00-088e - Honda Tech
Contents
1. warm up to its normal operating temperature so the idle speed will stabilize to its lowest rpm Raise the vehicle on a lift Check for loose wheel bearings You must correct for loose wheel bearings 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 Remove the front wheels then reinstall the wheel nuts with flat washers to compensate for the removed wheel Torque the wheel nuts to the required specification see the appropriate shop 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 or VSA make sure you install a brake pad spreader between the pads on the hanging caliper Also make sure the system is turned off anytime the engine is started If the system is not turned off the brakes may activate causing the brake pads on the hanging caliper to strike each other or the pistons to fall out 1of5 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 PROTECTIVE DAMPER 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 refinishi2. HONDA Export Service Bulletin 00 088 Applies To ALL Models Brake Disc Refinishing Guidelines Replaces 86 020 dated July 1999 Replacement of brake discs under warranty is not allowed unless the brake disc is beyond its service limit for refinishing If the brake disc is within its service limit it must be refinished You can find the maximum refinishing limits in the Conventional Brakes section of the appropriate shop manual 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 vehicle to start and stop the engine or to shift the transmission e No need to secure the o
3. cutting a larger diameter brake disc such as that used on 1986 90 Legends 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 15 CUTTING BIT HOLDERS Make sure the bit holders are installed facing the rotor as shown 4of5 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 you will damage the cutting bits Turn on the tool bed feed motor and snap it into place there should be tension o
4. n 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 shop 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 pad spreader to push the pistons back into the caliper Torque the nuts and bolts to the required specification see the appr
5. ng If you are working on a Prelude with ATTS do not use a tie down strap let both front wheels turn freely FABRIC TIE DOWN STRAP FRONT BRAKE DISC Peete to t A e one you are refinishing 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 This kit provides quicker more accurate mounting You can order this kit through the Honda Tool and Equipment Program see ORDERING INFORMATION 2of5 Honda 1 Piece Speed Mount Kit P N KWI 108003000 or 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 Attaching the Power Drive System 1 2 Make sure the drive motor assembly on the power drive system is level with the brake disc 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 AN DRIVESHAFT 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 DRIVE MOTOR SPINDLE NUT ASSEMBLY 00 088 4 Set the toggle switch on the drive mo
6. opriate shop manual 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 shop manual 00 088 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 You can either refinish the rear brake discs on the vehicle using the Kwik Way Brake Lathe and the Kwik Way Power Drive System 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 Do not install the protective band around the wheel nuts e Mount the brake lathe to the rear knuckle with the Honda Two Piece Adapter You can order the two piece adapter through the Honda Tool and Equipment Program see ORDERING INFORMATION Honda Two Piece Adapter P N KWI 108002000 KIT COMPONENTS Torque the bolts to 33 N m 24 Ib ft do not use an impact wrench BRAKE CALIPER BOLTS Torque to 54 N m 40 lb ft do not use an impact wrench 00 088 5of5
7. pposite 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 with the Traction Control System TCS or Vehicle Stability Assist VSA Increased cutting tool life because of consistent cutting speed ORDERING INFORMATION To order the Kwik Way Brake Lathe its component parts and the Kwik Way Power Drive System contact the Honda Tool and Equipment Program at 1 888 424 6857 Phone lines are open Monday thru Friday from 7 30 a m to 7 00 p m Central Time When calling make sure you enter the appropriate access code first see the Honda Tool and Equipment Catalog for a list of these codes 2001 American Honda Motor Co Inc All Rights Reserved XTB 20383 22705 0108 August 2001 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 best 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
8. tor 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 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 A ESA must ace upward This tip is worn out and should not be used 3of5 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 This is two divisions on the cutting knob Make sure you start your cut at least 3 mm beyond the worn area on the brake disc If you are
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