Re the lever removal to push the piston in further... had already done that (see post 6).
Re the turning of the bars and taping the lever hard in.... I have/had done both and also note that if the lever is tapped a hundred times and pulled in hard half a hundred times while the bars are turned hard left and then right, the combination of lever vibration and master cylinder angle will also clear the trapped air. Pays to cover the MC with glad wrap (cling film) held in place with a rubber band, to avoid squirting fluid all over the tank etc.
I tried installing a 3.5mm by 13mm dia plastic spacer and found that it was too big to allow MC priming. I ground it down to 2.5mm and re-installed. It works great. My previously huge (and prolonged) fluid fountain is now a mere squirt. Lever travel is now fine. It was about 35 -45mm of travel before engaging and is now about 13 - 15mm. (not perfect, but close)
I haven't taken it for a ride yet to bed in the new organic pads (which don't appear very sticky) but am confident that I have resolved the lever travel.
Once sure that all is well I will post an explanation of how the modification can be used to address at least some excessive lever travel issues.
Another thing I noticed was that the piston can be slightly depressed in if the brake lever assy is moved too close to the throttle grip assy (preventing the heel of the lever from fully returning). This could be problematic if it resulted in the seal being prevented from clearing the relief port.
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