completely stumped. Stripped, checked and cleaned. No obvious wear or damage to the bore, can see piston moving, and it moves freely and smoothly, seals all good and fitted correctly. Re-assembled it and its still not right. I can get the lever to touch the throttle grip, way too much travel. Tried pumping it in case there was air in the system but it made no difference. I have tied the lever back against the bars in case it has air in the upper section, but doubt it, as surely the lever would firm up if there was air in the system. Done all I can for tonight. Will check it tomorrow, perhaps a slow run.