2024 Honda XL750

May 7, 2025 - Bike mileage 7,140, over year old, and out of warranty. The brake system has not been touched prior to this incident. I slowed down using both front and rear brakes as usual for traffic and as I attempted to resume 40 mph the motor started struggling and bike slowed radically. At a nearby turn off to gravel parking lot, I turned into and nearly dropping the bike, and noticed the front brake lever had no take up. Got the bike off the pavement and discovered as I attempted to push the bike further into the parking lot, the front wheel would not turn. The front brakes were locked up. My son determined the return hydraulic fluid orifice at master cylinder was blocked due to manufacturing debris and not releasing the hydraulic pressure locking the front brakes. To insure system was free of debris my son disassembled and cleaned the master cylinder, cleared the return orifice of debris, disassembled and cleaned the calipers, pistons and flushed the lines. Assembled, bleed the lines with vacuum pump. Brakes are working to spec. Front brakes locking up on motorcycle is deadly. If would have been on a freeway doing 65 mph, i would have been flipped over the handle bars, dropped the bike, or both me and the motorcycle would have flipped over.