00-088BrakeDiscRefin..
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1. you will damage the cutting bits Turn on the tool bed feed motor and snap it into place there should be tension on the feed belt Cut the brake disc until the cutting bits clear the outer edge of the disc The cutting bits should produce a smooth consistent finish with no chatter marks or grooves If the disc did not clean up entirely on the first pass reset the brake lathe and make a second pass When done turn off the tool bed feed motor and turn off the drive motor on the power drive system If you are not using the power drive system turn off the engine and wait until the wheels come to a complete stop do not press the brake pedal If the vehicle has A T do not put the transmission in Park until the engine is off and the wheels have stopped Finishing the Job Remove the vibration damper and the protective band if used Use a micrometer to measure the thickness of the brake disc Make sure the thickness is within the service manual specifications Clean the brake disc with soapy water or brake cleaner then wipe it dry Use a vacuum cleaner to remove any dust or chips but do not use compressed air Unplug the tool bed feed motor from the drive motor assembly and remove the mounting yoke from the brake disc Remove the speed mount from the steering knuckle Apply a small amount of Molykote 77 grease to the brake pad shims Reinstall the caliper assembly If you did not use the power drive system use the brake pad2. reinstall the wheel nuts with flat washers to compensate for the removed wheel Torque the wheel nuts to the required specification see the appropriate service manual Remove the caliper assembly Use a wire or an S hook to hold the caliper to the spring or shock tower Do not kink the brake hose or use it to support the caliper If you are not using the power drive system and the vehicle has TCS make sure you install a brake pad spreader between the pads on the hanging caliper Also make sure the TCS is turned off anytime the engine is started If the system is not turned off the brakes could activate causing the brake pads on the hanging caliper to hit each other or the caliper pistons to fall out Install the vibration damper on the brake disc If you are not using the power drive system make sure you install the protective band around the wheel nuts VIBRATION DAMPER PROTECTIVE BAND If you are not using the power drive system use a fabric tie down strap to secure the brake disc that is opposite to the one you are refinishing If you are working on a Prelude with ATTS do not use a tie down strap let both wheels turn freely FABRIC TIE DOWN STRAP FRONT BRAKE DISC Prete to t e one you gt are refinishing 2 of 6 Mounting the Brake Lathe Remove the tool bed from the brake lathe then mount the brake lathe to the steering knuckle with a Honda 1 Piece Speed Mount Kit all vehicles except Pass
3. spreader to push the pistons back into the caliper Torque the nuts and bolts to the required specification see the appropriate service manual 00 088 Refinish the other front brake disc using the same guidelines If you used a fabric tie down strap make sure you switch it to the other side When you are done refinishing the brake disc reinstall the front wheels and torque the wheel nuts to the required specification see the appropriate service manual Lower the vehicle Check the brake fluid level then test drive the vehicle to make sure the brake pedal is firm and does not pulsate Lightly apply the brakes about 20 times during the test drive to seat the brake pads REAR BRAKE DISCS Refinish the rear brake discs on the vehicle using the Kwik Way Brake Lathe and the Kwik Way Power Drive System on S2000s and Passports if you are not using the power drive system you need only the brake lathe or refinish them off the vehicle using conventional brake disc refinishing equipment Follow the same guidelines you used for refinishing front brake discs noting these differences e All vehicles except Passport Mount the brake lathe to the rear knuckle with the Honda 2 Piece Adapter P N KWI 108002000 You can order the 2 piece adapter through the Honda Tool and Equipment Program see ORDERING INFORMATION e Passport Mount the brake lathe to the rear knuckle with the Passport Rear Speed Mount Kit P N KWI 108102570 Yo
4. vehicle to start and stop the engine or to shift the transmission e No need to secure the opposite wheel with a tie down strap No waiting for the engine to return to idle no concern about engine speed changes that can adversely affect brake disc cut and finish e No involvement of the Traction Control System TCS Increased cutting tool life because of consistent cutting speed 2003 American Honda Motor Co Inc All Rights Reserved ATB 624 25303 0306 00 088 June 3 2003 ORDERING INFORMATION Order the Kwik Way Brake Lathe its component parts and the Kwik Way Power Drive System through the Honda Tool and Equipment Program To place an order call 1 888 424 6857 or use the fax order form provided in your Honda Tool and Equipment Program Catalog Phone lines are open Monday thru Friday from 7 30 a m to 7 00 p m Central Time You can also order online through the Interactive Network iN Click on Service Tool and Equipment and then Online Catalog Click on Alignment Wheel and Brake Equipment and then On Car Brake Lathe or On Car Brake Lathe Accessories WARRANTY CLAIM INFORMATION None this bulletin is for information only FRONT BRAKE DISCS Whenever you replace a front brake disc you must refinish the new disc on the vehicle to avoid brake vibration Time for refinishing new front brake discs is included in the flat rate time for brake disc replacement Follow these guidelines to get the bes
5. E NUT ASSEMBLY 00 088 3 of 6 4 Set the lower toggle switch on the drive motor assembly to FWD counterclockwise rotation or REV clockwise rotation DRIVE MOTOR ASSEMBLY Setting Up and Adjusting the Brake Lathe Use Kwik Way cutting bits P N KWI 109109223 and the holding screws that come with them These bits are stamped KW and are available through the Honda Tool and Equipment Program see ORDERING INFORMATION TOOL HOLDER HOLDING SCREW YY Before you use the brake lathe inspect the tips of the cutting bits with a magnifying glass to make sure the tips are not worn out Each bit has three tips If a tip is worn rotate the bit and use a new tip A worn tip will produce a poor finish and may cause chattering KWIK WAY CUTTING BIT KW must face upward This tip is worn out and should not be used 4 of 6 Reinstall the tool bed on the brake lathe with the top of the cutting bits facing up and the feed knobs facing down Adjust the tool bed until the brake disc is centered between the cutting bits For proper refinishing the brake disc must turn toward the top of the cutting bits Brake disc must turn toward the top of the cutting bits LATHE MOVEMENT You may need to adjust the bit holder s for proper cutting of the brake disc Do not set the cutting depth on the brake lathe to more than 0 2 mm 0 008 in This is two divisions on the cutting knob Make sure you start yo
6. Skill Level MAINTENANCE HONDA Service Bulletin Applies To ALL Models Brake Disc Refinishing Guidelines Supersedes 00 088 dated November 19 2002 American Honda does not allow replacement of brake discs under warranty unless the brake disc is beyond its service limit for refinishing If the brake disc is within its service limit you must refinish it You can find the maximum refinishing limits in the Conventional Brakes section of the appropriate service manual Power Assisted Brake System section for the Passport You need to refinish brake discs every time they are replaced You also need to refinish brake discs when they become scored or if there is pulsation when the brakes are applied American Honda recommends two tools for brake disc refinishing the Kwik Way Brake Lathe and the Kwik Way Power Drive System These tools let you refinish both front and rear brake discs on the vehicle for most Honda models On vehicle refinishing ensures against brake pulsation that can result from off vehicle refinishing American Honda highly recommends using the power drive system to turn the front and rear brake discs You can also use the vehicle s engine to turn the brake discs depending on the model but the power drive system turns the brake disc at the proper torque and speed allowing the brake lathe to make a smooth consistent cut The power drive system also offers these advantages e No need to climb in and out of the
7. ports or the Passport Front Speed Mount Kit These kits provide quicker more accurate mounting and can be ordered through the Honda Tool and Equipment Program see ORDERING INFORMATION Honda 1 Piece Speed Mount Kit P N KWI 108003000 P N KWI 108004000 for large brake discs KIT COMPONENTS Torque the bolts to 33 N m 24 lb ft do not use an impact wrench Torque to 54 N m 40 lb ft do not use an impact wrench 00 088 Passport Front Speed Mount Kit Attaching the Power Drive System Left Front Mounting 1 Make sure the drive motor assembly on the power drive system is level with the brake disc 2 Attach the mounting yoke to the brake disc and secure it with one of the wheel nuts Torque the wheel nut to the required specification see the appropriate service manual WHEEL NUT MOUNTING YOKE DRIVESHAFT BRAKE CALIPER BOLTS Torque to 54 N m 40 lb ft do not use an impact wrench KIT COMPONENTS Torque the bolts to 33 N m 24 lb ft do not use an impact wrench Right Front Mounting BRAKE CALIPER BOLTS Torque to 54 N m lt 40 Ib ft do not use an impact wrench 3 Attach the driveshaft on the drive motor assembly to the mounting yoke making sure the center line of the driveshaft is level with the spindle nut on the wheel hub MOUNTING YOKE DRIVESHAFT KIT COMPONENTS Torque the bolts to 33 N m 24 lb ft do not use an impact wrench DRIVE MOTOR SPINDL
