Polaris VIRAGE W005197D User manual

PARTS MANUAL PN 9915581 and MICROFICHE PN 9917173 11/00
VIRAGE
Model #W005197D
INT’L VIRAGE
Model #W005197I
Rev. 01
E2000 Polaris Sales Inc.E2000 Polaris Sales Inc.

TABLE OF CONTENTS
VIRAGE W005197D and INT’L VIRAGE W005197I
Parts Manual
B
BATTERY BOX B10......................
BILGE PUMP B13........................
C
CARBURETOR C6......................
COOLING SYSTEM B11...................
CRANKCASE C3.......................
CRANKSHAFT and PISTON C5.............
CYLINDER & MANIFOLD C4...............
D
DECALS A10...........................
DRIVE SYSTEM B3......................
E
ELECTRICAL BOX C1-2....................
ENGINE AIR INTAKE/HULL AIR INLET B14....
ENGINE FOGGING SYSTEM C11............
ENGINE MOUNTING B9..................
EXHAUST SYSTEM B7-8...................
F
FRONT STORAGE COMPARTMENT A9......
FUEL SYSTEM A12......................
FUEL TANK A11.........................
F
FUEL/WATER SEPARATOR C10.............
H
HULL and BODY A7-8.....................
M
MAGNETO C8..........................
O
OIL PUMP C7..........................
OIL TANK A14..........................
P
PROPULSION B4.......................
R
REVERSE B5-6..........................
S
SEAT A13..............................
SHROUD A5-6...........................
STARTING MOTOR C9...................
STEERING B1-2..........................
T
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
17 US Gallons (64.26 l)
N/A
6 Quarts (5.68 l)
CARBURETION
Gas Type
Carburetor Type and
Number
Carburetion Idle Speed
Regular Unleaded 87
Octane or 89 Octane
Oxygenated
1-40mm
Diaphragm Type
1350 50 RPM
COOLING
Cooling System Type
Overheating Warning
Water Cooled, Thermostat Pop off
Warning Light/RPM Limit
DIMENSIONS
Number of Passengers
Length, Overall
Width, Overall
Height, Overall
Dry Weight
Load Limit
Hull/Deck Material
1-4 Persons
131.1²(330.5 cm)
49.3²(125 cm)
39²(99.06 cm)
650 lbs. (295 kg)
600 lbs. (273 kg)
Deck - FRC, Hull - SMC
ELECTRICAL
Alternator Output
Ignition System
Spark Plug Type
Spark Plug Gap
Starting System
Ignition Timing; BTDC
@3000 RPM
Battery
8.5 amps/60 watt at 4500 RPM
CDI
NGK BPR8ES
.028²(0.7 mm)
Electric Starter
23°
12V, 19A
ENGINE
Engine Type
Induction Type
Exhaust System
Lubrication
Oil Type
Number of Cylinders
Bore
Stroke
Displacement
Compression Ratio
Maximum Power (approx.)
Maximum Torque (approx.)
RPM Limiter Operation
Polaris Marine 700
Case Reed
Water Cooled/Injected
Oil Injection
Polaris TC-W3 or Injection
2
81mm
68mm
700cc
Effective 6:8
95 HP
69.2 @ 6500 RPM
7200 RPM 100
PROPULSION
Propulsion System
Jet Pump Type
Transmission
Minimum Water Level for Jet
Pump
Impeller Diameter
Impeller
Jet Drive
Axial Flow, Single Stage
Direct Drive
2feet(60cm)
5.83²(14.80 cm)
3 Blade, Slim Hub
Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements toits productswithout
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

A5
SHROUD
VIRAGE W005197D and INT’L VIRAGE W005197I
44
10
12
14
5
25
46
29
45
9
13
11
15
20
17
18
34 33
39
19
40
8
36
47
43
24
26
16
12
4
3
7
6
27
30
23
17
4
28
31
32
17
22
38
21
37
41
34
35
20
17
42
E2000 Polaris Sales Inc.

