VIRAGE
Model #W005197D
INT’L VIRAGE
Model #W005197I
Rev. 01
E 2000 Polaris Sales Inc.E 2000 Polaris Sales Inc.
P ARTS MANUAL PN 9915581 and MICROFICHE PN 9917173 11/00
T ABLE 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
CARBURETION
Gas Type
Carburetor Type and
Number
Carburetion Idle Speed
COOLING
Cooling System Type
Overheating Warning
DIMENSIONS
Number of Passengers
Length, Overall
Width, Overall
Height, Overall
Dry Weight
Load Limit
Hull/Deck Material
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
1350 50 RPM
Water Cooled, Thermostat Pop off
Warning Light/RPM Limit
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
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
PROPULSION
Propulsion System
Jet Pump Type
Transmission
Minimum Water Level for Jet
Pump
Impeller Diameter
Impeller
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
Jet Drive
Axial Flow, Single Stage
Direct Drive
2feet(60cm)
5.83² (14.80 cm)
3 Blade, Slim Hub
ELECTRICAL
Alternator Output
Ignition System
Spark Plug Type
Spark Plug Gap
Starting System
Ignition Timing; BTDC
@3000 RPM
Battery
Polaris Industries Inc. reserves theright to make changes in design and specifications and/or to make additions or improvements to its products without
notice.
8.5 amps/60 watt at 4500 RPM
CDI
NGK BPR8ES
.028² (0.7 mm)
Electric Starter
23°
12V , 19A
2000 POLARIS VIRAGE PUBLICATION NUMBERS
MODEL MODEL #
VIRAGE
INT’L VIRAGE
W005197D
W005197I
OWNER’S
MANUAL
9915574
9915574
PARTS
MANUAL
9915581
9915581
PARTS
MICROFICHE
9915589
9915589
ASSEMBLY
INSTRUCTIONS
9915597
9915597
SHROUD
VIRAGE W005197D and INT’L VIRAGE W005197I
1
6
7
8
10
13
12
2
4
3
4
5
47
46
9
34
11
45
44
15
16
14
17
E 2000 Polaris Sales Inc.
43
17
42
41
40
37
36
33
34
35
32
38
31
39
29
30
19
18
17
20
17
21
20
24
25
26
23
28
27
22
A5
SHROUD
VIRAGE W005197D and INT’L VIRAGE W005197I
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 3280339 1 Gauge, MFI, Analog/Digital
2 5411738 1 Gasket, MFI
3 8450070-190 1 Line, Pitot, Formed End
4 7041931 2 Spring, MFI Mounting
5 2632234 1 Asm., Console Latch
6 2201593 1 Kit - MFI Button Replacement
7 3280342 1 Bezel, MFI, Overlay
8 5433709-311 1 Lid, Console
9 7041754 1 Spring, Torsion, Console
10 5521478 1 Seal, Console Lid
11 7546705 2 Nut
12 581 1783 1 Pad, Console
13 7516609 2 Screw
14 521 1865 1 Plate, Hook
15 7517668 4 Screw
16 7556055 2 Washer, Lock
17 7555874 8 Washer, Flat
18 541 1557
5411558
19 2631973-070
2631972-070
20 7546804 4 Nut, Hex
21 7080926 1 Cable, Choke
22 7546704 2 Nut, Nylok
23 7555839 2 Washer
11Gasket, Mirror, LH
Gasket, Mirror, RH
11Asm., Mirror, RH (Incl. 18)
Asm., Mirror, LH (Incl. 18)
24 7541931 2 Nut
25 5244673 1 Bracket, Support, Shroud
26 7516717 2 Bolt
27 541 1664 1 Grommet, Deck, Wire Harness
28 2690151 1 Strap, Tool Kit, Lower
29 5433210-070 1 Cover , Wire, Shroud
30 -- -- -- -- -- -- -- 1 Kit, Tool (See Tool Kit Pg. C12)
31 2690150 1 Strap, Tool Kit, Upper
32 7710517 2 Ring, Retaining
33 7516805 6 Screw
34 7552613 8 Washer, Lock
35 7556094 6 Washer
36 5433589-311 1 Shroud, Steering
37 5812076 1 Bumper, Door/Shroud
38 2080004 1 Knob, Choke
39 2080005 1 Screw
40 5244670 1 Plate, Latch, Receiver
41 7555837 2 Washer, Flat
42 7517818 2 Screw
43 7512045 2 Screw
44 581 1552 1 Gasket, Console Hook
45 5433266 1 Hook, Console
46 5333698 1 Pin, Hinge
47 5433384 1 Hinge, Console
1/01
A6
HULL and BODY
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
Bulkhead
5
6
27
13
26
28
10
13
8
22
29
12
14
19
25
23
24
32
31
30
30
31
33
34
29
10
3
4
8
35
8
7
8
9
8
10
11
21
15
20
12
13
18
14
15
16
17
A7
HULL and BODY
VIRAGE W005197D and INT’L VIRAGE W005197I
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 5811915-070 1 Pad, Boarding Platform
2 5811913-070
5811914-070
3 5811911-070
5811912-070
4 5811909-070
5811910-070
5 5411158 2 Grommet
6 5411658 1 Grommet
7 7516807 2 Screw
8 7556094 14 Washer
9 5433671 1 Plate, Seat Tongue
10 7546704 8 Nut
11 5411758-070 1 Bumper, Front
