okay...

Master cylinder seals were good but reservoir was clogged.  Stripped and thoroughly cleaned.  Brake line was clogged (also thoroughly cleaned). Caliper was stripped and thoroughly cleaned.  It leaves me with a thoroughly clean and thoroughly empty system.

Have locked up the bleed nipple and filled the reservoir. pumping handle frantically led to some bubbles appearing in the reservoir.  Bubbles have now stopped and there is no resistance from the brake lever as I'm guessing the system is full of air.  I don't have a vacuum pump and its 10 days wait even if I bought one today.  I dare say there is a method of bridding the system of air that takes less than 240 hours.  Who's got a tip (that doesn't involve borrowing or buying a vacuum pump)?

Thanks All
(new goal is to ride the GS to opening night in October).
Jimmy

Remove the brake line at the caliper. Get hold of a syringe from the chemist or where ever. Fill the syringe with brake fluid and fill the caliper as best that you can. Then put the brake line back on and bleed as normal. It will still take a while to bleed out, but less than 240 hours.
John
PS i will post your taco tomorrow, sorry for the lateness.

no worries John, thanks for the tip.  The brakes have been an ongoing issue for 3 weeks now.  They're inspiring me to take a sledgehammer to the bike.

Jimmy
lemme know an email in a PM so I can reimburse you.

Here is the proceeder for you and others interested.
Remove the top of the master cylinder and fill with brake fluid. Pull the brake lever all the way in and hold it in while you loosen the bleeder nut about 1/4 turn. While still holding the brake lever "in" tighten the bleeder screw. Then and only then release the brake lever (at this point you can give the brake lever a couple of pumps if you feel like it, but it wont really help). Continue with this procedure until all the air is removed from the system. It will take a while to get any pressure at the lever but rest assured it will happen. Make sure you keep the master cylinder topped up with fluid.
John

Just curious - are you bleeding the front or rear brakes? I've always had issues with the rear brakes....

front. Although the seals were visually good and supple I'm guessing that they just aren't sealing anymore.

remove MC, fill with fluid, remove outlet hose, over a garbage can - cover outlet with thumb/finger and pump handle.  Fluid should start to squeeze by thumb when M/C start to prime.  if successful put back on bike and try and bleed from caliper.

Despite recon to master cylinder the system was getting nowhere.  Seemed that only a small amount of fluid was coming down the brake line.  Swapped for my eBay Master cylinder and bingo.  Brake pressure.  Bled the system, front and rear.  Have now given it a nice deep clean with many scrubbing brushes and many degreasing agents ready to and and touch up rust spots on the frame (surface rust).

Also grateful to find that two "scratches" in the tank were just marks that washed off with some elbow grease.

lessons learned.

1. I AM STILL MECHANICALLY INEPT.
2. The reservoir gasket is way different on the 1990 compared to the 2009.
3. The drain/outlet on the reservoir on the 09 has a strainer type arrangement whereas the old one has very little which may explain some crap being in there and not letting enough brake fluid through.
4. Bleeding rear brakes hurts ones knees.

Jimmy