8. t results from your Kwik Way brake lathe and power drive system For detailed instructions refer to the appropriate operating manual Setting Up the Vehicle Put the transmission in Neutral If you are not using the power drive system start the engine and let it warm up to its normal operating temperature so the idle speed will stabilize to its lowest rom Raise the vehicle on a lift On 4WD Passports if you are not using the power drive system make sure the AWD switch is on the light in the switch is lit and the transfer control lever is in HIGH where applicable Check for loose wheel bearings On early 4WD Passports with locking front hubs make sure the hub nut is properly adjusted with no end play You must correct for loose wheel bearings or hub nut end play before you refinish the brake discs If you do not the brake lathe will not correct for brake disc runout resulting in an uneven finish and brake pulsation 1 of 6 CUSTOMER INFORMATION The information in this bulletin is intended for use only by skilled technicians who have the proper tools equipment and training to correctly and safely maintain your vehicle These procedures should not be attempted by do it yourselfers and you should not assume this bulletin applies to your vehicle or that your vehicle has the condition described To determine whether this information applies contact an authorized Honda automobile dealer Remove the front wheels then
9. u can order the rear speed mount kit through the Honda Tool and Equipment Program see ORDERING INFORMATION Honda 2 Piece Adapter P N KWI 108002000 KIT COMPONENTS Torque the bolts to 33 N m 24 lb ft do not use an impact wrench BRAKE CALIPER BOLTS Torque to 54 N m 40 lb ft do not use an impact wrench 5 of 6 Passport Rear Speed Mount Kit Left Rear Mounting 94 02 Models BRAKE CALIPER BOLTS Torque to 54 N m 40 lb ft do not use an impact wrench KIT COMPONENTS Fo Torque the bolts to 33 N m 24 lb ft do not use an impact wrench Right Rear Mounting 94 97 Models BRAKE CALIPER BOLTS Torque to 54 N m 2 40 lb ft do not use a an impa N i lt NS f ct wrench a Ges KIT COMPONENTS Torque the bolts to 33 N m 24 lb ft do not use an impact wrench 6 of 6 Right Rear Mounting 98 02 Models NOTE On these models mount the kit bracket upside down to allow clearance for the brake lathe BRAKE CALIPER BOLTS Torque to 54 N m eee 40 lb ft do not use an impact wrench KIT COMPONENTS Torque the bolts to 33 N m 24 lb ft do not use an impact wrench 00 088
10. ur cut at least 3 mm 0 12 in beyond the worn area on the brake disc If you are cutting a larger diameter brake disc such as that used on 1999 and later Odysseys make sure you use the 15 cutting bit holders These bit holders available through the Honda Tool and Equipment Program see ORDERING INFORMATION supersede the original bit holders and provide better cutting coverage for larger diameter brake discs Each bit holder is clearly marked for proper installation on the tool holder TOOL F ial 15 CUTTING BIT HOLDERS Make sure the bit holders are installed facing the rotor as shown 00 088 Cutting the Brake Disc To get the smoothest cut and the best brake disc finish always use the slowest feed speed on the tool bed feed motor Place the drive belt on the smallest pulley of the feed motor and on the largest pulley of the hand wheel Make sure the lower toggle switch on the power drive system drive motor assembly is set to the proper rotation to turn the brake disc toward the top of the cutting bits Plug the tool bed feed motor into the power outlet on the drive motor assembly then turn on the drive motor with the upper toggle switch on the assembly If you are not using the power drive system make sure the transmission is in 1st gear 2nd gear on Preludes with ATTS or reverse and the engine is idling but not at a fast idle If the transmission and engine are at higher gears and speeds
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00 088BrakeDiscRefin..