12 762151 1 31 Rivet
13 5431994-070 29 Plug, Bumper, Rear
14 7542133 4 Nut, Nylok
15 7555839 12 Washer
16 7555870 2 Washer, Dish, Rubber
17 2670150 1 Strap, Bow
11Pad, Footwell, Rear, LH
Pad, Footwell, Rear, RH
11Pad, Footwell, Center, LH
Pad, Footwell, Center, RH
11Pad, Footwell, Front, LH
Pad, Footwell, Front, RH
18 5521568-070
5521569-070
19 581 1440 10 Washer
20 5432272-070
5432273-070
21 7515198 10 Bolt
22 7517320-070 2 Bolt
23 7555836 2 Washer
24 581 1918
5811919
25 5433531-070 1 Bumper, Rear
26 1060125 2 Plug, Bilge
27 751 1882 4 Screw
28 2632218 1 Hook, Tow
29 7517644 6 Screw
30 7555846 2 Washer
31 7542454 2 Nut
32 5020753 1 Plunger, Latch
33 5433474-070 1 Handle, Grab
34 7552607 1 Washer, Lock
35 5433473 1 Bucket, Rear Storage
11Rail, Rub, Side, LH
Rail, Rub, Side, RH
11Sponson, LH
Sponson, RH
11Pad, Heel, LH
Pad, Heel, RH
4/00
A8
FRONT STORAGE COMPARTMENT
VIRAGE W005197D and INT’L VIRAGE W005197I
1
10
11
12
2
13
14
19
15
20
21
22
22
24
23
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
9
8
7
6
5
16
18
4
17
3
1 2653012 1 Latch, Door
2 5433710-311 1 Door, Compartment
3 1013282 1 Asm., Door Hinge
4 7555890 5 Washer
5 7546704 5 Nut
6 7517669 5 Screw
7 7516805 4 Screw
8 7552613 4 Washer, Lock
9 7555839 4 Washer
10 7555837 2 Washer
11 7552615 2 Washer, Lock
12 7512045 2 Screw
13 5521565 1 Seal, Door
14 7621235 2 Rivet
15 7080853 1 Cable, Limiter, Hinge
16 7041758 1 Spring, Gas
17 541 1559 1 Boot, Gas Spring
18 7080483 2 Cable Tie
19 521 1740 1 Plate, Fire Extinguisher
20 5431842 1 Cover, Fire Extinguisher
21 10601 14
5431841
22 7621452 4 Rivet
23 541 1865 1 Seal, Bucket, Front
24 5433464 1 Bucket, Front Storage
11Asm., Fire Extinguisher Container
(Incl. 20 and Container)
Container, Fire Extinguisher
A9
3/01
DECALS
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
3
4
5
6
13
12
7
11
RH
10
9
8
15
16
14
7
3
17
LH
12
18
9
20
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
2201689 1 Kit - Decals
(Incl. All Except Seat Decals)
2200891 1 Kit - Vinyl Decal Application
(For Seat Decals)
1 7078583 1 Decal - Warning, Rear
2 7077812 1 Decal - Coast Guard, Exemption
3 7078582 2 Decal - “POLARIS”, Seat
4 7078884 1 Decal - Planet Sound Reduction
5 7077479 1 Decal - Fuel, Off/On
6 7078260 1 Decal - Fire Extinguisher
7 7077777 1 Decal - Star Emblem
8 7078564 1 Decal - Front, RH
19
9 7078570 2 Decal - “POLARIS”
10 7077768 1 Decal - Refueling Warning
11 7078566 1 Decal - Sidewall, RH
12 7078567 2 Decal - “Virage”
13 7078576 1 Decal - NMMA, 3 Passenger
14 7077766 1 Decal - MFI
15 7079001 1 Dacal - Warning, Reverse System
16 7078702 1 Decal - Reverse
17 7073865 1 Decal - Caution, Capsize
18 7078565 1 Decal - Sidewall, LH
19 707831 1 1 Decal - Warning, Seat/Engine
20 7078563 1 Decal - Front, LH
A10
3/00
FUEL TANK
VIRAGE W005197D and INT’L VIRAGE W005197I
7
4
8
6
3
2
1
3
4
5
3
2
1
10
11
9
25
3
2
16
19
18
17
16
15
14
4
12
13
26
2
22
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 5244279 6 Bracket, Strap
2 7552610 8 W asher, Lock
3 7515361 8 Screw
4 5243775 9 Hook, Strap, Narrow
5 5430621 3 Strap, Rubber
6 -- -- -- -- -- -- -- 1 Tank, Oil
(See Oil Tank Pg. A14, Ref. 19)
7 5243776 3 Hook, Strap
8 5410424 3 Strap, Battery Holddown
9 2520177 1 Cap, Fuel, Ratchet
10 7080710 1 Chain, Bead, Cap Retainer
11 7511873 1 Screw
12 7080442 2 Coupling, End, Fuel Cap Chain
13 5433553 1 Inlet, Fuel
21
20
21
20
24
23
14 581 1492 1 Seal, Fuel Inlet
15 5433621 1 Nut, Fuel Inlet
16 7080766 2 Clamp, Hose
17 541 1757 1 Hose, Fuel Fill
18 7080451 1 Clamp
19 2410124 1 Asm., Fuel Sender
20 7661040 2 Rivet
21 5812093 2 Pad, Fuel Tank Stop
22 5244758 2 Bracket, Fuel T ank Stop
23 5433018 1 Tank, Fuel
24 5812135 1 Pad, Fuel Tank
25 7621229 1 Rivet
26 541 1305 1 Seal, Fuel Cap
22
A11
3/00
FUEL SYSTEM
VIRAGE W005197D and INT’L VIRAGE W005197I
10
11
1
2
3
6
4
5
6
7
8
SEE NOTE
BELOW
7
6
9
7
12
13
14
13
7
6
15
6
NOTE: Fuel line from fuel/water
separator connects to fuel sender
fitting marked “ON.”
