Polaris Outlaw 110 & Polaris Sportsman 110 Rear Brake Disc Conversion

In the past years we've seen an interest for a rear brake improvement on the Polaris Outlaw 110, so we went ahead and made a bunch of tests. We thought we would offer you a detailed list of the best set-up we found. We also now sell a kit! If you'd like more info, please feel free to reach out to support@sterkproducts.com.

In our research, the best set-up we could find is a Kymco Mongoose 90 conversion, which is the same as the Kawasaki KFX 90. If you find a very cheap KFX 90 or Mongoose 90 for the parts, you're golden!

This kit is the winner because it is simple and it’s the safest route you can go! No need to cut the axle sleeve and no need to add any brackets so no welding.

In the list below you will find complete Kymco Mongoose 90 rear brake kit, this includes a new axle bearing cage with bearings in it with the brackets for the caliper, the pads, the hub, the disc, brake line, master cylinder, the lever, bolts, and nuts:

QTY. 1  43100-LLB1-800-NJA  CALIPER ASSY RR
QTY. 1  43530-PWA6-305  CYLINDER SET RR MASTER 
QTY. 1  42610-LBD4-800-N1S  HUB ASSY REAR 
QTY. 1  43126-PVA2-900  HOSE ASSY RR BRAKE
QTY. 1  43351-KEBE-900  DISK RR BRAKE
QTY. 1  43350-PVA2-900  BRACKET BRAKE DISK
QTY. 1  53178-PWA6-900-M2A  LEVER L STRG HNDL
QTY. 1  35350-KNBN-901  SW ASSY RR STOP
QTY. 2  90145-LEA3-E00  OIL BOLT 10*22
QTY. 3  90112-LBD4-800  BOLT DISK
QTY. 1  91356-PVA2-900  O-RING 30MM
QTY. 2  90120-PVA2-900  BOLT SOCKET SPECIAL 6X23
QTY. 1  90114-1F66-007  BOLT HANDLE LEVER
QTY. 1  94050-06060  NUT FLANGE 6MM
QTY. 4  90545-3L00-001  WASHER OIL BOLT
QTY. 1  93893-04012-18  SCREW WASHER 4X12

Those are all Kymco parts, but it doesn't mean you can't fit other parts, for instance on our test bike we tested and used a 1900 MM brake line from Aliexpress, much more affordable and still good quality. 
Link: : https://www.aliexpress.com/item/1005003025147617.html?spm=a2g0o.order_list.0.0.26d61802CLzs2C

We also tested 2 other master cylinders other than the Kymco, 1 from Ebay and 1 from Aliexpress. Those 3 options have the switch for the brake light.

The one from Aliexpress is our favorite for the adjustability but it doesn't have a parking brake. 
Link: https://www.aliexpress.com/item/32764808328.html?spm=a2g0o.order_list.0.0.26d61802CLzs2C

The second we tried, not much to it, it's a cheap Chinese master cylinder, worked well and has a parking brake, best route if you're trying to save money.
 Link: https://www.aliexpress.com/item/32764808328.html?spm=a2g0o.order_list.0.0.26d61802CLzs2C

Finally, the Kymco master cylinder is well built, we believe it is the best quality of all, it has a parking brake, but you have to file down a pin inside the loop to fit on handlebar. 

 The install is easy, you remove the wheels and axle, remove the axle bearing cage, replace it with new one, remove the drum, replace it with hub and disc. The hardest part is to remove the grip to be able to slide out the OEM lever, replace with master cylinder, slide new hose through, put oil, remove air in system and you're golden. 

Please feel free to reach out if you think we’ve missed something or if you have any questions. support@sterkproducts.com

 Thank you!