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Polaris VIRAGE W005197D manual

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Table of contents for the manual

  • Page 1

    P ARTS MANUAL PN 9915581 and MIC ROFI CHE PN 9917173 1 1/00 VIRAGE Model #W005197D INT’L VIRAGE Model #W005197I Rev . 01 E 2000 Polaris Sal es Inc. E 2000 Polaris Sal es Inc.[...]

  • Page 2

    T ABLE OF CONTENTS VI RAGE W005197D and INT’L V IRAGE W005197I Parts Manual B BA TTERY BOX B10 ...................... BILGE PUMP B13 ........................ C CARBURET OR C6 ...................... COOLING SYSTEM B1 1 ................... CRANKCASE C3 ....................... CRANKSHAFT and PISTON C5 ............. CYLINDER & MANIFOLD C4 .......[...]

  • Page 3

    2000 VIRAGE W A TERCRAF T SP ECIF ICA TIONS CAP ACI TI ES Fuel T ank Reserve Fuel T ank Injec tion Oil Res er vo ir 17 US Gal lons (64.26 l ) N/A 6 Qua r ts (5 .68 l ) CARBURET IO N Gas T ype Carburetor T ype and Number Carburetion I dle Speed Regular U nleaded 87 Octane or 89 Oct ane Oxygenated 1-40mm Diaphragm T ype 1350  50 RPM COOLING Cooli [...]

  • Page 4

    2000 POLARIS VI RAGE PUBLICA TION NUMBERS MODEL MODEL # OWNER’S MANUAL P ARTS MANUAL P ARTS MICROFICHE ASSEMBL Y INSTRUCTIONS VIRAGE INT’L VIRAGE W005197D W005197I 9915574 9915574 9915581 9915581 9915589 9915589 9915597 9915597[...]

  • Page 5

    A5 SHROUD VIRAG E W005197D and INT’L VI RAGE 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 1 2 4 3 7 6 27 30 23 17 4 28 31 32 17 22 38 21 37 41 34 35 20 17 42 E 2000 Polaris Sal es Inc.[...]

  • Page 6

    A6 SHROUD VIRAG E W005197D and INT’L VI RAGE W005197I Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 3280339 1 Gauge, MFI , Analog/ Digi tal 2 541 1738 1 G asket, M FI 3 8450070-190 1 Line, Pitot , Formed End 4 7041931 2 Spring, MFI M ounting 5 2632234 1 Asm. , Consol e Latch 6 2201593 1 Kit - MFI Butt on Replacement 7 328034[...]

  • Page 7

    A7 HULL and BODY VIRAG E W005197D and INT’L VI RAGE 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[...]

  • Page 8

    A8 HULL and BODY VIRAG E W005197D and INT’L VI RAGE W005197I Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 581 1915-070 1 Pad, Boarding Platf orm 2 581 1913-070 581 1914-070 1 1 Pad, Footwel l, Rear , LH Pad, Footwel l, Rear , RH 3 581 191 1-070 581 1912-070 1 1 Pad, Footwel l, Cent er , LH Pad, Footwel l, Cent er , RH 4 581[...]

  • Page 9

    A9 FRONT STORAGE COM P ARTM ENT VIRAG E W005197D and INT’L VI RAGE 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 . Descripti on Ref. Part No. Qty . Descripti on 1 2653012 1 Latch, Door 2 5433710-31 1 1 Door , Compartm ent 3 1013282 1 Asm., Door Hi nge 4 7555890 5 Washer 5 7546704 5 Nut 6 7517669 5 Sc[...]

  • Page 10

    A10 DECALS VIRAG E W005197D and INT’L VI RAGE 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 . Descripti on Ref. Part No. Qty . Descripti on 2201689 1 Kit - Decals (Incl. Al l Except Seat Decals) 2200891 1 Kit - V inyl Decal Appl icati on (For Seat Decal s) 1 7078583 1 Decal - War ning, Rear 2 7077812[...]

  • Page 11

    A1 1 FUEL T ANK VIRAG E W005197D and INT’L VI RAGE 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 . Descripti on Ref. Part No. Qty . Descripti on 1 5244279 6 Bracke t, Strap 2 7552610 8 Washer , Lock 3 7515361 8 Screw 4 5243775 9 Hook, St rap, Narrow 5 5430621 3 Strap,[...]

  • Page 12

    A12 FUEL SYST EM VIRAG E W005197D and INT’L VI RAGE W005197I 1 2 3 4 5 6 7 8 14 10 11 9 15 6 7 7 7 6 13 13 6 12 6 NOT E: Fuel line f rom f uel/wat er separat or connec ts to f uel sender fitting marked “ON.” SEE NOTE BELOW Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 7516302 1 Screw 2 7555840 1 Washer , Flat 3 5432836-0[...]