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7516302 1 Screw
2 7555840 1 Washer, Flat
3 5432836-070 1 Knob, Fuel Valve, Black
4 5431451 1 Nut, Fuel Valve
5 7052159 1 Valve, Fuel
6 7080476 12 Clamp, Hose
7 8450046-1525 AR Line, Fuel
8 -- -- -- -- -- -- -- 1 Separator, Fuel/Water (See Fuel/Water
Separator Pg. C10, Ref. 5)
9 7052111 1 Fitting, Tee
10 5410682 1 Grommet, Vent
11 7080483 1 Cable Tie
12 7051015 1 Valve, Check
13 7080138 2 Cable Tie
14 70521 18 1 Valve, Vacuum Check
15 -- -- -- -- -- -- -- 1 Asm., Fuel Sender
(See Fuel Tank Pg. A11, Ref. 19)
A12
11/99
SEAT
VIRAGE W005197D and INT’L VIRAGE W005197I
27
28
25
20
24
21
6
4
3
2
1
13
12
18
19
20
23
23
17
7
5
15
16
12
15
14
4
22
21
8
9
10
2
2
3
13
12
11
26
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7516806 2 Screw
2 7555839 5 W asher, Flat
3 5211314 2 Plate, Seat Base Latch
4 7042036 2 Spr ing, Seat Base Latch
5 5433779 1 Handle, Seat Latch
6 7621478 2 Rivet
7 5812025 1 Strap, Seat Latch
8 5411807 1 Seal, Seat, Rear
9 2682540-204
2682542-204
10 7517805 1 Screw
11 7517806 2 Screw
12 7555838 5 Washer, Lock
13 5431357 2 Plate, Bottom, Seat Base Latch
14 5431358 1 Handle, Seat Base Latch
11Asm., Seat, Rear
Cover, Seat, Rear
15 5431359 2 Plate, Top, Seat Base Latch
16 1013202 1 Asm., Hinge, Seat
17 7517669 4 Screw
18 7517717 1 Screw
19 7080914 1 Cable, Limiter, Hinge
20 7661044 3 Rivet
21 7542454 2 Nut
22 7552607 1 Washer, Lock
23 7555846 2 Washer, Flat
24 5020753 1 Plunger, Latch
25 2682541-204
2682543-204
26 5521490 10 Bumper, Seat
27 2682593-204 1 Strap, Seat
28 5521536 1 Seal, Seat, Main
11Asm., Seat, Main
Cover, Seat, Main
10/99
A13
OIL T ANK
VIRAGE W005197D and INT’L VIRAGE W005197I
1
5
6
2
4
3
7
8
9
10
11
1
22
9
21
19
15
21
20
17
18
12
13
14
15
14
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7080442 2 Coupling
2 7517241 1 Screw
3 7621229 1 Rivet
4 7080710 1 Chain
5 5432843 1 Cap, Oil Tank
6 7661038 4 Rivet
7 5433601 1 Inlet, Oil
8 5811554 1 Gasket, Oil Inlet
9 7080481 2 Clamp, Hose
10 7052130 1 Elbow, 90 Degree
11 2410131 1 Sender, Oil Level
17
16
12 7080138 2 Cable Tie
13 4010051-30 1 Conduit
14 7080307 2 Clamp, Hose
15 8450003-1525 AR Line, Fuel
16 2530015 1 Filter, Oil
17 7080474 2 Clamp, Hose
18 8450059-150 AR Line, Fuel
19 5433083 1 Tank, Oil
20 70521 18 1 Valve, Check, Vacuum
21 7080483 2 Cable Tie
22 541 1756 1 Hose, Oil Fill
7/00
A14
STEERING
VIRAGE W005197D and INT’L VIRAGE W005197I
4
5
3
2
1
30
27
26
28
25
24
6
29
23
7
8
22
21
19
18
11
12
9
10
14
20
13
15
6
16
17
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7517717 6 Screw
2 7552613 6 W asher, Lock
3 7555836 6 W asher
4 5433089-070 1 Pad, Handlebar
5 5433819-070 1 Pad, Handlebar, Bottom
6 7517660 8 Screw
7 5631017 1 Clamp, Handlebar
8 5433355-070 1 Handle, Grab
9 5433081 1 Block, Throttle, Split
10 7080787 1 Cable, Throttle
11 7080138 1 Cable Tie
12 2410168 1 Switch, START/STOP/BILGE
13 7080675 1 Lanyard w/Whistle
14 1820820-070 1 Handlebar w/Grip
15 5132317 1 Column, Steering
16 5433136 1 Housing, Steering
17 5433135 4 Bearing, Steering
18 7542335 4 Nut, Nylok
19 7555831 4 Washer
20 581 1551 1 Gasket, Steering Housing
21 7517787 4 Screw
22 5433737 1 Clamp, Throttle Block
23 7710426 1 Ring, Retaining
24 7555840 1 Washer
25 5433079 1 Lever, Throttle, Thumb
26 7661053 1 Pin, Retaining
27 7517684 2 Screw
28 7552615 2 Washer, Lock
29 7556098 2 Washer
30 7661099 1 Pin, Roll
B1
12/99
STEERING
VIRAGE W005197D and INT’L VIRAGE W005197I
2
3
22
21
23
13
12
14
18
19
11
20
17
16
24
15
14
13
1
6
7
8
9
10
11
12
4
5
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7542150 1 Nut
2 7515120 1 Screw
3 7555839 1 W asher
4 7060170 1 Rod End
5 7542133 1 Nut, Nylok
6 1860115 1 Washer, Steering Seal
7 1860117 1 Ring, Stopper
8 1860114 1 Nut, Steering Cable (Special)
9 7080723 1 Cable, Steering
10 5244681 1 Brace, Steering Cable
11 7555891 2 W asher