A6
SHROUD
VIRAGE W005197D and INT’L VIRAGE W005197I
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
13280339 1Gauge, MFI, Analog/Digital
25411738 1Gasket, MFI
38450070-190 1Line, Pitot, Formed End
47041931 2Spring, MFI Mounting
52632234 1Asm., Console Latch
62201593 1Kit - MFI Button Replacement
73280342 1Bezel, MFI, Overlay
85433709-311 1Lid, Console
97041754 1Spring, Torsion, Console
10 5521478 1Seal, Console Lid
11 7546705 2Nut
12 5811783 1Pad, Console
13 7516609 2Screw
14 5211865 1Plate, Hook
15 7517668 4Screw
16 7556055 2Washer, Lock
17 7555874 8Washer, Flat
18 5411557
5411558
1
1
Gasket, Mirror, LH
Gasket, Mirror, RH
19 2631973-070
2631972-070
1
1
Asm., Mirror, RH (Incl. 18)
Asm., Mirror, LH (Incl. 18)
20 7546804 4Nut, Hex
21 7080926 1Cable, Choke
22 7546704 2Nut, Nylok
23 7555839 2Washer
24 7541931 2Nut
25 5244673 1Bracket, Support, Shroud
26 7516717 2Bolt
27 5411664 1Grommet, Deck, Wire Harness
28 2690151 1Strap, Tool Kit, Lower
29 5433210-070 1Cover, Wire, Shroud
30 -- -- -- -- -- -- -- 1Kit, Tool (See Tool Kit Pg. C12)
31 2690150 1Strap, Tool Kit, Upper
32 7710517 2Ring, Retaining
33 7516805 6Screw
34 7552613 8Washer, Lock
35 7556094 6Washer
36 5433589-311 1Shroud, Steering
37 5812076 1Bumper, Door/Shroud
38 2080004 1Knob, Choke
39 2080005 1Screw
40 5244670 1Plate, Latch, Receiver
41 7555837 2Washer, Flat
42 7517818 2Screw
43 7512045 2Screw
44 5811552 1Gasket, Console Hook
45 5433266 1Hook, Console
46 5333698 1Pin, Hinge
47 5433384 1Hinge, Console
1/01

A7
HULL and BODY
VIRAGE W005197D and INT’L VIRAGE W005197I
35
26
2
24
1
18
22
10
25
4
3
27
11
20
17
19
21
33
32
12
13
31
15
8
30
14
28
23
10
13
14
15
12 13
34
16
8
31
30
8
10
5
9
Bulkhead
7
8
8
6
29
29

A8
HULL and BODY
VIRAGE W005197D and INT’L VIRAGE W005197I
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
15811915-070 1Pad, Boarding Platform
25811913-070
5811914-070
1
1
Pad, Footwell, Rear, LH
Pad, Footwell, Rear, RH
35811911-070
5811912-070
1
1
Pad, Footwell, Center, LH
Pad, Footwell, Center, RH
45811909-070
5811910-070
1
1
Pad, Footwell, Front, LH
Pad, Footwell, Front, RH
55411158 2Grommet
65411658 1Grommet
77516807 2Screw
87556094 14 Washer
95433671 1Plate, Seat Tongue
10 7546704 8Nut
11 5411758-070 1Bumper, Front
12 7621511 31 Rivet
13 5431994-070 29 Plug, Bumper, Rear
14 7542133 4Nut, Nylok
15 7555839 12 Washer
16 7555870 2Washer, Dish, Rubber
17 2670150 1Strap, Bow
18 5521568-070
5521569-070
1
1
Rail, Rub, Side, LH
Rail, Rub, Side, RH
19 5811440 10 Washer
20 5432272-070
5432273-070
1
1
Sponson, LH
Sponson, RH
21 7515198 10 Bolt
22 7517320-070 2Bolt
23 7555836 2Washer
24 5811918
5811919
1
1
Pad, Heel, LH
Pad, Heel, RH
25 5433531-070 1Bumper, Rear
26 1060125 2Plug, Bilge
27 7511882 4Screw
28 2632218 1Hook, Tow
29 7517644 6Screw
30 7555846 2Washer
31 7542454 2Nut
32 5020753 1Plunger, Latch
33 5433474-070 1Handle, Grab
34 7552607 1Washer, Lock
35 5433473 1Bucket, Rear Storage
4/00

A9
FRONT STORAGE COMPARTMENT
VIRAGE W005197D and INT’L VIRAGE W005197I
11
20
21
9
19
7
12
16
3
1
17
2
13
15
14
8
24
10
6
18
4
5
22
23
22
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
12653012 1Latch, Door
25433710-311 1Door, Compartment
31013282 1Asm., Door Hinge
47555890 5Washer
57546704 5Nut
67517669 5Screw
77516805 4Screw
87552613 4Washer, Lock
97555839 4Washer
10 7555837 2Washer
11 7552615 2Washer, Lock
12 7512045 2Screw
13 5521565 1Seal, Door
14 7621235 2Rivet
15 7080853 1Cable, Limiter, Hinge
16 7041758 1Spring, Gas
17 5411559 1Boot, Gas Spring
18 7080483 2Cable Tie
19 5211740 1Plate, Fire Extinguisher
20 5431842 1Cover, Fire Extinguisher
21 1060114
5431841
1
1
Asm., Fire Extinguisher Container
(Incl. 20 and Container)
Container, Fire Extinguisher
22 7621452 4Rivet
23 5411865 1Seal, Bucket, Front
24 5433464 1Bucket, Front Storage
3/01

