890 7546704 7517669 7516805 7552613 7555839 7555837 7552615 7512045 5521565 Qty. 1 1 1 5 5 5 4 4 4 2 2 2 1 24 Description Ref. Part No. Latch, Door Door, Compartment Asm., Door Hinge Washer Nut Screw Screw Washer, Lock Washer Washer Washer, Lock Screw Seal, Door 14 15 16 17 18 19 20 21 Qty. 7621235 7080853 7041758 5411559 7080483 5211740 5431842 1060114 2 1 1 1 2 1 1 1 5431841 22 7621452 23 5411865 24 5433464 1 4 1 1 Description Rivet Cable, Limiter, Hinge Spring, Gas Boot, Gas Spring Cable Tie Plate, Fire Extinguisher Cover, Fire Extinguisher Asm., Fire Extinguisher Container (Incl. 20 and Container) Container, Fire Extinguisher Rivet Seal, Bucket, Front Bucket, Front Storage 3/01 A9 DECALS VIRAGE W005197D and INT’L VIRAGE W005197I 1 3 2 5 4 6 13 7 12 11 RH 10 9 15 8 3 16 17 14 7 LH 20 Ref. Part No. 2201689 2200891 1 2 3 4 5 6 7 8 7078583 7077812 7078582 7078884 7077479 7078260 7077777 7078564 Qty. Description 1 Kit - Decals (Incl. All Except Seat Decals) 1 Kit - Vinyl Decal Application (For Seat Decals) 1 Decal - Warning, Rear 1 Decal - Coast Guard, Exemption 2 Decal - “POLARIS”, Seat 1 Decal - Planet Sound Reduction 1 Decal - Fuel, Off/On 1 Decal - Fire Extinguisher 1 Decal - Star Emblem 1 Decal - Front, RH 9 12 18 19 Ref. Part No. 9 10 11 12 13 14 15 16 17 18 19 20 7078570 7077768 7078566 7078567 7078576 7077766 7079001 7078702 7073865 7078565 7078311 7078563 Qty. 2 1 1 2 1 1 1 1 1 1 1 1 Description Decal - “POLARIS” Decal - Refueling Warning Decal - Sidewall, RH Decal - “Virage” Decal - NMMA, 3 Passenger Decal - MFI Dacal - Warning, Reverse System Decal - Reverse Decal - Caution, Capsize Decal - Sidewall, LH Decal - Warning, Seat/Engine Decal - Front, LH 3/00 A10 FUEL TANK VIRAGE W005197D and INT’L VIRAGE W005197I 7 4 8 6 5 3 4 3 2 2 4 1 1 10 12 11 9 14 13 16 15 16 17 26 19 25 18 3 2 3 2 22 20 21 21 20 22 24 23 Ref. Part No. Qty. 1 2 3 4 5 6 5244279 7552610 7515361 5243775 5430621 ------- 6 8 8 9 3 1 7 8 9 10 11 12 13 5243776 5410424 2520177 7080710 7511873 7080442 5433553 3 3 1 1 1 2 1 Description Ref. Part No. Bracket, Strap Washer, Lock Screw Hook, Strap, Narrow Strap, Rubber Tank, Oil (See Oil Tank Pg. A14, Ref. 19) Hook, Strap Strap, Battery Holddown Cap, Fuel, Ratchet Chain, Bead, Cap Retainer Screw Coupling, End, Fuel Cap Chain Inlet, Fuel 14 15 16 17 18 19 20 21 22 23 24 25 26 5811492 5433621 7080766 5411757 7080451 2410124 7661040 5812093 5244758 5433018 5812135 7621229 5411305 Qty. 1 1 2 1 1 1 2 2 2 1 1 1 1 Description Seal, Fuel Inlet Nut, Fuel Inlet Clamp, Hose Hose, Fuel Fill Clamp Asm., Fuel Sender Rivet Pad, Fuel Tank Stop Bracket, Fuel Tank Stop Tank, Fuel Pad, Fuel Tank Rivet Seal, Fuel Cap 3/00 A11 FUEL SYSTEM VIRAGE W005197D and INT’L VIRAGE W005197I 10 11 12 1 13 7 2 7 13 14 6 3 8 6 4 9 6 5 7 6 SEE NOTE BELOW 7 15 6 NOTE: Fuel line from fuel/water separator connects to fuel sender fitting marked “ON.” Ref. Part No. 1 2 3 4 5 6 7 8 7516302 7555840 5432836-070 5431451 7052159 7080476 8450046-1525 ------- Qty. 1 1 1 1 1 12 AR 1 Description Ref. Part No. Screw Washer, Flat Knob, Fuel Valve, Black Nut, Fuel Valve Valve, Fuel Clamp, Hose Line, Fuel Separator, Fuel/Water (See Fuel/Water Separator Pg. C10, Ref. 5) 9 10 11 12 13 14 