12 7516717 2 Bolt
13 7542528 2 Nut
14 1860103 2 Washer
15 7571625 1 Washer, Lock
16 1860105 1 Cover
17 7080931 1 Tube, Guide
18 7060154 1 Rod End
19 7555837 1 Washer
20 7541931 1 Nut
21 7512041 1 Screw
22 -- -- -- -- -- -- -- 1 Column, Steering
(See Steering Pg. B1, Ref. 15)
23 7546704 2 Nut
24 5244290 1 Bracket, Steering Cable
B2
10/02
DRIVE SYSTEM
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
3
5
6
7
8
9
8
4
10
4
4
5
11
12
13
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 1060119 1 Asm., Drive Coupler
2 5410735 1 O-Ring
3 5432129 1 Shr oud, Coupler
4 7080481 3 Clamp, Hose
5 5410663 2 Bumper, Drive Shaft
6 6230103 1 Shaft, Drive
7 7080629 1 Fitting, Lubrication
8 3610040 2 Seal, Bearing
9 1341145 1 Asm., Bearing Housing (Incl. 7, 8)
10 541 1027 1 Hose, Bearing Housing
11 5432298 1 Shaft, Housing, Thru-Hull
12 541 1174 1 O-Ring
13 5431985 1 Nut, Shaft, Housing
B3
10/99
PROPULSION
VIRAGE W005197D and INT’L VIRAGE W005197I
4
6
5
4
9
10
7
8
3
2
1
17
2
18
19
20
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 5244556 1 Br acket, Steering Cable Nut
2 5132111 4 Stud, Mounting, Pump
3 5411107 1 Seal, Water Pipe
4 5410735 2 O-Ring
5 5432269 1 Pipe, Water, Engine
6 5130983 1 Stator, Pump
7 5010294 1 Spacer, Bearing
8 3514008 2 Bearing
9 3610043 2 Seal, Stator Bearing
10 5010295 1 Spacer, Impeller
11 5132372 1 Impeller
12 541 1644 1 Seal, Impeller/Shaft
13 5131 196 1 Extension, Pump
14 7522019 1 Screw
15 5630598 1 Anode, Zinc
16 7555941 4 Washer, Pump Stud
17 5131573 1 Housing, Pump
18 7555966 3 Washer, Flat
19 7542455 4 Nut, Nylok
14
15
16
21
13
12
37
8
11
24
23
22
31
32
33
34
35
36
20 5410652 1 O-Ring
21 5410817 1 O-Ring
22 581 1984 1 Seal, Tailcone
23 5431523 1 Screen, Engine Inlet
24 5130999 1 Nozzle, Steering
25 7515366 2 Screw
26 5130938 2 Collar
27 7552610 4 Washer, Lock
28 7555835 4 Washer, Flat
29 5431518 2 Bearing, Steering Nozzle
30 7515389 4 Bolt
31 5131569 1 Nozzle, Stationary
32 5432841 1 Wedge, Pump
33 7512064 3 Screw
34 5431519 1 Cone, Pump
35 5410819 1 O-Ring
36 5020697 1 Shaft, Stub
37 5410818 1 O-Ring
29
25
26
27
28
30
7/00
B4
REVERSE
VIRAGE W005197D and INT’L VIRAGE W005197I
1
21
20
25
7
24
26
34
18
33
16
23
10
31
11
28
27
29
30
8
9
17
26
25
12
13
16
14
15
6
5
4
3
2
19
22
32
41
40
39
38
42
43
32
37
36
33
44
45
34
35
47
46
B5
REVERSE
VIRAGE W005197D and INT’L VIRAGE W005197I
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 5433677-070 1 Cap
2 7516816 1 Screw
3 7517669 4 Screw
4 7661040 8 Rivet
5 5433646 1 Flange
6 5811982 1 Gasket
7 5433643 1 Plate, Base
8 5433911 1 Bushing
9 5433910 1 Bushing
10 5433645 1 Pinion
11 5433674 1 Bushing
12 5433675 1 Shaft, Cam
13 7555839 1 Washer
14 7517331 1 Screw
15 5433872 1 Reverse, Lock
16 7041888 2 Spring
17 7517717 2 Screw
18 7556094 2 Washer
19 5244288 1 Bracket, Reverse Plate, Forward
20 5433605-070 1 Handle, Reverse
21 5244289 1 Bracket, Reverse Plate, Rear
22 7661041 4 Rivet
23 5433647 1 Bushing
24 5433673 1 Plunger
25 5240257 2 Plate, Cable
26 7512049 4 Screw
27 5433954 1 Arm, Reverse
28 7555952 1 Washer
29 7516806 1 Screw
30 7661010 1 Pin, Cotter
31 7555837 1 Washer
32 7080899 1 Cable, Reverse
33 7542528 2 Nut
34 1860103 2 Washer
35 7571625 1 Washer
36 541 1818 1 Seal, Rod
37 541 1819 1 Seal, Rod
38 7080950 1 Tube, Guide, Reverse
39 7061062 1 Rod End
40 7542133 1 Nut, Nylok
41 5631036 1 Gate, Reverse, Directional
42 7517749 1 Screw
43 7555866 2 Washer
44 5020683 2 Collar
45 7555874 2 Washer
46 7515368 2 Screw
47 5244902 1 Bracket, Reverse Stop
3/00
B6
EXHAUST SYSTEM
VIRAGE W005197D and INT’L VIRAGE W005197I
43
38
41
38
1
4
3
2
5
3
2
6
7
8
9
44
40
39
38
37
24
21
42
36
38
36
45
38
37
43
38
38
44
45
38
37
36
35
24
42
36
38
41
40
39
38
37
16
15
17
13
14
10
12
17
16
15
34
21
11
18
19
20
29
25
23
28
22
24
16
26
24
30
27
24
22
32
31
33
24
23
B7
EXHAUST SYSTEM
VIRAGE W005197D and INT’L VIRAGE W005197I
