JellyBeanDriver Dave,
You inspired me to write a final treatise on the subject...If I don't do it now, I know I'll never get around to doing it! I hope this helps you!
You asked about brass tubes in the intake ports...I believe your 92 is just like my 93, and they are not an issue for us. See the references I quoted below....
EGR doesn't operate at WOT, so maybe that is why you don't have a problem at 70+....
I don't remember what precisely trips an EGR code, but if you have 356K miles on a 92 and have never cleared out the passage in the head, I would wager it is clogged. BTW, where are you in SoCal?
I would attend to this now so you don't have to pay an extra $50 for a late smog, and you are not pressured for time. I did end up with a couple of Pandora's Box issues, including one more I didn't mention below--a wire that sends the engine temp to the gauge broke off during my manhandling of the huge number of wires around the EGR valve... Pretend your smog is due in Feb.!

Remember, you will get an instant fail if the Check Engine light comes on during the test....

YEAH! EUREKA! We have liftoff! I got the passages completely cleared! Just when I was nearing the end of my patience threshold.... Even thoughts of turning it in to the State of California for $1000 came to mind....
TO SUMMARIZE:
* Diagnostic tests of all the EGR components, Stall & Live Test understanding, and the greatest EGR system map were from jtgh in the suzuki-forums (sidekick forum). From his thread titled "major EGR update" (
http://www.kick-fix.com/EGR-choice.html) you can find his old EGR treatise, which I also found helpful (
http://www.kick-fix.com/EGR.html). That it is for a 1.6L engine is irrelevant--the Gen 1 - 8 valve engines use the same EGR valve, and other EGR components as the 1 L Geo Metro. Figure 1 - EGR System, titled "EGR Functions 1989-1998" was INDISPENSIBLE in my understanding of the system.

* Oconice's pics from teamswift were of help in the beginning.
* BillP's note about
not using the drill was of great help--I ended up only using my bare hands--they had the best grip on the cables and auger drill bit, and enabled me to push the cables up further than I could when I tried the drill.
* There were many who suggested pulling away the exhaust manifold, right off the bat, and there were just as many who said to just try cleaning it from the EGR portals. From my experience, I
know that I could not have cleared out that portal in the head from the EGR portal, or at least that it would have taken hours and hours -- mine had never been cleared out, and with 117K on it, and it eating oil, the passage was densely clogged, including the "U" passage in the exhaust manifold itself. The easily obtainable 3/8" Auger Drill Bit (about 7" long), twisted and pushed by hand into the head's straight passage, cleaned it out quite nicely and quickly (+ sprays of carb cleaner and Seafoam Deep Creep (Autozone)). I had to pull the auger bit out every minute or so to clean it with a tooth brush and Seafoam. The galvanized 1/8" cable worked well for cleaning out the "U" passage (+sprays). Even if a cable from the EGR portal could have made it that far, all that gook would have fallen down into the exhaust manifold, and then into the cat. Since I just put in a new cat, and their price has doubled this year, I wasn't going to risk that...
* On the con side of the "off the bat" pulling away the manifold, mwebb reminded me that it could be opening up a Pandora's Box, and in my case it was... It created an exhaust leak at the junction between the manifold and pipe, and I'll need a new exhaust pipe seal and gasket, and two flange bolts (probably a dealer part).

Mine were so rusted they'll need to be replaced.
******CORRECTION: IT TURNS OUT I DID
NOT NEED TO REPLACE THE EXHAUST GASKET AND FLANGE BOLTS BETWEEN THE PIPE AND MANIFOLD! -- the leak was from a bad weld on the new cat I had had someone install a month ago--the exhaust smoke just crept up the pipe &
appeared to come from the gasket area. But do be gentle when pulling the ex. man. away from the head, and rest it on something like a rubber mat or towel on the ground... *********
I was able to reuse the head to manifold gasket though, after thoroughly cleaning it with Seafoam, and spraying with PB Blaster. I cleaned all the nuts and bolts, and then applied Hi-Temp Antisieze Lubricant. Supposed to torque them to 17 lbs, but my torque wrench doesn't go down that low. Tighten them gradually, in several steps, going from the center out each time... Is there even a torque wrench in existence that could be used on the lower two nuts? I couldn't even get a ratchet wrench on it--had to use a box end.
* After clearing out the straight head passage from the exhaust manifold side with the auger drill bit, I decided to try a thin cable I had with a small round ball on the end (about 3/16" diameter ball--maybe a parking brake cable?). Using my hands only, I pushed it in the head passage, twisted & pushed more, and finally broke through the first bend or two, getting it in a couple of extra inches--to maybe 9 " total. Coming in from the EGR portal, I also was able to get past the 3" bend, and got it in about a total of 5". Knowing that the total passage is 11", I knew I had broken through. But it took a speedometer cable to actually get in one end and out the other. Once I got totally through, I pulled it back & forth like a saw, then repeatedly pulled it out, cleaned it off on blue paper shop towels, and stuck it in a Seafoam gas treatment bottle, swirled it around, and then immediately stuck it back in & sawed. I repeated this until the speedo cable no longer had black gook on it--about 10 passes. Periodically I sprayed Seafoam Deep Creep spray in the EGR portal, and alternated that with carb cleaner (a short can, or I could maneuver a large Gumout can because theirs doesn't have to be precisely upright, and their red nozzle is strong and can be bent, without falling out). The carb spray would spurt out the head portal.

