Fitted up the CBR954 callipers and master cylinder today. I bought these off EvilBay from a seller in the eastern USA, they were said to be in good order bar a seized lever. The lever assembly came off nicely but the piston was jammed. A few light hammer taps got it moving inward and I was able to tap it back out once I had the banjo off so I could drive it back out. Turned out to be some crystal deposits which cleaned off easily enough, and the bore and piston were perfect. Looks like the original pads, half worn, and the callipers and pistons cleaned up a treat.
I opted to file the relief into the fork legs, leaving the outer face untouched for a stock appearance and not touching the callipers at all. Ended up with a snug fit but the bolts went in smoothly.
Looking at the 954 lines I decided to re-use the Storm lines, as the brackets that tie the hose to the fork leg looked unusable on the 954. Drained all the fluid out of both systems, disassembled both and then swapped the master and callipers leaving the hoses in place. Used my vacuum bleeder and got a pretty good lever feel. I might go the whole hog and add some braided lines in the near future as even with a good bleed, I can feel the lines bulging a little.
Also on my list, replacing the rusty Torx bolts with something shiny. Can anyone advise the size and grade I need?