A10
DECALS
VIRAGE W005197D and INT’L VIRAGE W005197I
7
14
1
17
11
9
10
18
20
RH
7
LH
3
8
12
3
6
5
19
9
2
13
12
16
4
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2201689 1Kit - Decals
(Incl. All Except Seat Decals)
2200891 1Kit - Vinyl Decal Application
(For Seat Decals)
17078583 1Decal - Warning, Rear
27077812 1Decal - Coast Guard, Exemption
37078582 2Decal - “POLARIS”, Seat
47078884 1Decal - Planet Sound Reduction
57077479 1Decal - Fuel, Off/On
67078260 1Decal - Fire Extinguisher
77077777 1Decal - Star Emblem
87078564 1Decal - Front, RH
97078570 2Decal - “POLARIS”
10 7077768 1Decal - Refueling Warning
11 7078566 1Decal - Sidewall, RH
12 7078567 2Decal - “Virage”
13 7078576 1Decal - NMMA, 3 Passenger
14 7077766 1Decal - MFI
15 7079001 1Dacal - Warning, Reverse System
16 7078702 1Decal - Reverse
17 7073865 1Decal - Caution, Capsize
18 7078565 1Decal - Sidewall, LH
19 7078311 1Decal - Warning, Seat/Engine
20 7078563 1Decal - Front, LH
3/00

A11
FUEL TANK
VIRAGE W005197D and INT’L VIRAGE W005197I
4
16
17
23
15
5
19
3
14 13
11
26
9
12
25
4
7
8
4
10
6
18
16
3
2
2
2
2
3
3
1
1
21 21
22
22
20
20
24
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
15244279 6Bracket, Strap
27552610 8Washer, Lock
37515361 8Screw
45243775 9Hook, Strap, Narrow
55430621 3Strap, Rubber
6-- -- -- -- -- -- -- 1Tank, Oil
(See Oil Tank Pg. A14, Ref. 19)
75243776 3Hook, Strap
85410424 3Strap, Battery Holddown
92520177 1Cap, Fuel, Ratchet
10 7080710 1Chain, Bead, Cap Retainer
11 7511873 1Screw
12 7080442 2Coupling, End, Fuel Cap Chain
13 5433553 1Inlet, Fuel
14 5811492 1Seal, Fuel Inlet
15 5433621 1Nut, Fuel Inlet
16 7080766 2Clamp, Hose
17 5411757 1Hose, Fuel Fill
18 7080451 1Clamp
19 2410124 1Asm., Fuel Sender
20 7661040 2Rivet
21 5812093 2Pad, Fuel Tank Stop
22 5244758 2Bracket, Fuel Tank Stop
23 5433018 1Tank, Fuel
24 5812135 1Pad, Fuel Tank
25 7621229 1Rivet
26 5411305 1Seal, Fuel Cap
3/00

A12
FUEL SYSTEM
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
3
4
5
6
7
8
14
10
11
9
15
6
7
7
7
6
13
13
6
12
6
NOTE: Fuel line from fuel/water
separator connects to fuel sender
fitting marked “ON.”
SEE NOTE
BELOW
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
17516302 1Screw
27555840 1Washer, Flat
35432836-070 1Knob, Fuel Valve, Black
45431451 1Nut, Fuel Valve
57052159 1Valve, Fuel
67080476 12 Clamp, Hose
78450046-1525 AR Line, Fuel
8-- -- -- -- -- -- -- 1Separator, Fuel/Water (See Fuel/Water
Separator Pg. C10, Ref. 5)
97052111 1Fitting, Tee
10 5410682 1Grommet, Vent
11 7080483 1Cable Tie
12 7051015 1Valve, Check
13 7080138 2Cable Tie
14 7052118 1Valve, Vacuum Check
15 -- -- -- -- -- -- -- 1Asm., Fuel Sender
(See Fuel Tank Pg. A11, Ref. 19)
11/99