15 7052111 5410682 7080483 7051015 7080138 7052118 ------- Qty. 1 1 1 1 2 1 1 Description Fitting, Tee Grommet, Vent Cable Tie Valve, Check Cable Tie Valve, Vacuum Check Asm., Fuel Sender (See Fuel Tank Pg. A11, Ref. 19) 11/99 A12 SEAT VIRAGE W005197D and INT’L VIRAGE W005197I 6 1 3 4 2 8 5 12 13 18 17 28 7 16 12 19 27 24 21 9 15 20 2 10 23 20 15 14 2 4 3 25 23 13 22 21 12 11 26 Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7516806 7555839 5211314 7042036 5433779 7621478 5812025 5411807 2682540-204 2682542-204 7517805 7517806 7555838 5431357 5431358 Qty. 2 5 2 2 1 2 1 1 1 1 1 2 5 2 1 Description Ref. Part No. Screw Washer, Flat Plate, Seat Base Latch Spring, Seat Base Latch Handle, Seat Latch Rivet Strap, Seat Latch Seal, Seat, Rear Asm., Seat, Rear Cover, Seat, Rear Screw Screw Washer, Lock Plate, Bottom, Seat Base Latch Handle, Seat Base Latch 15 16 17 18 19 20 21 22 23 24 25 5431359 1013202 7517669 7517717 7080914 7661044 7542454 7552607 7555846 5020753 2682541-204 2682543-204 26 5521490 27 2682593-204 28 5521536 Qty. 2 1 4 1 1 3 2 1 2 1 1 1 10 1 1 Description Plate, Top, Seat Base Latch Asm., Hinge, Seat Screw Screw Cable, Limiter, Hinge Rivet Nut Washer, Lock Washer, Flat Plunger, Latch Asm., Seat, Main Cover, Seat, Main Bumper, Seat Strap, Seat Seal, Seat, Main 10/99 A13 OIL TANK VIRAGE W005197D and INT’L VIRAGE W005197I 1 5 4 3 2 6 1 7 8 9 22 9 10 21 11 15 21 20 19 17 18 12 17 13 16 14 15 14 Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 7080442 7517241 7621229 7080710 5432843 7661038 5433601 5811554 7080481 7052130 2410131 Qty. 2 1 1 1 1 4 1 1 2 1 1 Description Ref. Part No. Coupling Screw Rivet Chain Cap, Oil Tank Rivet Inlet, Oil Gasket, Oil Inlet Clamp, Hose Elbow, 90 Degree Sender, Oil Level 12 13 14 15 16 17 18 19 20 21 22 7080138 4010051-30 7080307 8450003-1525 2530015 7080474 8450059-150 5433083 7052118 7080483 5411756 Qty. 2 1 2 AR 1 2 AR 1 1 2 1 Description Cable Tie Conduit Clamp, Hose Line, Fuel Filter, Oil Clamp, Hose Line, Fuel Tank, Oil Valve, Check, Vacuum Cable Tie Hose, Oil Fill 7/00 A14 STEERING VIRAGE W005197D and INT’L VIRAGE W005197I 4 5 3 6 7 11 2 1 8 30 12 29 28 9 27 13 10 26 14 25 24 23 15 22 21 6 16 20 17 19 18 Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7517717 7552613 7555836 5433089-070 5433819-070 7517660 5631017 5433355-070 5433081 7080787 7080138 2410168 7080675 1820820-070 5132317 Qty. 6 6 6 1 1 8 1 1 1 1 1 1 1 1 1 Description Ref. Part No. Screw Washer, Lock Washer Pad, Handlebar Pad, Handlebar, Bottom Screw Clamp, Handlebar Handle, Grab Block, Throttle, Split Cable, Throttle Cable Tie Switch, START/STOP/BILGE Lanyard w/Whistle Handlebar w/Grip Column, Steering 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 5433136 5433135 7542335 7555831 5811551 7517787 5433737 7710426 7555840 5433079 7661053 7517684 7552615 7556098 7661099 Qty. 1 4 4 4 1 4 1 1 1 1 1 2 2 2 1 Description Housing, Steering Bearing, Steering Nut, Nylok Washer Gasket, Steering Housing Screw Clamp, Throttle Block Ring, Retaining Washer Lever, Throttle, Thumb Pin, Retaining Screw Washer, Lock Washer Pin, Roll 12/99 B1 STEERING VIRAGE W005197D and INT’L VIRAGE W005197I 2 3 4 1 20 19 18 17 16 10 15 11 13 12 Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 7542150 7515120 7555839 7060170 7542133 1860115 1860117 1860114 7080723 5244681 7555891 7516717 7542528 Qty. 1 1 1 1 1 1 1 1 1 1 2 2 2 12 14 14 23 5 8 9 21 22 6 7 13 24 11 Description Ref. Part No. Nut Screw Washer Rod End Nut, Nylok Washer, Steering Seal Ring, Stopper Nut, Steering Cable (Special) Cable, Steering Brace, Steering Cable Washer Bolt Nut 14 15 16 17 18 19 20 21 22 1860103 7571625 1860105 7080931 7060154 7555837 7541931 7512041 ------- 23 7546704 24 5244290 Qty. Description 2 1 1 1 1 1 1 1 1 Washer Washer, Lock Cover Tube, Guide Rod End Washer Nut Screw Column, Steering (See Steering Pg. B1, Ref. 15) 2 Nut 1 Bracket, Steering Cable 10/02 B2 DRIVE SYSTEM VIRAGE W005197D and INT’L VIRAGE W005197I 1 2 3 5 4 6 7 5 8 4 9 8 10 4 11 12 13 Ref. Part No. 1 2 3 4 5 6 7 1060119 5410735 5432129 7080481 5410663 6230103 7080629 Qty. 1 1 1 3 2 1 1 Description Ref. Part No. Asm., Drive Coupler O-Ring Shroud, Coupler Clamp, Hose Bumper, Drive Shaft Shaft, Drive Fitting, Lubrication 8 9 10 11 12 13 3610040 1341145 5411027 5432298 5411174 5431985 Qty. 2 1 1 1 1 1 Description Seal, Bearing Asm., Bearing Housing (Incl. 7, 8) Hose, Bearing Housing Shaft, Housing, Thru-Hull O-Ring Nut, Shaft, Housing 10/99 B3 PROPULSION VIRAGE W005197D and INT’L VIRAGE W005197I 4 6 5 7 4 10 3 12 9 8 25 11 24 13 1 2 26 14 15 16 17 29 23 2 19 30 22 18 20 27 28 32 34 21 36 31 33 35 37 8 Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 5244556 5132111 5411107 5410735 5432269 5130983 5010294 3514008 3610043 5010295 5132372 5411644 5131196 7522019 5630598 7555941 5131573 7555966 7542455 Qty. 1 4 1 2 1 1 1 2 2 1 1 1 1 1 1 4 1 3 4 Description Ref. Part No. Bracket, Steering Cable Nut Stud, Mounting, Pump Seal, Water Pipe O-Ring Pipe, Water, Engine Stator, Pump Spacer, Bearing Bearing Seal, Stator Bearing Spacer, Impeller Impeller Seal, Impeller/Shaft Extension, Pump Screw Anode, Zinc Washer, Pump Stud Housing, Pump Washer, Flat Nut, Nylok 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 5410652 5410817 5811984 5431523 5130999 7515366 5130938 7552610 7555835 5431518 7515389 5131569 5432841 7512064 5431519 5410819 5020697 5410818 Qty. 1 1 1 1 1 2 2 4 4 2 4 1 1 3 1 1 1 1 Description O-Ring O-Ring Seal, Tailcone Screen, Engine Inlet Nozzle, Steering Screw Collar Washer, Lock Washer, Flat Bearing, Steering Nozzle Bolt Nozzle, Stationary Wedge, Pump Screw Cone, Pump O-Ring Shaft, Stub O-Ring 7/00 B4 REVERSE VIRAGE W005197D and INT’L VIRAGE W005197I 3 1 4 7 6 5 8 2 9 10 12 11 13 20 21 17 18 16 19 14 15 22 23 24 28 29 27 26 16 25 30 26 31 25 32 33 34 33 32 36 37 34 35 38 39 47 40 41 42 43 44 45 46 B5 REVERSE VIRAGE W005197D and INT’L VIRAGE W005197I Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5433677-070 7516816 7517669 7661040 5433646 5811982 5433643 5433911 5433910 5433645 5433674 5433675 7555839 7517331 5433872 7041888 7517717 7556094 5244288 5433605-070 5244289 7661041 5433647 5433673 Qty. 1 1 4 8 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 4 1 1 Description Ref. Part No. Cap Screw Screw Rivet Flange Gasket Plate, Base Bushing Bushing Pinion Bushing Shaft, Cam Washer Screw Reverse, Lock Spring Screw Washer Bracket, Reverse