75 Commando Front Brake woes

Am I right that you are still using the stock Caliper pistons ? These corrode. Use stainless ones with new square section seals.

If you consider the disk brake to be inadequste, for whatever reason, you sure wouldn't have liked the original 2LS drum set-up. It took some serious thinking before we realised that the brake back-plate was too flimsy and was distorting under the lever loads. The brake was Italian-made and we had a tough time persuading them there was a problem. The later 2LS-equipped bikes were better after the back-plate was re-designed to make it stiffer.

My emigration to Boeing pre-dated the disk-brake's appearance.

Looking for any ideas, before I plunk down $250 bucks for a new master cylinder to eliminate one more possibility.

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If you are not precious about keeping the original look of the MC and want to get away from all of the hassle of sleeved down MC and the B/S that surrounds them, look to the dark side and try one from a early Suzuki Burgman 125 1/2" bore, they bleed with out a problem work like a dream and fit with the MK3 switch gear. Banjo fitting required on your brake line, I purchased mine from Ebay for £25 works like a dream!

If you are not hung up on correctness, Google Mike's XS. He supplies parts for Yamaha XS 650 plus others. Copy of a Yamaha 13mm $61.00 made of pure Chineseium. I bought one but have not finished bike so I don't know how well it will work, but I assume it will.