Understanding brake rotor/disc thickness

fazedsilverfox2023

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Newbie Here:

Early this year, upon my annual UK MOT (roadworthiness inspection), I was told that all brake rotors (discs) on my 2004 FZS will likely need replacement during the next 12 months. Measuring these today, all were 4.5mm thick. This measurement was at the thinnest point where the pads touch the rotors.

Section 4-2 of the service manual states the brake rotor thickness limit (minimum) is 4.5mm for all rotors. The thickness of new rotors is not stated in the manual but online sellers quote the new rotor thickness is 5mm (or less). The implication here is that only 0.5mm of wear can occur before new rotors must be fitted. I try to measure accurately, with a micrometer, but, even so, it does seem only a very limited amount of wear is permitted. Am I missing something obvious?
 

yzrfz6

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Discs are usually really slow-wearing items unless you use sintered pads on discs not made for it. As for why, I would guess heat dissipation worsens and risk of the disc cracking increases
 
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