Plate, Forward Handle, Reverse Bracket, Reverse Plate, Rear Rivet Bushing Plunger 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 5240257 7512049 5433954 7555952 7516806 7661010 7555837 7080899 7542528 1860103 7571625 5411818 5411819 7080950 7061062 7542133 5631036 7517749 7555866 5020683 7555874 7515368 5244902 Qty. 2 4 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 2 2 2 2 1 Description Plate, Cable Screw Arm, Reverse Washer Screw Pin, Cotter Washer Cable, Reverse Nut Washer Washer Seal, Rod Seal, Rod Tube, Guide, Reverse Rod End Nut, Nylok Gate, Reverse, Directional Screw Washer Collar Washer Screw Bracket, Reverse Stop 3/00 B6 EXHAUST SYSTEM VIRAGE W005197D and INT’L VIRAGE W005197I 42 43 36 41 38 42 43 38 38 38 41 38 38 44 4 1 5 3 2 6 3 2 38 45 37 45 8 38 36 35 37 39 38 36 38 40 44 37 40 39 37 7 24 24 21 9 34 21 10 33 24 26 25 11 24 13 23 12 27 24 22 14 15 16 17 15 16 17 24 23 18 19 22 20 31 28 29 B7 30 16 36 32 EXHAUST SYSTEM VIRAGE W005197D and INT’L VIRAGE W005197I Ref. Part No. 1 2 3 4 5 6 Qty. 5020668 7555856 7552611 7517268 7517004 ------- 1 4 4 2 2 1 7 ------- 1 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1261023-093 7080446 5411165 7080451 5430621 5811342 5224472 7515127 7555838 7555839 5410414 5222696 1260581-093 5812094 7080445 5411951 1 1 1 1 1 1 2 2 6 2 2 1 1 3 2 2 Description Ref. Part No. Fitting, Inlet, Water Washer, Flat Washer, Lock Screw Screw Fitting, Screen, Exhaust (See Cooling System Pg. B11, Ref. 8) Gasket, Exhaust (See Battery Box Pg. B9, Ref. 5) Asm., Exhaust Pipe Clamp, Hose Hose, Pipe/Silencer Clamp, Hose Strap, Rubber Pad, Foam D-Hook Screw Washer, Lock Washer, Flat Bumper, Rubber Cradle, Silencer Silencer, Exhaust Pad Clamp, Hose Hose 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 7080907 5433810 5830197 5411863 7555836 7515116 5245072 5810529 5132446 5433632 5433811 5411932 5521561 7552613 7517717 7556094 7547151 5411851 5433787 5433788 7516809 7516807 7546704 5244270 Qty. 6 1 1 1 4 4 1 1 1 1 1 1 1 4 4 10 2 2 1 1 2 2 2 2 Description Clamp Resonator 1 Pad Hose, Exhaust Washer, Flat Screw Plate, Exhaust Seal Seal Fitting, Exhaust Resonator 3 Resonator 2 Hose, Crossover (Incl. Conduit) Conduit Washer, Lock Screw Washer Nut, Cage Mount, Rubber Protector, Seat, LH Protector, Seat, RH Screw Screw Nut Bracket 4/00 B8 ENGINE MOUNTING VIRAGE W005197D and INT’L VIRAGE W005197I 4 3 1 5 2 6 27 26 7 25 24 23 22 8 21 20 16 19 18 9 17 10 15 16 11 14 12 13 Ref. Part No. 1 2 3 4 5 6 Qty. 2410187 5242488 7077026 7515149 5830051 ------- 1 1 1 2 1 1 7 ------- 2 8 9 10 11 12 13 14 7051527 5630585 5630584 7552609 7517330 5244508 3021103 1 1 1 4 4 2 4 Description Ref. Part No. Asm., Temperature Switch Ground, Spark Plug Decal - Spark Plug Screw Gasket, Exhaust Decal - Warning (See Cylinder and Manifold Pg. C4, Ref. 1) Spark Plug, NGK BPR8ES (See Cylinder and Manifold Pg. C4, Ref. 5) Plug, Pipe Plate, Front Mount Plate, Rear Mount Washer, Lock Screw Plate, Repair Mount, Engine 15 16 17 18 19 20 21 22 23 24 25 5211727 7552610 7517627 1060142 7555835 7515357 7555848 7542725 7556055 7517497 2201620 26 5240876 27 7516603 Qty. Description AR 10 8 1 2 2 4 4 1 1 1 Shim, Engine Mount Washer, Lock Screw Bracket, Rear Muffler Washer, Flat Bolt Washer, Flat Nut Washer, Lock Bolt Engine, Short Block NOTE: The Short Block assembly contains a crankcase assembly, cylinder, and cylinder head assembly. 