  • Page 13

    A13 SEA T VIRAG E W005197D and INT’L VI RAGE W005197I 27 26 11 9 21 10 18 17 5 8 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 . Descripti on Ref. Part No. Qty . Descripti on 1 7516806 2 Screw 2 7555839 5 Washer , Flat 3 521 1314 2 Pl ate, Seat Base Latch 4 7042036 2 Spring, Seat Base Latch 5 54337[...]

  • Page 14

    A14 OIL T ANK VIRAG E W005197D and INT’L VI RAGE 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 . Descripti on Ref. Part No. Qty . Descripti on 1 7080442 2 Coupli ng 2 7517241 1 Screw 3 7621229 1 Rivet 4 7080710 1 Chain 5 5432843 1 Cap, Oi l T ank 6 7661038 4 Rivet 7 5433601 1 Inle t, Oil 8 581[...]

  • Page 15

    B1 STE ERING VIRAG E W005197D and INT’L VI RAGE 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 . Descripti on Ref. Part No. Qty . Descripti on 1 7517717 6 Screw 2 7552613 6 Washer , Lock 3 7555836 6 Washer 4 5433089-070 1 Pad, Handlebar 5 5433819-070 1 Pad, Handlebar , B ottom 6 75176[...]

  • Page 16

    B2 STE ERING VIRAG E W005197D and INT’L VI RAGE 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 . Descripti on Ref. Part No. Qty . Descripti on 1 7542150 1 Nut 2 7515120 1 Screw 3 7555839 1 Washer 4 7060170 1 Rod End 5 7542133 1 Nut, Nylok 6 18601 15 1 Washer , St eering Seal 7 18601 17 1 R in[...]

  • Page 17

    B3 DR IVE SYSTEM VIRAG E W005197D and INT’L VI RAGE W005197I 6 1 2 3 5 9 10 11 5 8 7 8 4 4 12 13 4 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 10601 19 1 Asm ., Drive Coupl er 2 5410735 1 O-Rin g 3 5432129 1 Shroud, Coupler 4 7080481 3 Clam p, Hose 5 5410663 2 Bumper , Drive Shaf t 6 6230103 1 Sha ft, Dr ive 7 7080629 1 Fi[...]

  • Page 18

    B4 PROPULSION VIRAG E W005197D and INT’L VI RAGE 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 2 26 20 4 19 22 12 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 5244556 1 Bracket, St eering Cable Nut 2 51321 1 1 4 St ud, Mounti ng, Pump 3 541 1 107 1 Seal , Water Pi pe 4 541[...]

  • Page 19

    B5 REVER SE VIRAG E W005197D and INT’L VI RAGE 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 6 7 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[...]

  • Page 20

    B6 REVER SE VIRAG E W005197D and INT’L VI RAGE W005197I Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 5433677-070 1 Cap 2 7516816 1 Screw 3 7517669 4 Screw 4 7661040 8 Rivet 5 5433646 1 Flange 6 581 1982 1 G asket 7 5433643 1 Plate, Base 8 543391 1 1 Bushing 9 5433910 1 Bushing 10 5433645 1 Pinion 11 5433674 1 Bushing 12 543[...]

  • Page 21

    B7 EX HAUST SYSTEM VIRAG E W005197D and INT’L VI RAGE W005197I 8 11 12 10 14 15 15 16 16 17 17 18 19 13 20 42 38 45 16 5 4 3 2 3 2 7 9 40 44 1 6 35 24 34 25 33 27 23 32 31 28 26 42 37 38 40 44 24 23 22 22 24 24 24 24 38 38 38 38 38 38 37 37 37 38 41 39 43 45 39 41 38 43 36 36 36 36 29 30 21 21[...]

  • Page 22

    B8 EX HAUST SYSTEM VIRAG E W005197D and INT’L VI RAGE W005197I Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 5020668 1 Fittin g, Inle t, W ate r 2 7555856 4 Washer , Flat 3 755261 1 4 Washer , Lock 4 7517268 2 Screw 5 7517004 2 Screw 6 -- -- -- -- -- -- -- 1 Fitt ing, Screen, Exhaust (See Cooling System Pg. B1 1, Ref . 8) 7 [...]

  • Page 23

    B9 ENGINE M OUNTING VIRAG E W005197D and INT’L VI RAGE W005197I 25 21 12 5 26 27 1 18 20 19 14 11 15 6 7 9 10 17 16 16 22 2 4 23 24 3 8 13 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 2410187 1 Asm., T emperat ure Switch 2 5242488 1 Ground, Spark Plug 3 7077026 1 Decal - Spark Plug 4 7515149 2 Screw 5 5830051 1 Gasket, Exha[...]

