Wear limit on front brake disc xt125r 06 - 2006 Yamaha XT 125 R

check brake pad/disc rotor condition. Check front wheel bearings check CV joints for wear and alignment.

14 lbs and 2 clicks

Depends on how handy you are???, there are no tricks or special tools required, you will more than likely require the disc rotors to be replaced at the same time as these brakes tend to wear down as a pair, these also are easy to repalce as they are only held onto the stub with a couple of screws.

SECTION 206-03: Front Disc Brake 1999 Escort/Tracer Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 06/06/1998 Front Disc Brake Front Disc Brake System Components
Item Part Number Description 1 1125 Front Disc Brake Rotor 2 2B296 Disc Brake Caliper Locating Pin 3 2B120 Disc Brake Caliper 4 2001 Brake Pads 5 - Copper Washers (2 Req'd) 6 - Banjo Bolt 7 2078 Front Brake Hose 8 2W303 Brake Caliper Bolt- (2 Req'd) 9 2814 Brake Hose Clip The front disc brake system consists of a single-piston front disc brake caliper (2B120) and a ventilated front disc brake rotor (1125). The brake shoes and linings (2001) are held in the front disc brake caliper by two front disc brake caliper locating pins (2B296) and two springs. The inboard brake shoe and lining is equipped with a wear indicator that makes a squealing noise when the brake shoes and linings are worn beyond recommended use.

Section 06-03: Brakes, Front Disc 1999 Taurus, Sable Workshop Manual REMOVAL AND INSTALLATION Brake Shoe and Lining Removal

1. Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478) . Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
   

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120) , front disc brake rotor shield (2K004) or front wheel knuckle (3K185) .
   

1. Remove rear brake pin retainers (2N386).
   

1. NOTE: It is not necessary to disconnect hydraulic connections.
   
   Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125) . Do not pry directly against metal caliper piston or damage will occur.
   

1. NOTE: To prevent damage, do not allow disc brake caliper to hang by the front brake hose (2078) .
   
   Position disc brake caliper out of the way.
   

1. Remove inner outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate .
   

1. Inspect both rotor braking surfaces. Minor scoring or buildup of lining material does not require machining or replacement of front disc brake rotor.
   

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remove the 2 pins, #10 in pic. Usually has a dust cover over pin accessopening. Usually torx haed or hex head bolts (pins).

Brake Pads
Removal & Installation
Front





3.4L front disc brake assembly









4.0L and 4.7L front disc brake assembly




To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of
   this section.
   
2. Remove or disconnect the following:
   
   
   
   • Front wheel
     
   • Clip, 2 caliper pins, the anti-rattle spring then remove the 2 brake pads
     and the 4 anti-squeal shims

To Install:

CAUTION
Only replace brake pads on 1 side of the
vehicle at a time. Failure to use this procedure could cause the caliper pistons
on the opposite side of the vehicle to pop out requiring the reconditioning or
replacement of the brake caliper.

1. Remove a small amount of brake fluid from the master cylinder.
   
2. Install a used brake pad into the caliper and compress the caliper pistons.
   
3. Apply disc brake grease to both sides of the inner anti-squeal shims.
   
4. Install or connect the following:
   
   
   
   • Anti-squeal shims to the new brake pads
     NOTE: When replacing worn pads, the anti-squeal shims must be replaced
     together with the pads.
     
     
   • 2 brake pads
     
   • Anti-rattle spring and the 2 caliper pins
     
   • Clip
     
   • Front wheel
   
   
5. Depress the brake pedal several times to seat the brake pads.
   
6. Check the brake fluid level and top off as needed.

Rear
To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of
   this section.
   
2. Remove or disconnect the following:
   
   
   
   • Rear wheel
     
     
     
     
     
     
     
     
     
     
     
   • 2 cylinder slide pins from rear caliper assembly
     
   • Caliper assembly from rear caliper mounting
     
   • 2 brake pads with anti-squeal shims from rear caliper mounting
     
   • 2 anti-squeal shims from each disc brake pads
     
   • Pad wear indicator plate from the inner side disc brake pad
     
   • 4 pad support plates from the rear caliper mounting

To Install:

1. Install or connect the following:
   
   
   
   • 4 pad support plates on the rear caliper mounting
     
   • Pad wear indicator plate on the inside brake pad
     Note: Install the pad wear indicator facing downward.
     
     
   • Anti-squeal shims on each brake pad
     
   • 2 disc brake pads with anti-squeal shims to the caliper assembly
   
   
2. Apply lithium soap base glycol grease to the sliding part of 2 caliper slide
   pins.
   
3. Install or connect the following:
   
   
   
   • Disc brake caliper assembly with 2 caliper slide pins
     
   • Torque to 65 ft-lbs (88 Nm)
     
   • Rear wheel
   
   
4. Depress the brake pedal several times to seat the brake pads.
   
5. Check the brake fluid level and top off as needed.

--- Removal & Installation
Front
To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of
   this section.
   