1 Clip, Retainer 1 Bolt 11/99 B9 BATTERY BOX VIRAGE W005197D and INT’L VIRAGE W005197I E 2000 Polaris Sales Inc. 1 2 3 4 5 6 12 11 7 8 10 9 13 Ref. Part No. 1 2 3 4 5 6 7 7515192 7517824 7555839 5211676 5432413 5410682 7080483 Qty. 1 1 1 1 1 1 3 Description Ref. Part No. Stud Screw Washer, Flat Bracket, Battery Hold Down Cover, Battery Grommet, Vent Cable Tie 8 9 10 11 12 13 7052078 5432121 4140009 2200619 4010118 5850136 Qty. 1 AR 1 2 1 1 Description Connector Hose, Vent Battery, 19 Amp Kit - Battery Bolt Cable, Ground, Battery/Engine Pad, Battery 11/00 B10 COOLING SYSTEM VIRAGE W005197D and INT’L VIRAGE W005197I 1 3 2 9 4 7 1 8 7 10 51 1 6 11 1 7 9 4 4 21 13 20 28 1 12 14 15 7 19 17 18 16 27 22 26 23 24 25 Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7080475 5431444 5811317 5521287-63 5411049 5431784 7080476 7052128 8450054-100 5020747 5411050 7080138 7516727 7516725 Qty. 6 1 1 4 1 1 4 1 1 1 1 10 2 4 Description Ref. Part No. Clamp, Hose Fitting, Thru-Hull Gasket Conduit, Flex Hose, Outlet, Pump Fitting, Tee Clamp, Hose Fitting, Screen, Exhaust Hose, Water Fitting, Injector, Exhaust Hose, Inlet Cable Tie Screw Screw 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1260694 7555856 7552611 7517004 5811045 5020746 5521398-13 5432799 7051008 5410781 5131008 7041310 5410860 5411479 Qty. 1 1 1 1 2 1 1 1 1 1 1 1 1 1 Description Asm., Exhaust Manifold Washer, Flat Washer, Lock Screw Gasket, Exhaust Fitting, Drain Exhaust Conduit, Flex Valve, Pop-Off Thermostat, 143 Degrees F. Gasket, Thermostat Cover, Thermostat, Machined Spring, Compression Seal, Thermostat Housing Hose, Water Out 10/99 B11 WATER INLET VIRAGE W005197D and INT’L VIRAGE W005197I 1 2 9 3 4 5 6 5 8 7 15 10 11 14 12 13 Ref. Part No. 1 2 3 4 5 6 7 8 7080483 ------7547003 7555873 5810879 7555848 5431634 5131602 Qty. 1 1 1 1 2 1 1 1 Description Cable Tie Line, Pitot (See Shroud Pg. A6, Ref. 3) Nut, Hex, Nylon Washer, Flat Gasket, Pitot Washer, Flat Fitting, Pitot Scoop, Inlet Ref. Part No. 9 ------10 11 12 13 14 15 5630542-067 7515155 7517267 7515126 5630659 7010083 Qty. Description 1 O-Ring (See Propulsion Pg. B4, Ref. 20) 1 Grate, Inlet 1 Screw 8 Screw 2 Screw 1 Plate, Ride, Long, Angled 8 Insert, Sponson/Ride Plate 10/99 B12 BILGE PUMP VIRAGE W005197D and INT’L VIRAGE W005197I 1 2 4 3 2 2 5 6 4 7 2 9 8 10 Ref. Part No. 1 2 3 4 5 7052141 7080475 8450050-26 7080492 5431444 Qty. 1 4 1 2 1 Description Ref. Part No. Elbow Clamp Hose, Water Cable Tie Fitting, Water, Thru-Hull 6 7 8 9 10 5811317 5411595 2410169 7512043 7555837 Qty. 1 1 1 2 2 Description Gasket Hose Asm., Bilge Pump Screw Washer 3/00 B13 ENGINE AIR INTAKE/HULL AIR INLET VIRAGE W005197D and INT’L VIRAGE W005197I ENGINE AIR INTAKE 10 1 2 9 11 HULL AIR INLET 12 8 10 13 11 14 12 15 15 7 16 16 6 3 17 5 4 Ref. Part No. 1 2 3 4 5 6 7 8 9 5432138-070 5410589 5132353 5830062 5631070 7517799 2520185 5432464-070 7546708 Qty. 1 1 2 1 1 2 1 1 2 Description Ref. Part No. Plug, Intake Silencer O-Ring Stud Gasket Base, Intake Screw Filter, Intake Cover, Intake