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 5020668 1 Fitting, Inlet, Water
2 7555856 4 W asher, Flat
3 7552611 4 Washer, Lock
4 7517268 2 Screw
5 7517004 2 Screw
6 -- -- -- -- -- -- -- 1 Fitting, Screen, Exhaust
(See Cooling System Pg. B11, Ref. 8)
7 -- -- -- -- -- -- -- 1 Gasket, Exhaust
(See Battery Box Pg. B9, Ref. 5)
8 1261023-093 1 Asm., Exhaust Pipe
9 7080446 1 Clamp, Hose
10 541 1165 1 Hose, Pipe/Silencer
11 7080451 1 Clamp, Hose
12 5430621 1 Strap, Rubber
13 581 1342 1 Pad, Foam
14 5224472 2 D-Hook
15 7515127 2 Screw
16 7555838 6 Washer, Lock
17 7555839 2 Washer, Flat
18 5410414 2 Bumper, Rubber
19 5222696 1 Cradle, Silencer
20 1260581-093 1 Silencer, Exhaust
21 5812094 3 Pad
22 7080445 2 Clamp, Hose
23 541 1951 2 Hose
24 7080907 6 Clamp
25 5433810 1 Resonator 1
26 5830197 1 Pad
27 541 1863 1 Hose, Exhaust
28 7555836 4 Washer, Flat
29 75151 16 4 Screw
30 5245072 1 Plate, Exhaust Seal
31 5810529 1 Seal
32 5132446 1 Fitting, Exhaust
33 5433632 1 Resonator 3
34 543381 1 1 Resonator 2
35 541 1932
5521561
36 7552613 4 Washer, Lock
37 7517717 4 Screw
38 7556094 10 Washer
39 7547151 2 Nut, Cage
40 541 1851 2 Mount, Rubber
41 5433787
5433788
42 7516809 2 Screw
43 7516807 2 Screw
44 7546704 2 Nut
45 5244270 2 Bracket
11Hose, Crossover (Incl. Conduit)
Conduit
11Protector, Seat, LH
Protector, Seat, RH
4/00
B8
ENGINE MOUNTING
VIRAGE W005197D and INT’L VIRAGE W005197I
4
1
27
26
3
5
2
25
24
23
6
7
22
21
20
16
19
18
17
16
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 2410187 1 Asm., Temperature Switch
2 5242488 1 Ground, Spark Plug
3 7077026 1 Decal - Spark Plug
4 7515149 2 Screw
5 5830051 1 Gasket, Exhaust
6 -- -- -- -- -- -- -- 1 Decal - Warning (See Cylinder and
Manifold Pg. C4, Ref. 1)
7 -- -- -- -- -- -- -- 2 Spark Plug, NGK BPR8ES (See Cylin-
der and Manifold Pg. C4, Ref. 5)
8 7051527 1 Plug, Pipe
9 5630585 1 Plate, Front Mount
10 5630584 1 Plate, Rear Mount
11 7552609 4 W asher, Lock
12 7517330 4 Screw
13 5244508 2 Plate, Repair
14 3021 103 4 Mount, Engine
15
14
13
15 521 1727 AR Shim, Engine Mount
16 7552610 10 Washer, Lock
17 7517627 8 Screw
18 1060142 1 Bracket, Rear Muffler
19 7555835 2 Washer, Flat
20 7515357 2 Bolt
21 7555848 4 Washer, Flat
22 7542725 4 Nut
23 7556055 1 Washer, Lock
24 7517497 1 Bolt
25 2201620 1 Engine, Short Block NOTE: The Short
26 5240876 1 Clip, Retainer
27 7516603 1 Bolt
10
11
12
Block assembly contains a crankcase
assembly, cylinder, and cylinder head
assembly.
8
9
11/99
B9
VIRAGE W005197D and INT’L VIRAGE W005197I
E 2000 Polaris Sales Inc.
BATTERY BOX
12
1
4
5
11
10
2
3
6
8
7
9
13
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7515192 1 Stud
2 7517824 1 Screw
3 7555839 1 W asher, Flat
4 5211676 1 Bracket, Battery Hold Down
5 5432413 1 Cover, Battery
6 5410682 1 Grommet, Vent
7 7080483 3 Cable Tie
8 7052078 1 Connector
9 5432121 AR Hose, Vent
10 4140009 1 Battery, 19 Amp
11 2200619 2 Kit - Battery Bolt
12 40101 18 1 Cable, Ground, Battery/Engine
13 5850136 1 Pad, Battery
B10
11/00
COOLING SYSTEM
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
3
9
4
1
5
1
6
7
9
4
28
1
21
20
7
1
7
19
8
7
10
1
11
12
4
13
14
15
16
17
18
27
22
23
26
25
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7080475 6 Clamp, Hose
2 5431444 1 Fitting, Thru-Hull
3 5811317 1 Gasket
4 5521287-63 4 Conduit, Flex
5 5411049 1 Hose, Outlet, Pump
6 5431784 1 Fitting, Tee
7 7080476 4 Clamp, Hose
8 7052128 1 Fitting, Screen, Exhaust
9 8450054-100 1 Hose, Water
10 5020747 1 Fitting, Injector, Exhaust
11 5411050 1 Hose, Inlet
12 7080138 10 Cable Tie
13 7516727 2 Screw
14 7516725 4 Screw
24
15 1260694 1 Asm., Exhaust Manifold
16 7555856 1 Washer, Flat
17 755261 1 1 Washer, Lock
18 7517004 1 Screw
19 581 1045 2 Gasket, Exhaust
20 5020746 1 Fitting, Drain Exhaust
21 5521398-13 1 Conduit, Flex
22 5432799 1 Valve, Pop-Off
23 7051008 1 Thermostat, 143 Degrees F.
