Disc Removal; Disc Replacement - Polaris Outlaw 500 Service Manual

Disc Removal

1. With ATV on the ground, loosen wheel nuts and hub nuts.
2. Safely lift and support the rear of the ATV under the main
frame.
3. Remove right rear wheel and hub.
4. Remove rear caliper and secure out of the way.
NOTE: Do not allow the caliper to hang by the brake
line. Brake line damage may result.
5. Remove right upper carrier bolt and secure upper a-arm out
of the way.
6. Tilt right hub carrier outward while pulling rear CV shaft
end from carrier assembly.
7. Remove brake disc mounting bolts (4).
8. Lift and rotate disc, slipping it over the hub assembly and
off the driveshaft, exiting the frame from the side.

Disc Replacement

1. Install disc, slipping it over the over the drive shaft and hub
assembly. Disc mounting holes will be on the inside face
of the hub assembly for correct installation.
2. Install brake disc mounting bolts. Torque mounting bolts to
18 ft.lbs. (24 Nm).
3. Install CV shaft into hub carrier.
4. Install upper a-arm, bolt and nut on to hub carrier. Torque
mounting bolt to 30 ft.lbs. (40.6 Nm).
5. Install wheel hub, domed washer and nut (dome of washer
facing out). Torque to 90 ft.lbs. (122 Nm). Install cotter pin.
BRAKES
6
6.23