A13
SEAT
VIRAGE W005197D and INT’L VIRAGE W005197I
27
26
11
9
21 10
18 17
58
24
7
19
3
25
12
13
22
4
14
15
1
2
28
23
16
6
20
23
21
12
2
15
4
3
13
2
12
20
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
17516806 2Screw
27555839 5Washer, Flat
35211314 2Plate, Seat Base Latch
47042036 2Spring, Seat Base Latch
55433779 1Handle, Seat Latch
67621478 2Rivet
75812025 1Strap, Seat Latch
85411807 1Seal, Seat, Rear
92682540-204
2682542-204
1
1
Asm., Seat, Rear
Cover, Seat, Rear
10 7517805 1Screw
11 7517806 2Screw
12 7555838 5Washer, Lock
13 5431357 2Plate, Bottom, Seat Base Latch
14 5431358 1Handle, Seat Base Latch
15 5431359 2Plate, Top, Seat Base Latch
16 1013202 1Asm., Hinge, Seat
17 7517669 4Screw
18 7517717 1Screw
19 7080914 1Cable, Limiter, Hinge
20 7661044 3Rivet
21 7542454 2Nut
22 7552607 1Washer, Lock
23 7555846 2Washer, Flat
24 5020753 1Plunger, Latch
25 2682541-204
2682543-204
1
1
Asm., Seat, Main
Cover, Seat, Main
26 5521490 10 Bumper, Seat
27 2682593-204 1Strap, Seat
28 5521536 1Seal, Seat, Main
10/99

A14
OIL TANK
VIRAGE W005197D and INT’L VIRAGE W005197I
11
5
8
19
9
16
20
7
10
6
22
17
9
15
18
14
14
21
21 15
17
1
2
3
4
1
12 13
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
17080442 2Coupling
27517241 1Screw
37621229 1Rivet
47080710 1Chain
55432843 1Cap, Oil Tank
67661038 4Rivet
75433601 1Inlet, Oil
85811554 1Gasket, Oil Inlet
97080481 2Clamp, Hose
10 7052130 1Elbow, 90 Degree
11 2410131 1Sender, Oil Level
12 7080138 2Cable Tie
13 4010051-30 1Conduit
14 7080307 2Clamp, Hose
15 8450003-1525 AR Line, Fuel
16 2530015 1Filter, Oil
17 7080474 2Clamp, Hose
18 8450059-150 AR Line, Fuel
19 5433083 1Tank, Oil
20 7052118 1Valve, Check, Vacuum
21 7080483 2Cable Tie
22 5411756 1Hose, Oil Fill
7/00

B1
STEERING
VIRAGE W005197D and INT’L VIRAGE W005197I
14
18
17
29
3
19
10
23
12
27
4
22
13
20
7
25
15
24
26
16
6
2
6
28
8
9
11
5
1
21
30
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
17517717 6Screw
27552613 6Washer, Lock
37555836 6Washer
45433089-070 1Pad, Handlebar
55433819-070 1Pad, Handlebar, Bottom
67517660 8Screw
75631017 1Clamp, Handlebar
85433355-070 1Handle, Grab
95433081 1Block, Throttle, Split
10 7080787 1Cable, Throttle
11 7080138 1Cable Tie
12 2410168 1Switch, START/STOP/BILGE
13 7080675 1Lanyard w/Whistle
14 1820820-070 1Handlebar w/Grip
15 5132317 1Column, Steering
16 5433136 1Housing, Steering
17 5433135 4Bearing, Steering
18 7542335 4Nut, Nylok
19 7555831 4Washer
20 5811551 1Gasket, Steering Housing
21 7517787 4Screw
22 5433737 1Clamp, Throttle Block
23 7710426 1Ring, Retaining
24 7555840 1Washer
25 5433079 1Lever, Throttle, Thumb
26 7661053 1Pin, Retaining
27 7517684 2Screw
28 7552615 2Washer, Lock
29 7556098 2Washer
30 7661099 1Pin, Roll
12/99

B2
STEERING
VIRAGE W005197D and INT’L VIRAGE W005197I
2
3
4
5
9
18
19
20
1
8
13
14
16
15
13
21
17
6
14
22
24
10
11
12
23
11
12
7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
17542150 1Nut
27515120 1Screw
37555839 1Washer
47060170 1Rod End
57542133 1Nut, Nylok
61860115 1Washer, Steering Seal
71860117 1Ring, Stopper
81860114 1Nut, Steering Cable (Special)
97080723 1Cable, Steering
10 5244681 1Brace, Steering Cable
11 7555891 2Washer
12 7516717 2Bolt
13 7542528 2Nut
14 1860103 2Washer
15 7571625 1Washer, Lock
16 1860105 1Cover
17 7080931 1Tube, Guide
18 7060154 1Rod End
19 7555837 1Washer
20 7541931 1Nut
21 7512041 1Screw
22 -- -- -- -- -- -- -- 1Column, Steering
(See Steering Pg. B1, Ref. 15)
23 7546704 2Nut
24 5244290 1Bracket, Steering Cable
10/02