24 5410781 1 Gasket, Thermostat
25 5131008 1 Cover, Thermostat, Machined
26 7041310 1 Spring, Compression
27 5410860 1 Seal, Thermostat Housing
28 541 1479 1 Hose, Water Out
10/99
B11
WATER INLET
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
3
4
5
6
5
7
8
9
15
10
11
12
13
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7080483 1 Cable Tie
2 -- -- -- -- -- -- -- 1 Line, Pitot (See Shroud Pg. A6, Ref. 3)
3 7547003 1 Nut, Hex, Nylon
4 7555873 1 W asher, Flat
5 5810879 2 Gasket, Pitot
6 7555848 1 W asher, Flat
7 5431634 1 Fitting, Pitot
8 5131602 1 Scoop, Inlet
9 -- -- -- -- -- -- -- 1 O-Ring
(See Propulsion Pg. B4, Ref. 20)
10 5630542-067 1 Grate, Inlet
11 7515155 1 Screw
12 7517267 8 Screw
13 7515126 2 Screw
14 5630659 1 Plate, Ride, Long, Angled
15 7010083 8 Insert, Sponson/Ride Plate
14
B12
10/99
BILGE PUMP
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
2
4
3
2
5
6
4
7
2
9
10
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7052141 1 Elbow
2 7080475 4 Clamp
3 8450050-26 1 Hose, Water
4 7080492 2 Cable Tie
5 5431444 1 Fitting, Water, Thru-Hull
8
6 5811317 1 Gasket
7 5411595 1 Hose
8 2410169 1 Asm., Bilge Pump
9 7512043 2 Screw
10 7555837 2 Washer
3/00
B13
ENGINE AIR INTAKE/HULL AIR INLET
VIRAGE W005197D and INT’L VIRAGE W005197I
ENGINE AIR I NTAKE
1
2
9
8
7
10
11
12
HULL AIR INLET
10
13
11
14
12
15
15
16
16
6
3
5
4
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 5432138-070 1 Plug, Intake Silencer
2 5410589 1 O-Ring
3 5132353 2 Stud
4 5830062 1 Gasket
5 5631070 1 Base, Intake
6 7517799 2 Screw
7 2520185 1 Filter, Intake
8 5432464-070 1 Cover, Intake
9 7546708 2 Nut
10 7661042 10 Rivet
11 5433220 2 Flange, Air Inlet
12 541 1545 2 Gasket
13 5812108 1 Panel
14 541 1958 1 Gasket
15 7080439 2 Clamp
16 5433082 2 Duct, Air Inlet
17 7080492 5 Cable Tie
17
3/00
B14
ELECTRICAL BOX
VIRAGE W005197D and INT’L VIRAGE W005197I
28
29
27
26
16
25
18
17
21
24
20
19
23
18
22
31
16
1
2
3
4
5
6
7
8
Top View
30
32
33
34
10
8
9
11
15
13
14
12
17
36
37
38
41
35
39
40
C1
ELECTRICAL BOX
VIRAGE W005197D and INT’L VIRAGE W005197I
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 2460898 1 Harness, Main Wire
2 5410346 4 Insulator
3 7546705 2 Nut
4 7552613 2 W asher, Lock
5 7555882 2 W asher
6 -- -- -- -- -- -- -- 1 Solenoid, Starter
(See Magneto Pg. C8, Ref. 10)
7 7517671 2 Screw
8 7555839 4 W asher
9 7546704 2 Nut
10 4060161 1 Fuse, 3 Amp
11 4060111 1 Fuse, 1/4 Amp
12 5432503 4 Latch
13 5333544 4 Pin, Latch
14 -- -- -- -- -- -- -- 1 Controller, Ignition
(See Magneto Pg. C8, Ref. 9)
15 5244335 1 Strap, Grounding
16 7547061 3 Nut
17 7555837 7 Washer
18 7512042 3 Screw
19 4010304 1 Regulator, 1 Button
20 7547059 4 Nut
21 4010238 1 Cable, Battery/Solenoid
22 4010237 1 Cable, Solenoid/Starter
23 541 1491 1 O-Ring
24 7080461 1 Boot, Threaded
25 75151 13 2 Screw
26 7555836 2 Washer
27 5432574 1 Plate, Stator
28 7077691 1 Decal - “RESET ELEC SYSTEM”
29 7073713 1 Decal - High Voltage Warning
30 2460718 1 Harness,8WireStator
31 2460826 1 Harness, Pigtail
32 54331 19 1 Cover, Electrical Box
33 5432569 1 Seal
34 5244370 1 Bracket, Coil
35 -- -- -- -- -- -- -- 1 Coil, Ignition
(See Magneto Pg. C8, Ref. 11)
36 2410201 1 Asm., Terminal Board
37 243401 1 1 Breaker, Circuit
38 2632137 1 Asm., Electrical Box, Ignition
(Incl. 12,13,32,33)
39 541 1235 1 Grommet
40 5432502 1 Cap
41 7517825 4 Screw
4/03
C2
CRANKCASE
VIRAGE W005197D and INT’L VIRAGE W005197I
6
5
11
7
1
10
8
9
12
18
13
17
14
4
2
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 2201619 1 Kit - Asm., Crankcase (Incl. 2-4,20-22)
2 5131677 8 Stud, Cylinder Flange
3 7663001 2 Pin, Dowel
4 7052145 1 Fitting
5 5243231 1 Clamp, Stator Wires
6 7517431 1 Screw
7 3569805 1 Bushing
8 5433130 1 Plug
9 3574214 1 Bushing
10 7041457 1 Spring
11 3569806 1 Bushing
3
19
21
