2009 with 67,000. They are suggesting on my next visit I might need new rotors. How can I tell if they are truly needed?
What is the cost?

Measure the thickness with some calipers and see if they are within spec.

Yep, if you aren't having any other issues with them it's a thickness thing..

Service limit is 4.5mm on the front.  Rear is 5.5mm, which is weird because the standard is 5.3 to 5.7mm.  I'm looking in my 08 manual, which may have 'errors'.

Service tech said... "Within about 1000 miles, what's going to happen is you're going to apply the brakes and they are going to lock up."

I have not measured them, I don't own calipers, but I'll see what I can find.
So anything lower than 4.5 mm in the front?

When Murph refers to this as a set, is that a set of front, or a set of front and one rear?
http://www.murphskits.com/product_info.php?cPath=142_146&products_id=411

Anything lower or close to 4.5mm should be replaced.  Those EBC rotors are $420 for a set of 2 for the front.  You have to buy the EBC pads to go with them in order for the EBC Warranty to be valid.  This is the EBC rear http://www.murphskits.com/product_info.php?cPath=130_157&products_id=433

I would ask the tech what he means by 'lock up'.  Pads low, rotor worn out, leaking brake cylinder, front or back?  Pretty darn vague statement.

Anything lower or close to 4.5mm should be replaced.  Those EBC rotors are $420 for a set of 2 for the front.  You have to buy the EBC pads to go with them in order for the EBC Warranty to be valid.  This is the EBC rear http://www.murphskits.com/product_info.php?cPath=130_157&products_id=433

I would ask the tech what he means by 'lock up'.  Pads low, rotor worn out, leaking brake cylinder?

#1 I think its a scare tactic
#2 I can't imagine its even possible for ABS brakes

If I have to go with rotors again, I'm not going EBC...  I'm going Chinese and Kwackers pads.  But that's my opinion.

Is 67,000 early for a non aggressive rider?

Dunno, mine warped so I changed them out to EBCs.  The rear is still  stock, don't use it that much so unless you are a heavy rear braker then I rather doubt it needs replacing.

OK, by my very rough measurements, both front and rear are below 5.5 mm.
I made ticks from a ruler on a business card. I don't own calipers.

Problem is, I have a trip, two up, to Oregon in couple weeks.
We toyed with the idea of driving the new car.

Just not sure if I should choose the car over the bike now.
Not sure I want to go back to the dealer to get these changed just yet.

Are the front rotors an easy swap?
I don't have the magic nut for the front wheel. I would need that too.

It's really hard to tell what's going on with your brakes without being there in person and looking at them.  Go back to that mechanic and ask him for some detail on what's wrong with it.  To put the rotors on you need to remove the front wheel.  If you're not 'handy' then you have to depend on someone doing the work for you.  Heck, I'd help for beer and steak but I'm on the wrong coast.

Handy? Yes
Willing to take off my rear wheel, or do a valve check? No

I can't believe that there's anything wrong with the rear wheel.  It's most likely the front.  I don't do valve adjusts either, but I take wheels off all the time.

Mine went down to 3.8 before I changed them. They felt perfect but WHO needs the extra concern. Went with EBC and they feel just like the worn rotors.

Is 67,000 early for a non aggressive rider?

Almost exactly when mine went below 4.5mm. I went with EBC because they are half price. But if I had to do it again I would spend the bucks and go OEM. The EBC's work but they don't feel as nice as the OEM's did.

Them brakes are gonna lock up and you're going right over the handlebars, Brent!

 

I guess that's the real question. Is there any risk of this reported "locking" of the brakes?
I've never heard of such a thing.

The rear has locked up before but that was addressed by two recalls.  The ABS unit can cause issues but it seems only on the rear.   The rear master cylinder can lock it up but only on the rear.  Never heard of it happening on the front wheel.  If the current owner drinks Coke all sorts of bad things happen.

When Murph refers to this as a set, is that a set of front, or a set of front and one rear?
http://www.murphskits.com/product_info.php?cPath=142_146&products_id=411

A set consists of the two fronts.