Disc Removal / Replacement - Polaris Sportsman 850 Service Manual

DISC REMOVAL / REPLACEMENT

1. Loosen the (4) wheel nuts.
2. Elevate and support the side of the ATV in which the
brake disc is being serviced.
CAUTION
Use care when supporting vehicle so that it does not tip
or fall. Severe injury may occur if machine tips or falls.
3. Remove the wheel nuts and wheel.
4. Remove the axle nut cotter pin, the axle castle nut,
and cone washers.
5. Remove the two brake caliper mounting bolts.
CAUTION
Do not hang the caliper by the brake line. Use wire to
hang caliper to prevent damage to the brake line.
6. Remove the wheel hub assembly from the bearing
carrier.
7. Press out the wheel studs and remove the brake
disc.
8. Clean the wheel hub mating surface.
9. Install the new disc and press new wheel studs into
the hub until they are flush with the mating surface.
CAUTION
Always use new wheel studs if removed from the wheel
hub assembly.
10. Install wheel hub assembly, cone washers, and hand
tighten the castle nut. Install washers with domed
side out.
11. Install the brake caliper and torque the new mounting
bolts to specification.
CAUTION
New bolts have a pre-applied locking agent which is
destroyed upon removal. Always use new brake caliper
mounting bolts upon assembly.
TORQUE
Caliper Mounting Bolts:
37 ft. lbs (50 Nm)
BRAKE SYSTEM
9
9.23