22
20
12 7517676 6 Screw
13 7516806 1 Screw
14 1201923 1 Asm., Flywheel Cover (Incl. 11)
15 581 1550 1 Gasket, Flywheel Cover
16 7516723 4 Screw
17 7663002 3 Pin, Dowel
18 541 1564 1 O-Ring
19 1201938 1 Asm., Flywheel Housing (Incl. 7,17)
20 7517628 4 Screw
21 7051529 2 Plug
22 7516913 2 Screw
16
15
11/99
C3
CYLINDER & MANIFOLD
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
3
4
5
6
7
8
9
10
11
27
26
25
24
23
22
12
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7075383 1 Decal - Warning
2 7516806 4 Screw
3 7077026 1 Decal - Spark Plug
4 7051527 1 Plug, Pipe
5 3070174 2 Spark Plug, NGK BPR8ES
6 7516722 8 Screw
7 7517352 12 Screw
8 5410917 2 O-Ring
9 5410932 2 O-Ring
10 5410931 2 O-Ring
11 7547021 8 Nut
12 3021019 2 Cylinder
13 5830043 1 Gasket, Carb
14 7517306 2 Screw
21
20
19
13
14
15 7080654 1 Retainer, Vinyl Coated
16 5241 134 1 Bracket, Oil Pump Cable
17 7516807 10 Screw
18 5630656 1 Manifold, Intake
19 5432104 2 Stuffer, Reed Block
20 1201689 2 Asm., Valve, Reed
21 5830123 2 Gasket, Cylinder Base
22 3021 117 2 Head, Cylinder
23 5241944 2 Ring, Head
24 5241768-093 1 Bracket, Head, Twin
25 5630527-093 2 Cover, Head
26 5830061 2 Gasket, Water, Manifold
27 5630826-093 1 Manifold, Outlet, Water
18
15
17
16
10/99
C4
CRANKSHAFT and PISTON
VIRAGE W005197D and INT’L VIRAGE W005197I
3
1
15
14
13
12
21
4
5
6
7
26
16
11
10
25
24
23
2
3
2
1
9
7
6
5
10
11
16
1
8
9
4
5
8
5
22
20
19
18
17
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 3022950 4 Circlip, Piston
2 3021091 2 Pin, Piston
3 2200902
2200903
2200904
2200918
2200917
2200916
4 2201626
2201627
2201628
5 -- -- -- -- -- -- -- 4 Washer, Thrust
6 -- -- -- -- -- -- -- 2 Pin, Crankshaft
7 -- -- -- -- -- -- -- 2 Bearing, Connecting Rod
8 2201022 1 Kit - Connecting Rod Assembly (Incl. 5-7)
9 3584001 2 Bearing, Connecting Rod (20 mm)
10 3585503 4 Bearing, Ball
1
Kit - Piston Rings (Std.)(2 Rings)
1
Kit - Piston Rings (.25mm OS)
1
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.
1
Kit - Piston Rings (Std.)(2 Rings)
1
Kit - Piston Rings (.25mm OS)
1
Kit - Piston Rings (.50 mm OS) NOTE: If the
number stamped on the head of piston
reads ELKO 2194a use the above 3 kits.
1
Kit - Piston Asm. (Std.)(Incl.1,2,3)
1
Kit - Piston Asm. (.25 mm OS)(Incl.1,2,3)
1
Kit - Piston Asm. (.50 mm OS)(Incl.1,2,3)
11 7710441 2 Ring, Retaining (72 mm)
12 541 1524 1 Seal
13 7710435 1 Ring, Retaining (72 mm)
14 5410613 1 O-Ring
15 5131 195 1 Collar, Crankshaft
16 7555905 2 Bushing
17 5131083 1 Crankweb, PTO
18 5131084 2 Crankweb, Center
19 5131086 1 Labyrinth
20 5131085 1 Crankweb, Mag.
21 2201243 1 Kit - Crankshaft, 2 Cylinder
(Incl. 10,16-20,22)
22 7721 117 1 Key, Woodruff
23 3610044 1 Seal
24 -- -- -- -- -- -- -- 1 Washer (See Magneto Pg. C8, Ref. 7)
25 -- -- -- -- -- -- -- 1 Nut, Pump Drive
(See Magneto Pg. C8, Ref. 8)
26 5432576 1 Coupler
10/99
C5
CARBURETOR
VIRAGE W005197D and INT’L VIRAGE W005197I
8
7
6
9
Jet Block
10
11
5
4
17
18
3
2
1
Ref. Part No . Qty. Description Ref. Part No. Qty. Description
1253334 1 Asm., Carburetor
2200910 1 Kit - Carb Rebuild (Incl. 8,15,21)
1 3050136 4 Screw, Fuel Pump
2 2200687 1 Kit - Fuel Pump Body
3 2200686 1 Kit - Gasket, Fuel Pump
4 5830062 1 Gasket, Carburetor, Upper
5 3050144 2 Scr een, Fuel Strainer
6 2200733 1 Kit - Needle Valve
7 3050117 1 Jet, Main, Keihin
8 3050193 1 Jet, Main, Keihin
9 3050133 1 Jet, Pilot, Keihin
10 3050135 8 Screw, Jet Block Cover
22
21
11 3050139 2 Cover, Jet Block
12 2200730 1 Kit - Diaphragm, Jet Block
13 3050137 1 Screw, Jet Block
14 3050204 2 Block, Jet
15 3050147 2 O-Ring, Jet Block
16 3050138 2 Collar
17 3050148 4 O-Ring, Valve Seat
18 2200688 2 Kit - Check Valve
19 2200689 2 Kit - Idler Mixture Screw
20 3050140 2 Cap, Limiter
21 5830043 2 Gasket, Lower
22 2200731 1 Kit - Idle Stop Screw
15
16
13
14