Nut 10 11 12 13 14 15 16 17 7661042 5433220 5411545 5812108 5411958 7080439 5433082 7080492 Qty. 10 2 2 1 1 2 2 5 Description Rivet Flange, Air Inlet Gasket Panel Gasket Clamp Duct, Air Inlet Cable Tie 3/00 B14 ELECTRICAL BOX VIRAGE W005197D and INT’L VIRAGE W005197I 28 25 1 26 29 Top View 27 23 24 22 30 21 31 20 32 2 3 4 5 18 17 7 8 6 8 9 33 19 16 16 18 34 35 15 14 36 37 10 11 38 13 39 12 40 17 C1 41 ELECTRICAL BOX VIRAGE W005197D and INT’L VIRAGE W005197I Ref. Part No. Qty. 1 2 3 4 5 6 2460898 5410346 7546705 7552613 7555882 ------- 1 4 2 2 2 1 7 8 9 10 11 12 13 14 7517671 7555839 7546704 4060161 4060111 5432503 5333544 ------- 2 4 2 1 1 4 4 1 15 16 17 18 19 20 21 5244335 7547061 7555837 7512042 4010304 7547059 4010238 1 3 7 3 1 4 1 Description Ref. Part No. Harness, Main Wire Insulator Nut Washer, Lock Washer Solenoid, Starter (See Magneto Pg. C8, Ref. 10) Screw Washer Nut Fuse, 3 Amp Fuse, 1/4 Amp Latch Pin, Latch Controller, Ignition (See Magneto Pg. C8, Ref. 9) Strap, Grounding Nut Washer Screw Regulator, 1 Button Nut Cable, Battery/Solenoid 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Qty. 4010237 5411491 7080461 7515113 7555836 5432574 7077691 7073713 2460718 2460826 5433119 5432569 5244370 ------- 1 1 1 2 2 1 1 1 1 1 1 1 1 1 36 2410201 37 2434011 38 2632137 1 1 1 39 5411235 40 5432502 41 7517825 1 1 4 Description Cable, Solenoid/Starter O-Ring Boot, Threaded Screw Washer Plate, Stator Decal - “RESET ELEC SYSTEM” Decal - High Voltage Warning Harness, 8 Wire Stator Harness, Pigtail Cover, Electrical Box Seal Bracket, Coil Coil, Ignition (See Magneto Pg. C8, Ref. 11) Asm., Terminal Board Breaker, Circuit Asm., Electrical Box, Ignition (Incl. 12,13,32,33) Grommet Cap Screw 4/03 C2 CRANKCASE VIRAGE W005197D and INT’L VIRAGE W005197I 6 5 7 11 8 9 10 12 18 13 17 1 14 4 2 16 3 15 19 21 20 22 Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 2201619 5131677 7663001 7052145 5243231 7517431 3569805 5433130 3574214 7041457 3569806 Qty. 1 8 2 1 1 1 1 1 1 1 1 Description Ref. Part No. Kit - Asm., Crankcase (Incl. 2-4,20-22) Stud, Cylinder Flange Pin, Dowel Fitting Clamp, Stator Wires Screw Bushing Plug Bushing Spring Bushing 12 13 14 15 16 17 18 19 20 21 22 7517676 7516806 1201923 5811550 7516723 7663002 5411564 1201938 7517628 7051529 7516913 Qty. 6 1 1 1 4 3 1 1 4 2 2 Description Screw Screw Asm., Flywheel Cover (Incl. 11) Gasket, Flywheel Cover Screw Pin, Dowel O-Ring Asm., Flywheel Housing (Incl. 7,17) Screw Plug Screw 11/99 C3 CYLINDER & MANIFOLD VIRAGE W005197D and INT’L VIRAGE W005197I 1 3 2 4 27 5 26 6 25 24 7 23 22 8 9 10 11 12 21 20 19 18 17 16 15 13 Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7075383 7516806 7077026 7051527 3070174 7516722 7517352 5410917 5410932 5410931 7547021 3021019 5830043 7517306 Qty. 1 4 1 1 2 8 12 2 2 2 8 2 1 2 Description Ref. Part No. Decal - Warning Screw Decal - Spark Plug Plug, Pipe Spark Plug, NGK BPR8ES Screw Screw O-Ring O-Ring O-Ring Nut Cylinder Gasket, Carb Screw 15 16 17 18 19 20 21 22 23 24 25 26 27 7080654 5241134 7516807 5630656 5432104 1201689 5830123 3021117 5241944 5241768-093 5630527-093 5830061 5630826-093 14 Qty. 1 1 10 1 2 2 2 2 2 1 2 2 1 Description Retainer, Vinyl Coated