Ok, I did a more thorough job of cleaning up the master cylinder and flushing the lines. Yep, there were many little floaters that I didn't clean out well enough before- lesson painfully learned.
While working on it, I compared my bike with the one in the "How to rebuild your front master cylinder" guide http://goldwingdocs.com/forum/viewtopic.php?f=11&t=46...#p99
, but am curious on two points, I'd love to get some experienced perspectives on. Maybe what I noticed is trivial, but I'd like to make sure.
1. In the walk-through in picture 8/8a, it looks as if the brake fluid return port is part of a metallic element at the bottom of the plastic reservoir, whereas the one on my 82 GL1100 appears to be molded into the plastic of the reservoir.
2. Instead of a small pinhole, mine is a fairly decent size - just a hair smaller than the main hole in the middle of the depression, and the same size as the hole on the opposite side of the depression. Is this something unique to my bike?
I'm not sure if the image will come through, if not, see the full photo here http://twitpic.com/9nu98h/full
Any thoughts? I don't know if there is something different with this model year, or this particular '82 GL1100, or if a previous owner tried to modify it. Mainly, I'm concerned about whether it is safe, as it would seem that with "larger than a pinhole" sized brake fluid return ports, it would be even harder to let a little sludge block it, yet it has happened twice (granted, before I did a good job removing the sludge, but still
). Time for new brake lines? Rebuild the calipers? Or send it to a shop and let someone qualified take a shot?