19
8
9
12
20
10/99
C6
OIL PUMP
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
3
5
4
8
7
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7080679 1 Cable, Oil Pump
2 8450061-54 2 Line, Oil
3 7080603 4 Clamp, 7 mm
4 7555944 1 W asher
5 7710427 1 E-Ring
6 5411293 1 O-Ring
7 7516605 2 Screw
8 2540073 1 Pump, Oil (Incl. 6)
6
10/99
C7
MAGNETO
VIRAGE W005197D and INT’L VIRAGE W005197I
2
1
3
14
13
15
12
4
16
5
6
11
10
7
8
9
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 4010172 1 Stator, Twin
2 7517384 3 Screw
3 5811320 1 O-Ring
4 5432282 1 Holder, Magnet
5 4010189 1 Asm., Flywheel
6 7517431 1 Screw
7 7555907 1 W asher
8 7546909 1 Nut
9 4010348 1 Controller, Ignition
10 4010228 1 Solenoid, Starter
11 4010175 1 Coil, Ignition
12 7080471 1 Clip
13 4010173-42 1 Wire, Spark Plug
14 4010173-56 1 Wire, Spark Plug
15 7080483 2 Cable Tie
16 4020155 2 Cap, Spark Plug
C8
11/02
STARTING MOTOR
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
4
3
10
9
12
11
13
9
14
17
25
24
5
6
7
8
15
16
21
23
22
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
4060118 1 Starter, Big Bore
1 3240113 2 Bolt, Through
2 7516807 2 Screw
3 3240111 4 Spring, Brush
4 3240115 1 Asm., Brush (Incl. 3-8)
5 3084408 1 O-Ring
6 3240119 1 Washer
7 3240117 1 Washer, Spring
8 3240116 1 Nut
9 3084405 2 Ring, Rubber
10 3240207 1 Asm., Rear Bracket
11 3240118 AR Washer, Thrust
12 32401 12 1 Washer, Thrust
20
19
18
17
13 3240205 1 Asm., Armature
14 40601 19 1 Asm., Bendix (Incl. 17-25)
15 3240206 1 Asm., Front Bracket
16 32401 14 1 O-Ring
17 3083737 1 Washer
18 3240126 1 Ring, Snap
19 3240125 1 Stopper
20 3240123 1 Cover
21 7041457 1 Spring
22 3574214 1 Bushing, Flanged
23 7555908 1 Washer, Thrust
24 3240122 1 Asm., Gear
25 3240120 1 Asm., Gear (Incl. 17-24)
C9
10/99
FUEL/WATER SEPARATOR
VIRAGE W005197D and INT’L VIRAGE W005197I
1
2
3
4
6
7
8
9
5
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
1 7517798 2 Screw
2 7552613 2 W asher, Lock
3 7555870 2 W asher, Dish
4 5132374 2 Spacer
5 3240220 1 Separ ator, Fuel/Water (Incl. 6-9)
6 3240209 1 O-Ring
7 3240239 1 Element
8 3240238 1 Spring
9 3240240 1 Float
C10
3/00
ENGINE FOGGING SYSTEM
INT’L VIRAGE W005197I
8
9
7
1
10
1
2
3
4
3
6
11
6
12
5
2
13
14
15
21
20
19
18
17
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
2872635 1 Kit - Engine Fogging
1 7080138 4 Cable Tie
2 7080484 2 Clamp, Hose
3 7080476 2 Clamp, Hose
4 7052139 1 Fitting, Tee
5 7075738 1 Decal - Engine Primer
6 8450062 AR Line, Oil
7 3160114 1 Primer, Engine, Fog
8 -- -- -- -- -- -- -- 2 Screw (See Fuel/Water Separator Pg.
C10, Ref. 1)
9 -- -- -- -- -- -- -- 2 Washer, Lock (See Fuel/Water Sepa-
rator Pg. C10, Ref. 2)
10 -- -- -- -- -- -- -- 2 Washer, Dish (See Fuel/Water Separa-
tor Pg. C10, Ref. 3)
11 -- -- -- -- -- -- -- 1 Separator, Fuel/Water (See Fuel/Water
Separator Pg. C10, Ref. 5)
12 7075732 1 Decal - ‘‘Fogging Oil Only”
13 7555837 2 Washer
14 7541931 2 Nut
15 7052047 1 Valve, Check, Vent
16 7052138 2 Fitting, 90 Degree
17 5432362 1 Tank, Oil
18 5810279 1 Gasket, Overflow Cap
19 5432359 1 Cap, Oil Bottle
20 7512045 2 Screw
21 5244295 1 Bracket, Oil Tank
C11
16
10/99
TOOL KIT
VIRAGE W005197D and INT’L VIRAGE W005197I
1
5
2
6
3
4
Ref. Part No . Qty. Description Ref. Part No . Qty. Description
2872114 1 Asm.,ToolKit(Incl.1-6)
1 -- -- -- -- -- -- -- 1 Wrench, Spark Plug
2 -- -- -- -- -- -- -- 1 Wrench, Open End
3 -- -- -- -- -- -- -- 1 Screwdriver
4 9915574 1 Manual, Owners, ’00 Watercraft
5 -- -- -- -- -- -- -- 1 Pouch, Tool Kit
6 -- -- -- -- -- -- -- 1 Wrench, Allen, Plated, 3/16
C12
10/99
PRINTED IN THE USA PARTS MANUAL PN 9915581 and MICROFICHE PN 9917173 11/00
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Changed pages in 9915581
A cover toc
B
C x
D
E
F
G
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