B3
DRIVE SYSTEM
VIRAGE W005197D and INT’L VIRAGE W005197I
6
1
2
3
5
9
10
11
5
8
7
84
4
12
13
4
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
11060119 1Asm., Drive Coupler
25410735 1O-Ring
35432129 1Shroud, Coupler
47080481 3Clamp, Hose
55410663 2Bumper, Drive Shaft
66230103 1Shaft, Drive
77080629 1Fitting, Lubrication
83610040 2Seal, Bearing
91341145 1Asm., Bearing Housing (Incl. 7, 8)
10 5411027 1Hose, Bearing Housing
11 5432298 1Shaft, Housing, Thru-Hull
12 5411174 1O-Ring
13 5431985 1Nut, Shaft, Housing
10/99

B4
PROPULSION
VIRAGE W005197D and INT’L VIRAGE W005197I
3
37
27
23
28
32
35
36
21
8
25
29
6
4
5
24
34
31
30
7
9
10
11
17
13
8
15
14
18
33
2
1
16
226
20
4
19
22
12
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
15244556 1Bracket, Steering Cable Nut
25132111 4Stud, Mounting, Pump
35411107 1Seal, Water Pipe
45410735 2O-Ring
55432269 1Pipe, Water, Engine
65130983 1Stator, Pump
75010294 1Spacer, Bearing
83514008 2Bearing
93610043 2Seal, Stator Bearing
10 5010295 1Spacer, Impeller
11 5132372 1Impeller
12 5411644 1Seal, Impeller/Shaft
13 5131196 1Extension, Pump
14 7522019 1Screw
15 5630598 1Anode, Zinc
16 7555941 4Washer, Pump Stud
17 5131573 1Housing, Pump
18 7555966 3Washer, Flat
19 7542455 4Nut, Nylok
20 5410652 1O-Ring
21 5410817 1O-Ring
22 5811984 1Seal, Tailcone
23 5431523 1Screen, Engine Inlet
24 5130999 1Nozzle, Steering
25 7515366 2Screw
26 5130938 2Collar
27 7552610 4Washer, Lock
28 7555835 4Washer, Flat
29 5431518 2Bearing, Steering Nozzle
30 7515389 4Bolt
31 5131569 1Nozzle, Stationary
32 5432841 1Wedge, Pump
33 7512064 3Screw
34 5431519 1Cone, Pump
35 5410819 1O-Ring
36 5020697 1Shaft, Stub
37 5410818 1O-Ring
7/00

B5
REVERSE
VIRAGE W005197D and INT’L VIRAGE W005197I
16
34
39
36
12
23
15
32
11
24
25
1
33
43
30
27
46
45
37
5
40
44
34
33
67
10
41
13
28
19
21
29
2
3
9
20
4
14
32
26
26
25
17
18
42
16
31
35
38
8
22
47

B6
REVERSE
VIRAGE W005197D and INT’L VIRAGE W005197I
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
15433677-070 1Cap
27516816 1Screw
37517669 4Screw
47661040 8Rivet
55433646 1Flange
65811982 1Gasket
75433643 1Plate, Base
85433911 1Bushing
95433910 1Bushing
10 5433645 1Pinion
11 5433674 1Bushing
12 5433675 1Shaft, Cam
13 7555839 1Washer
14 7517331 1Screw
15 5433872 1Reverse, Lock
16 7041888 2Spring
17 7517717 2Screw
18 7556094 2Washer
19 5244288 1Bracket, Reverse Plate, Forward
20 5433605-070 1Handle, Reverse
21 5244289 1Bracket, Reverse Plate, Rear
22 7661041 4Rivet
23 5433647 1Bushing
24 5433673 1Plunger
25 5240257 2Plate, Cable
26 7512049 4Screw
27 5433954 1Arm, Reverse
28 7555952 1Washer
29 7516806 1Screw
30 7661010 1Pin, Cotter
31 7555837 1Washer
32 7080899 1Cable, Reverse
33 7542528 2Nut
34 1860103 2Washer
35 7571625 1Washer
36 5411818 1Seal, Rod
37 5411819 1Seal, Rod
38 7080950 1Tube, Guide, Reverse
39 7061062 1Rod End
40 7542133 1Nut, Nylok
41 5631036 1Gate, Reverse, Directional
42 7517749 1Screw
43 7555866 2Washer
44 5020683 2Collar
45 7555874 2Washer
46 7515368 2Screw
47 5244902 1Bracket, Reverse Stop
3/00