Headache with Brakes, any help appreciated

Thank you all so much for the advice and support, came to the conclusion last night after yet another session of bleeding and fettling that I do indeed need to bite the bullet and replace the SMC with a new unit. Ordered one first thing for delivery tomorrow. Whilst I’m waiting a few other jobs can be carried out. I will let you know how it goes 👍
Inspect and check the rear caliper bracket as well, so you don’t have to do the job twice again.
Replacing the SMC only, may not fix the issue.
 
Someone already sliced one open and did something similar. See @jfheath 's post above.
That'd be me.

Unsure how you'd clear such a tiny port (and the rest of the tiny passage) on the side down in the plunger's bore....

You can get to it from the inlet port - but you have to remove the cap (2 screws) and extract the gauze filter cartridge - which also has a tiny port.
You'd be pushing the gunge into the bore though - it should flush away, but that is not guaranteed. If the SMC piston cannot fully return, you would damage the primary seal - but tif the piston cannot fully returns you need a brand new SMC anyway.
 
I should add - I once had a problem with rear brakes which I could not pin down. I bought a new SMC anyway to avoid worrying about it. The problem turned out to be something else. The original SMC is still tucked away somewhere safe in case I need it. There was nothing wrong , but I'd fit a new service kit to that one quite happily. Fowlers have them in stock at present - about £246. At the way things are going, you could get a brand new SMC for the cost of a couple of tanks of petrol.

But note Larry's comment - there are more to rear brake problems than the SMC. Like mine, your rear brake issues could be something else entirely.
Read Avoidng the pitfalls. See articles, filter on 'jfheath'.
 
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