[planedoc1958]

I’m approaching the wear limit recommend in the Service Manual, i.e. 4.5mm, after nearly 29,000 miles of mixed motorway/urban commuting in all weathers. Are Suzuki (and bike manufacturer’s generally) being a little cautious with this wear limit number, which represents only 0.5mm of wear, given they charge £300 (nearly US$400) per OE disc from Suzuki UK? Yes, that’s OE cost for each disc!!

Any thoughts from those of you with high mileages? Have you run them a bit thinner without issues?

My 1050 discs at 31,500 miles are at 4.6mm. I’m planning on replacing them at next tire or pad change, whichever comes first. The rear is still at 4.9mm. I don’t use the rear brake. It should go more than 100,000!

 

[planedoc1958]

I change discs when they reach minimum thickness. If you go past minimum, be sure to not let your pads also go to minimum, the caliper pistons may extend out too much.

Corndog is right. Don’t go below minimum thickness. If the discs get too thin, they crack. And if you have undersized discs with worn pads, the pistons will protrude out so far the orings pop out. Releasing all your brake fluid onto the tire. You will have no brakes and will likely lose the front end too. Not worth the risk.