Polaris VIRAGE W005197I, VIRAGE W005197D User Manual

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

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

17

7

5

15

16

12

15

14

4

22

21

8

9

10

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