Bracket, Oil Pump Cable Screw Manifold, Intake Stuffer, Reed Block Asm., Valve, Reed Gasket, Cylinder Base Head, Cylinder Ring, Head Bracket, Head, Twin Cover, Head Gasket, Water, Manifold Manifold, Outlet, Water 10/99 C4 CRANKSHAFT and PISTON VIRAGE W005197D and INT’L VIRAGE W005197I 3 1 4 2 3 1 5 8 9 2 1 4 6 7 5 8 9 16 5 22 7 6 23 24 25 26 11 5 10 20 10 15 Ref. Part No. 14 12 13 4 2 1 1 1 2200918 2200917 2200916 1 1 1 4 2201626 2201627 2201628 5 ------6 ------7 ------8 2201022 9 3584001 10 3585503 1 1 1 4 2 2 1 2 4 11 21 17 16 Qty. 1 3022950 2 3021091 3 2200902 2200903 2200904 19 18 Description Circlip, Piston Pin, Piston Kit - Piston Rings (Std.)(2 Rings) Kit - Piston Rings (.25mm OS) Kit - Piston Rings (.50 mm OS) NOTE: If the number stamped on the head of piston reads ELKO 2102/6 use the above 3 kits. Kit - Piston Rings (Std.)(2 Rings) Kit - Piston Rings (.25mm OS) Kit - Piston Rings (.50 mm OS) NOTE: If the number stamped on the head of piston reads ELKO 2194a use the above 3 kits. Kit - Piston Asm. (Std.)(Incl.1,2,3) Kit - Piston Asm. (.25 mm OS)(Incl.1,2,3) Kit - Piston Asm. (.50 mm OS)(Incl.1,2,3) Washer, Thrust Pin, Crankshaft Bearing, Connecting Rod Kit - Connecting Rod Assembly (Incl. 5-7) Bearing, Connecting Rod (20 mm) Bearing, Ball Ref. Part No. Qty. 11 12 13 14 15 16 17 18 19 20 21 7710441 5411524 7710435 5410613 5131195 7555905 5131083 5131084 5131086 5131085 2201243 2 1 1 1 1 2 1 2 1 1 1 22 23 24 25 7721117 3610044 ------------- 1 1 1 1 26 5432576 1 Description Ring, Retaining (72 mm) Seal Ring, Retaining (72 mm) O-Ring Collar, Crankshaft Bushing Crankweb, PTO Crankweb, Center Labyrinth Crankweb, Mag. Kit - Crankshaft, 2 Cylinder (Incl. 10,16-20,22) Key, Woodruff Seal Washer (See Magneto Pg. C8, Ref. 7) Nut, Pump Drive (See Magneto Pg. C8, Ref. 8) Coupler 10/99 C5 CARBURETOR VIRAGE W005197D and INT’L VIRAGE W005197I 9 8 7 Jet Block 6 10 11 5 4 13 9 8 12 17 14 18 16 15 19 3 20 2 1 22 21 Ref. Part No. Qty. 1253334 2200910 3050136 2200687 2200686 5830062 3050144 2200733 3050117 3050193 3050133 3050135 1 1 4 1 1 1 2 1 1 1 1 8 1 2 3 4 5 6 7 8 9 10 Description Ref. Part No. Asm., Carburetor Kit - Carb Rebuild (Incl. 8,15,21) Screw, Fuel Pump Kit - Fuel Pump Body Kit - Gasket, Fuel Pump Gasket, Carburetor, Upper Screen, Fuel Strainer Kit - Needle Valve Jet, Main, Keihin Jet, Main, Keihin Jet, Pilot, Keihin Screw, Jet Block Cover 11 12 13 14 15 16 17 18 19 20 21 22 3050139 2200730 3050137 3050204 3050147 3050138 3050148 2200688 2200689 3050140 5830043 2200731 Qty. 2 1 1 2 2 2 4 2 2 2 2 1 Description Cover, Jet Block Kit - Diaphragm, Jet Block Screw, Jet Block Block, Jet O-Ring, Jet Block Collar O-Ring, Valve Seat Kit - Check Valve Kit - Idler Mixture Screw Cap, Limiter Gasket, Lower Kit - Idle Stop Screw 10/99 C6 OIL PUMP VIRAGE W005197D and INT’L VIRAGE W005197I 1 5 2 4 3 8 6 7 Ref. Part No. 1 2 3 4 7080679 8450061-54 7080603 7555944 Qty. 1 2 4 1 Description Ref. Part No. Cable, Oil Pump Line, Oil Clamp, 7 mm Washer 5 6 7 8 7710427 5411293 7516605 2540073 Qty. 1 1 2 1 Description E-Ring O-Ring Screw Pump, Oil (Incl. 6) 10/99 C7 MAGNETO VIRAGE W005197D and INT’L VIRAGE W005197I 2 1 3 4 15 16 5 7 8 6 14 13 12 11 10 9 Ref. Part No. 1 2 3 