  • Page 24

    B10 BA TTE R Y BOX VIRAG E W005197D and INT’L VI RAGE W005197I 5 10 7 6 8 9 4 2 12 11 13 3 1 E 2000 Polaris Sal es Inc. Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 7515192 1 Stud 2 7517824 1 Screw 3 7555839 1 Washer , Flat 4 521 1676 1 Bracket, Battery Hold Do wn 5 5432413 1 Cov er , Batte r y 6 5410682 1 Grommet , V ent 7[...]

  • Page 25

    B1 1 COOLING SYSTEM VIRAG E W005197D and INT’L VI RAGE W005197I 3 15 1 5 1 9 28 6 8 27 22 26 23 1 1 7 7 7 24 19 12 4 1 1 25 16 17 18 13 14 20 4 4 11 9 2 10 21 7 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 7080475 6 Clam p, Hose 2 5431444 1 Fitt ing, Thru-Hull 3 581 1317 1 G asket 4 5521287-63 4 Conduit, Fl ex 5 541 1049 1 [...]

  • Page 26

    B12 WAT E R I N L E T VIRAG E W005197D and INT’L VI RAGE W005197I 6 9 8 10 11 12 13 14 15 3 4 5 7 1 2 5 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 7080483 1 Cable Tie 2 -- -- -- -- -- -- -- 1 Line, Pit ot (See Shroud Pg. A6, Ref. 3) 3 7547003 1 Nut, Hex, Ny lon 4 7555873 1 Washer , Flat 5 5810879 2 Gas ke t, Pito t 6 7555[...]

  • Page 27

    B13 BILGE PUM P VIRAG E W005197D and INT’L VI RAGE W005197I 7 2 8 9 10 5 2 6 2 2 3 1 4 4 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 7052141 1 Elbow 2 7080475 4 Clamp 3 8450050-26 1 Hose, Water 4 7080492 2 Cable Tie 5 5431444 1 Fittin g, W ate r , Thr u- Hu ll 6 581 1317 1 G asket 7 541 1595 1 Hose 8 2410169 1 Asm., Bilg e[...]

  • Page 28

    B14 ENGINE AIR INT AKE /HULL AIR INLET VIRAG E W005197D and INT’L VI RAGE W005197I 5 9 8 7 2 1 10 3 12 11 4 16 15 6 ENGINE AIR INT AKE HULL A IR INLE T 15 16 10 11 12 14 13 17 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 5432138-070 1 Plug, I ntake Sil encer 2 5410589 1 O-Rin g 3 5132353 2 Stud 4 5830062 1 Gasket 5 5631070 [...]

  • Page 29

    C1 ELE CTRICAL BOX VIRAG E W005197D and INT’L VI RAGE W005197I 38 13 12 27 37 24 36 29 28 23 26 6 14 35 17 21 22 7 9 30 32 33 41 25 15 19 34 18 16 1 10 11 18 31 2 40 39 20 8 8 17 16 4 5 3 To p V i e w[...]

  • Page 30

    C2 ELE CTRICAL BOX VIRAG E W005197D and INT’L VI RAGE W005197I Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 2460898 1 Har nes s, Main Wir e 2 5410346 4 Ins ula tor 3 7546705 2 Nut 4 7552613 2 Washer , Lock 5 7555882 2 Washer 6 -- -- -- -- -- -- -- 1 Solenoid, St arter (See Magneto Pg. C8, Ref . 10) 7 7517671 2 Screw 8 75558[...]

  • Page 31

    C3 CRANKCASE VIRAG E W005197D and INT’L VI RAGE W005197I 1 2 3 4 20 22 21 19 8 16 14 15 6 11 7 17 9 10 5 12 18 13 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 2201619 1 Kit - Asm., Crankcase (Incl. 2-4,20-22) 2 5131677 8 Stud, Cylinder Fl ange 3 7663001 2 Pin, Dowel 4 7052145 1 Fittin g 5 5243231 1 Clam p, St ator W ires 6 [...]

  • Page 32

    C4 CYLINDER & M ANIFOLD VIRAG E W005197D and INT’L VI RAGE W005197I 1 2 4 6 26 25 7 8 10 11 12 21 19 18 17 9 5 20 14 27 22 13 15 24 23 3 16 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 7075383 1 Deca l - War ning 2 7516806 4 Screw 3 7077026 1 Decal - Spark Plug 4 7051527 1 Plug, Pipe 5 3070174 2 Spark Plug, NG K BPR8ES [...]

