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    Click avatar for tech links/info, donation request K447's Avatar
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    Arrow 2002-1996 Virage, SL, SLX, SLTX waterbox bracket; potential damage to waterbox bottom

    I noticed and fixed this problem a while ago, but didn't get around to posting about it. According to the Polaris cross reference, the same cradle part number 5241732 was used from 1996-2002.

    If you have the same waterbox and/or mounting cradle, I suggest you check for damage on the waterbox bottom.

    I discovered that both of my 2002 Virage TXi had damage to the bottom of the waterbox silencer, where the mounting bolt for the cradle, and the SS cradle itself was actually contacting the waterbox shell, when strapped down under the stock rubber strapping.

    The last few photos are of the damaged areas. In each case, the holes had not yet worn all the way through the casing, but they were getting there. Obviously, if it had worn through, it would be harder to repair, and would be a source of water into the hull.

    The fix was straight forward enough, shown in the first photos. Remove and bend the cradle bracket to lift the waterbox away from the bracket, repair (repaint) the worn areas, and re-install.

    Make sure the foam pad is positioned properly under the front of the waterbox, and that the exhaust hoses are properly connected and positioned.

    Last few pictures are of the repaired result.

    At the same time, I checked for contact between the hull and the Planet resonators, and loose brackets at the top of the resonators. Adjusted and tightened things so there was no hull contact where there shouldn't be.
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    Last edited by K447; 07-20-2008 at 11:43 AM.


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