2. Remove or disconnect the following:
   
   
   
   • Front wheel
     
   • Front brake caliper assembly
   
   
3. Make matchmarks on the disc and the axle hub.
   
4. Remove the front disc.

To Install:

1. Align matchmarks and disc onto axle hub.
   
2. Install or connect the following:
   
   
   
   • Front brake caliper assembly with the 2 bolts
     
     
     
     1. Torque to 90 ft-lbs (123 Nm)
     
     
   • Front wheel

This is by design. When you have new pads on the bike and a rotor within limits the lever has very limited travel before engaging.
As these parts wear the position of which the lever engages changes. Unless you know that at the last brake pad change the caliper was "centered" this could account for the travel and will result in premature wear on the components.

JP

1999 Taurus/Sable Section 06-03: Brakes, Front Disc 1999 Taurus/Sable Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/25/1998 Disc Removal

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly. Be careful to avoid damage or interference with caliper bleeder screw fitting and front disc brake rotor shield (2K004).
   

1. CAUTION: Handle front disc brake rotor (1125) and disc brake caliper (2B120) assembly in such a way as to prevent deformation of front disc brake rotor , and nicking, scratching or contamination of brake linings/rotor surfaces.
   NOTE: To prevent damage, do not allow disc brake caliper to hang by the front brake hose (2078) .
   
   
   Remove caliper anchor plate bolts and discard. Position disc brake caliper out of the way. Prevent separation of caliper housing from anchor bracket because contamination of guide pin journals can occur.
   

1. NOTE: If excessive force must be used during front disc brake rotor removal, the front disc brake rotor should be checked for runout prior to installation.
   
   
   If additional force is required to remove front disc brake rotor , apply Rust Penetrant and Inhibitor F2AZ-19A501-A or equivalent meeting Ford specification ESR-M99C56-A on front and rear rotor/hub mating surfaces. First, strike front disc brake rotor between lug bolts (1107) with a plastic hammer. If this does not work, attach 2-3 Jaw Puller 205-D027 (D80L-1013-A) or equivalent and remove front disc brake rotor . Remove front disc brake rotor from wheel hub (1104) assembly by pulling it off the lug bolts.
   

Installation

1. If original front disc brake rotor is being installed, make sure rotor braking and mounting surfaces are clean.
   

1. CAUTION: Failure to clean rust and foreign material from rotor and hub mounting faces when installing new or old front disc brake rotors will result in high rotor runout, which will speed up the development of brake roughness shudder vibration.
   Apply a small amount of Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to pilot diameter of front disc brake rotor.
   

1. Install front disc brake rotor on wheel hub assembly.
   

1. Install disc brake caliper and new caliper anchor bracket bolts on front disc brake rotor . Tighten caliper anchor bracket bolts to 88-118 Nm (65-87 lb-ft).
   

1. CAUTION: Failure to tighten lug nuts (1012) in a star pattern may result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration.
   Install wheel and tire assembly on vehicle. Tighten lug nuts to 115-142 Nm (85-104 lb-ft) using Rotunda Accutorq® Lug Nut Socket 164-R0303 or equivalent on a 1/2 inch air impact wrench, or use a torque wrench.
   

1. Lower vehicle.
   

1. Pump brake pedal prior to moving vehicle to position brake linings.
   

1. Road test vehicle.
   

here is procedure

Section 04-01: Suspension and Wheel Hubs, Front 1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION Wheel Hub Bolt Removal

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly. Refer to Section 04-04 .
   

1. Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
   

Brake Shoe and Lining Removal

1. Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478). Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
   

1. Raise vehicle on hoist. Refer to Section 00-02 .
   

1. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120), front disc brake rotor shield (2K004) or front wheel knuckle (3K185).
   

1. Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
   

1. NOTE: It is not necessary to disconnect hydraulic connections.
   
   Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125). Do not pry directly against metal caliper piston or damage will occur.
   

1. Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
   

1. Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
   

1. Remove inner brake shoe and lining assembly.
   

1. Position lug bolt (1107) to clear front wheel knuckle (3K185).
   

1. Remove lug bolt from wheel hub (1104).
   
   
   
   

Installation

1. Install lug bolt into wheel hub.
   

1. Using a lug nut (1012), seat wheel hub bolt into wheel hub.
   

1. Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
   

1. Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).
   

hi,depends your chassis number,if 210.055 your front disc thickness is 28mm,wear limit was 25.4mm,if 210.004,010,020,035,037 your disc is 25 mm. wear limit is 22.4mm,ty