I have a small fleet of 30 2007-2011 Honda 680 Rincon's. My operators are experiencing front brake failure while in 2wd. The front brake lever goes to the grip at times and requires pumping to get pressure back up in order to brake. The system has been bled several times, fluid changed out, using DOT 4 fluid. On some I have changed out the master cylinder, discs, calipers and have the same issue.

This can happen when backing off of a trailer or going down a steep grade to being on a flat surface. There is no consistency to the claims to help point to a certain type of operation.

My operators go through a two week orientaition course to learn on how to ride. I get the failures from both the expierienced and beginner riders.

Honda claims there is no problem (as all manufactures do). Here are some questions:

1. When in 4X4 any brake lever you press you get four wheel braking. is there a solenoid that controls this and could the valve not be reseting properly? How does this work?

2. Could the hub bearing be failing and causing the caliper to open up during hard turns? The ones I checked the bearings seem tight with no up and down movement.

I really don't like to throw parts and hope that will solve the problem. Money is real tight. I need to find a solution before one of my employees get hurt.

Thanks for any help in advance.