Metal matrix composite materials are created by combining two or more components, one of which is a metal. In the current perspective, the acceptance of aluminum alloy composites rises day today for general purpose and engineering applications as a result of their desirable properties like high strength, low density, better wear, and corrosion resistance. This work aimed at the fabrication of aluminum alloy (AA6063) based composite reinforced with 150µm particle size kaolin clay with a chemical composition of 65.14% of SiO2, 22.20% of Al2O3, 1.04% of Fe2O3, and 1.12% of CaO powders via stir casting method and to investigate the influence of reinforcement on the wear resistance, hardness, tensile, compressive, density, and microstructural behavior of the base alloy. The thermal conductivity of the selected material was experimentally measured and the finite element analysis was conducted using ANSYS software. The reinforcement has been added by varying kaolin clay to 0%, 6%, 12%, 18%, and 24%, and stirred at 600rpm for 10 minutes. The wear rate decreases with an increase in the weight fraction of clay up to 18 wt.%. Increased clay particle to 24 wt. % resulted in increased wear. The coefficient of friction, hardness, tensile, and compressive strength increased with an increase in the weight fraction of kaolin clay powder up to 18 wt.%. Further increase in the reinforcement to 24 wt.% clay reduces the hardness, tensile, and compressive strength. The density of composites decreases with an increase in the weight composition of clay. Considering the above properties, as well as cost, Sample C4 (18% clay, 81% AA6063 alloy, and 1% magnesium powder) was selected as the best material for motorbike brake disc rotor application. The maximum temperature during braking was 185.44 °C for the composite, and 218.44 °C for the gray cast iron brake rotors. Kaolin clay-aluminum AA6063 metal matrix composite brake disc rotor was manufactured and assembled for Apache RTR 180cc motorcycle and saves 49.29% of the material. The benefits that can be gained from using this composite material are a reduction in unsprung weight of the vehicle and hence improving the dynamics of the vehicle. Keywords: Aluminum metal matrix composites; Clay; Material characterization; Stir casting; Wear properties.