Over time your KVR rotor will show wear or warpage. Some Mechanics will shy away from working on the rotors because of the holes. Do not believe them! It is possible to cut these rotors, it just requires a little effort and patience.
1. Most of you do not have access to a lathe but a local machine shop can do the job for you. Here are some key points that should be observed:
After the rotors have been cut, have the machine shop ruff the surface of the rotors with the 36 Grit Rollock pad while the rotors are still in the lathe. It is not recommended to attempt to ruff the surface of the rotor while it is not in the lathe. Do not press hard. While the lathe is turning apply an even up and down stroke over the entire surface of each side of the rotor.
2. Once the rotors have been cut and the surface is ruff, it is time to clean out the cross drilled holes. Carefully take the 3/16" drill bit and slowly drill all the way through the existing holes in the rotor. You will want the drill bit to pass all the way through the rotor so put it in a position that will not damage your work area. You may find that it will take a while for some of the holes to be worked out. Please be patient and do not let the drill bit break inside one of the holes or scratch the face of the rotor.
3. Once you have all the small holes drilled out take the 15/64" drill bit and run it over the top of the holes. Do not press hard. All you want to do is clean the indentation on the front of the rotor. Do this on both sides of the rotor.
4. Once you have all the holes drilled out, wipe off the rotor. Then clean liberally with brake cleaner. Inspect all the holes and make sure that they are free of derbies before you have the rotors installed by qualified personnel.
5. Brake-in the rotors as if they are new:
This procedure may seem complicated but it is not. I will like to note that it is time consuming and I do not think many Mechanics will take the time to do the procedure properly unless you pay extra and insist that they do. It only took me a half an hour to drill and clean both rotors after the lathe work was finished. But I move faster than most people.
Written by J.Miller with help from my good buddy Jeff Tatro.