4 5 6 7 8 4010172 7517384 5811320 5432282 4010189 7517431 7555907 7546909 Qty. 1 3 1 1 1 1 1 1 Description Stator, Twin Screw O-Ring Holder, Magnet Asm., Flywheel Screw Washer Nut Ref. Part No. 9 4010348 10 11 12 13 14 15 16 4010228 4010175 7080471 4010173-42 4010173-56 7080483 4020155 Qty. Description 1 Controller, Ignition 1 1 1 1 1 2 2 Solenoid, Starter Coil, Ignition Clip Wire, Spark Plug Wire, Spark Plug Cable Tie Cap, Spark Plug 11/02 C8 STARTING MOTOR VIRAGE W005197D and INT’L VIRAGE W005197I 1 2 4 3 5 6 7 8 10 9 12 11 13 9 14 17 25 15 24 21 23 Ref. Part No. Qty. 4060118 3240113 7516807 3240111 3240115 3084408 3240119 3240117 3240116 3084405 3240207 3240118 3240112 1 2 2 4 1 1 1 1 1 2 1 AR 1 1 2 3 4 5 6 7 8 9 10 11 12 20 22 19 18 Description Ref. Part No. Starter, Big Bore Bolt, Through Screw Spring, Brush Asm., Brush (Incl. 3-8) O-Ring Washer Washer, Spring Nut Ring, Rubber Asm., Rear Bracket Washer, Thrust Washer, Thrust 13 14 15 16 17 18 19 20 21 22 23 24 25 3240205 4060119 3240206 3240114 3083737 3240126 3240125 3240123 7041457 3574214 7555908 3240122 3240120 16 17 Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Asm., Armature Asm., Bendix (Incl. 17-25) Asm., Front Bracket O-Ring Washer Ring, Snap Stopper Cover Spring Bushing, Flanged Washer, Thrust Asm., Gear Asm., Gear (Incl. 17-24) 10/99 C9 FUEL/WATER SEPARATOR VIRAGE W005197D and INT’L VIRAGE W005197I 1 2 3 4 5 6 7 8 9 Ref. Part No. 1 2 3 4 5 7517798 7552613 7555870 5132374 3240220 Qty. 2 2 2 2 1 Description Screw Washer, Lock Washer, Dish Spacer Separator, Fuel/Water (Incl. 6-9) Ref. Part No. 6 7 8 9 3240209 3240239 3240238 3240240 Qty. 1 1 1 1 Description O-Ring Element Spring Float 3/00 C10 ENGINE FOGGING SYSTEM INT’L VIRAGE W005197I 8 9 10 7 1 21 6 1 2 11 20 3 4 6 3 12 5 19 18 13 14 2 17 15 16 Ref. Part No. Qty. 2872635 7080138 7080484 7080476 7052139 7075738 8450062 3160114 ------- 1 4 2 2 1 1 AR 1 2 1 2 3 4 5 6 7 8 9 ------10 - - - - - - - Description Ref. Part No. Kit - Engine Fogging Cable Tie Clamp, Hose Clamp, Hose Fitting, Tee Decal - Engine Primer Line, Oil Primer, Engine, Fog Screw (See Fuel/Water Separator Pg. C10, Ref. 1) 2 Washer, Lock (See Fuel/Water Separator Pg. C10, Ref. 2) 2 Washer, Dish (See Fuel/Water Separator Pg. C10, Ref. 3) 11 - - - - - - 12 13 14 15 16 17 18 19 20 21 7075732 7555837 7541931 7052047 7052138 5432362 5810279 5432359 7512045 5244295 Qty. Description 1 Separator, Fuel/Water (See Fuel/Water Separator Pg. C10, Ref. 5) 1 Decal - ‘‘Fogging Oil Only” 2 Washer 2 Nut 1 Valve, Check, Vent 2 Fitting, 90 Degree 1 Tank, Oil 1 Gasket, Overflow Cap 1 Cap, Oil Bottle 2 Screw 1 Bracket, Oil Tank 10/99 C11 TOOL KIT VIRAGE W005197D and INT’L VIRAGE W005197I 1 2 3 4 5 Ref. Part No. Qty. 2872114 1 ------2 ------3 ------- 1 1 1 1 Description Asm., Tool Kit (Incl. 1-6) Wrench, Spark Plug Wrench, Open End Screwdriver 6 Ref. Part No. 4 9915574 5 ------6 ------- Qty. Description 1 Manual, Owners, ’00 Watercraft 1 Pouch, Tool Kit 1 Wrench, Allen, Plated, 3/16 10/99 C12 PRINTED IN THE USA PARTS MANUAL PN 9915581 and MICROFICHE PN 9917173 11/00 G F E D C B A 1 cover 1 2 x toc 2 3 3 4 4 Changed pages in 9915581 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14
