Just bought a used Foreman 450 4x4. I knew the brakes were poor all the way around & negotiated a good price planning to get them repaired. Anyway, got it out of the shop after they replaced linings, cables, & a few other little things. The rear brake works well, but the front brakes are about useless. They work, but are very weak - they do very little to slow or hold the bike. I bled them & checked the lining clearance. No air & lining clearance was right on both sides. Pumping the brake has no effect either. If I have the bike in neutral on a small hill (not real steep, but enough that it would easily coast all the way down), the front brake alone won't hold it from a dead stop.

I've never been on a bike with such a weak front brake. Is this normal & it's supposed to only do a little to supplement the rear brake? Or should the front brakes have close to the same stopping/holding power of the rear ones?

 

Front brakes are spongy, don't hold-
1. Air in brake line. Caused by inattention to master cylinder fluid level or by leakage. Locate problem and bleed brakes.
2. Linings worn.
3. Brake fluid leak.
4. Contaminated linings. Caused by contamination with oil, grease, brake fluid, etc. Clean or replace linings. Clean drum thoroughly with brake cleaner.
5. Brake fluid dteriorated. Fluid is old or contaminated. Drain system, replenish with new fluid and bleed the system.
6. Master cylinder internal parts are worn or damaged causing fluid to bypass.
7. Master cylinder bore scratched by foreignmaterial or broken spring. Repair or replace master cylinder.
8. Drum warped. Replace drum.

I haven't had to change my brakes yet. The brakes seem to work well. The above was taken from a Haynes troubleshooting.

I'm hoping that the new 2005 Foreman's disc brakes will work on the older models. Then when I'm ready for new brakes. I'll install the disc brakes. Highlifter offers a disc brake. The main reason I don't want to purchase from them is because of brake pads. I would have to purchase the pads from them forever at their set prices. The Honda disc brakes would hopefully have a few companies producing pads for them. I like a choice in product and price. Maybe the 2005 disc brakes won't work on the older Foremans. I hope they do.

 

I think I should replace the master cylinder assembly. Can't think of another reason that I'd be having this problem other than it simply isn't giving the right hydraulic pressure?

No air in brake lines. Fluid came out when bled & it didn't spit or hiss like air was in the system.
The fluid was just changed at the shop.
Linings are brand new, Honda OEM.
No evidence of fluid leakage anywhere. Master cylinder full.
Linings clean.
Drums appear normal. Could be out of spec but not apparent in visual inspection.

 

Id take it back to the shop that did the work, and make them finish the job.
Everyone complains about the front brakes, on hondas....but i can lock them up at will, so yours should work much better than they do.

 

Replace the rubber stuff in the master cylinder. I had a 1997 recon with the same problem. I tried everything. Fluid, pads, lines, leaks, adjustment. Finally broke down and bought the master cylinder kit from bike bandit, popped it in, and the thing would lock the front tires up in third gear. Sold the recon and got an '06 Rincon.

Master Cylinder Set
Part No. 135283-001 $37.42
(Bike Bandit)