  • Page 33

    C5 CRANKSHAFT and PIS TON VIRAG E W005197D and INT’L VI RAGE W005197I 1 4 1 2 4 1 3 9 6 8 7 3 9 8 7 5 17 18 20 15 14 12 10 16 10 23 24 2 5 16 13 6 5 5 25 22 21 11 11 19 26 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 3022950 4 Circ lip, Pis ton 2 3021091 2 Pin, Pist on 3 2200902 2200903 2200904 2200918 2200917 2200916 1 1 1[...]

  • Page 34

    C6 CARBURETOR VIRAG E W005197D and INT’L VI RAGE W005197I 1 2 3 4 14 5 6 8 9 10 11 12 13 15 19 20 16 17 22 21 8 9 18 7 Jet Block Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descri ption 1253334 1 Asm., C arburetor 2200910 1 Kit - Carb Rebui ld (Incl . 8,15, 21) 1 3050136 4 Screw , Fuel Pump 2 2200687 1 Kit - Fuel Pump Body 3 2200686 1 Ki[...]

  • Page 35

    C7 OIL PUMP VIRAG E W005197D and INT’L VI RAGE W005197I 7 1 8 6 2 3 4 5 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 7080679 1 Cable, O il Pum p 2 8450061-54 2 Line, Oil 3 7080603 4 Clam p, 7 mm 4 7555944 1 Washer 5 7710427 1 E-Ring 6 541 1293 1 O-Ring 7 7516605 2 Screw 8 2540073 1 Pump , Oil ( Incl. 6 ) 10/99[...]

  • Page 36

    C8 MAGN ET O VIRAG E W005197D and INT’L VI RAGE W005197I 2 1 5 8 9 7 11 16 15 13 10 6 14 12 3 4 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 4010172 1 Stator , T wi n 2 7517384 3 Screw 3 581 1320 1 O-Ring 4 5432282 1 Holder , Magnet 5 4010189 1 Asm., F lywheel 6 7517431 1 Screw 7 7555907 1 Washer 8 7546909 1 Nut 9 4010348 1[...]

  • Page 37

    C9 ST ARTING MOTOR VIRAG E W005197D and INT’L VI RAGE W005197I 12 1 2 3 5 6 7 8 9 11 9 16 17 18 19 20 21 25 17 13 15 10 22 23 14 4 24 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 40601 18 1 St arter , Big Bore 1 32401 13 2 Bol t, Through 2 7516807 2 Screw 3 32401 1 1 4 Spring, Brush 4 32401 15 1 Asm ., Brush (Incl. 3-8) 5 308[...]

  • Page 38

    C10 FUEL /W A TER SEP ARA T OR VIRAG E W005197D and INT’L VI RAGE W005197I 5 6 8 7 9 1 2 3 4 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 1 7517798 2 Screw 2 7552613 2 Washer , Lock 3 7555870 2 Washer , Dish 4 5132374 2 Spacer 5 3240220 1 Separator , Fuel /Water (Incl. 6-9) 6 3240209 1 O-Rin g 7 3240239 1 Element 8 3240238 1 [...]

  • Page 39

    C1 1 ENGINE FOGGING SYSTE M INT’ L VIRA GE W005197I 14 13 6 7 4 3 12 21 2 17 18 19 15 20 16 5 1 1 6 2 11 8 9 10 3 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 2872635 1 Kit - Engine Fogging 1 7080138 4 Cable Tie 2 7080484 2 Clam p, Hose 3 7080476 2 Clam p, Hose 4 7052139 1 Fittin g, T ee 5 7075738 1 Decal - Engi ne Primer 6 8[...]

  • Page 40

    C12 TOOL K IT VIRAG E W005197D and INT’L VI RAGE W005197I 1 2 3 5 6 4 Ref. Part No. Qty . Descripti on Ref. Part No. Qty . Descripti on 28721 14 1 A s m . ,T o o lK i t( I n c l .1 - 6 ) 1 -- -- -- -- -- -- -- 1 Wrench, Spark Plug 2 -- -- -- -- -- -- -- 1 Wrench, Open End 3 -- -- -- -- -- -- -- 1 Scre wdri ve r 4 9915574 1 Manual, O wners, ’00 [...]

  • Page 41

    PRINTED I N THE USA P ARTS MANU AL PN 9915581 and MICROFI CHE PN 9917173 1 1/00[...]

  • Page 42

    Changed pages in 9915581 1 2 3 4 5 6 7 8 9 10 11 12 13 14 A cover toc B C x D E F G 1 2 3 4 5 6 7 8 9 10 11 12 13 14[...]