BTW, I do not think the Snake Bit flexible drill bit would have negotiated the sharp turns in the GEO's EGR passages--its 3/16" diameter and stiff bit at the end probably would stop at the first 90 degree turn...IMHO...(if only they made it thinner...it seems like a great idea!)
* For the intake side, the cable with the ball on it helped me get in an extra inch or so, to about 7" total. (Remember, I had good vacuum at this portal from the beginning, when I ran the engine with the EGR valve off, so it probably wasn't clogged up). I then used the speedo cable, and repeatedly soaked it, and pushed and rotated it in the passage, as above. I didn't get much more gook than I had gotten previously by using short and long Qtips dipped in Seafoam, after the initial clean with a scratch awl. Be careful with the Qtips though--you don't want pieces breaking off--so use them only a brief amount of time, and replace frequently. I used about 40 of them! They also worked great at the beginning of the EGR exhaust portal because there is some kind of obstruction inside, and they squeezed right through it--I used two Qtips at a time, dipped in Seafoam.
* With the exhaust manifold back on, I covered a large black rubber vacuum cap with several rounds of electrical tape, and squeezed it on to the intake EGR portal, while someone else started the car. (Duct tape would work too, but don't leave on for long, and even then you'll have to clean off the sticky residue). Fairly loud exhaust noise & fumes emanated from the exhaust EGR portal, so I knew it was finally clear (it used to only emit subtle smoke rings). I then increased the RPMs a lot, removed the intake plug, and quickly sprayed Seafoam Deep Creep into the portal, from a prepositioned can. The car alternately races and dies down, several times. I wanted to do this to clear out as much gunk as possible from the intake portal before putting the (thoroughly cleaned) EGR valve back on. The revving somehow kicked off a vehicle speed sensor code on the computer...
* I put the EGR valve back on, with a new 99 cent felpro gasket, and took off the neg battery cable, then put it back on, so as to clear any computer codes. Remember, when you think all is dandy, to check for any codes by putting the spare fuse into the diagnostic bay in the fuse box by the driver's left leg, with the key OFF, then turning it ON, and looking for the flashing light pattern of the Check Engine light.... BTW, the EGR valve still held a vacuum--just wanted to check....
* The car purrrrrred like a kitten, and started to stall when I applied 10" vacuum to the EGR valve--CHECK!. When warmed up, with RPMS increased, I could see the valve move at the underside of the mushroom--CHECK!
*Smog check tomorrow. If all is well, you won't hear from me again on this topic.... Remember to do regular Seafoam maintenance on these cars in the future, to keep those passages clean (see a post on this in geometroforum)!
For those Calif. folks--I always do an offline (MAKE SURE THEY DON'T CONNECT WITH SACTO!!) smog test at a cheap place ($16.75) before going to the Test Only station. If you fail several times online you will be labeled a gross polluter and go through bureaucratic hell....And, by the way, they now charge $50 (they've got to pay for their pensions somehow..) to get an extension for smog, and after 60 days you can't drive the car without going to them, waiting for 6 hrs in line, just to get a one day pass! That is unless you had the foresight to make an appt. 2-3 weeks in advance!
Good Luck Dave!
TIP FOR THE DAY:

I
love the Harbor Freight Mini Flashlight with 8 LEDs (Item 95750). It is heavy duty metal and rubber, with 6 sided ends so it doesn't roll. It worked perfectly for the EGR--I could place it under a rubber cable by the fire wall and direct it straight on the EGR & the portals.
I also
love their headlight LED light--but I had to put a layer of Molefoam on it so it would feel comfortable on my forehead. It is GREAT having light everywhere you turn! Put a little adhesive under the switch tab or it will fall off, and be careful to set the thing where it wont get tossled about and accidentally turned on....