NHTSA Complaint #10631448 — 2006 HONDA ST1300A

THE POOR DESIGN OF THE SECONDARY MASTER BRAKE CYLINDER (SMC), WHICH APPLIES THE REAR BRAKE WHEN THE FRONT BRAKES ARE IN USE, ALLOWS CORROSION, FROM EXPOSURE TO THE ELEMENTS, TO DEVELOP. WATER, AND ROAD DEBRIS COLLECT AT THE TOP OF THE SMC, AND SLOWLY SEEPS IN PAST THE EXTERNAL RUBBER BOOT, AND THE INTERNAL BRAKE ROD SHAFT-SEAL, WHERE IT BEGINS TO ATTACK THE BRAKE CYLINDER BORE SURFACE. THE CORROSION CAUSES THE SMC PISTON TO SEIZE-UP WITHIN THE SMC BORE, RESULTING IN A FAILURE TO RELEASE THE REAR BRAKE CALIPER. THE DESIGN OF THE SMC IS SUCH THAT PRESSURIZED BRAKE FLUID (PROVIDED BY THE REAR BRAKE CIRCUIT) CAN PASS AROUND THE SEIZED PISTON TO ACTUATE THE REAR BRAKE CALIPER, HOWEVER THE SEIZED PISTON PREVENTS THE RETURN OF BRAKE FLUID, WHICH RESULTS IN THE REAR BRAKE CALIPER NOT RELEASING. A NON RELEASING BRAKE CALIPER CAN CREATE A SERIOUS, AND LIFE THREATENING SITUATION. MY HONDA ST1300A (VIN [XXX]) HAS HAD THE SMC SEIZE UP ON THREE SEPARATE OCCASIONS, THE FIRST TIME AT 8,600 MILES, THE SECOND TIME AT 57,000 MILES, AND THE LAST TIME AT 66,200 MILES. CURRENTLY I HAVE 90,123 MILES ON THIS MOTORCYCLE. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR