Attaining a Flat Deck

To run a big bore kit -- or even for normal use -- the cylinder deck of the TR1 often must be modified. We shall list two ways.

First off, the surface gets too hot for the use of metallic epoxy. The cured agent would slowly crystallize from the heat and turn to powder. It is possible that there are compounds that would hold up, but are you willing to keep pulling your heads until you find one?

At the very least, a barrier between the head gasket recess and that of the cam chain tunnel o-ring must be raised. A mere touch of heli-arc should do the trick. Then it would be a matter of shaping it to clear the gaskets, and skimming it in a mill to ensure flatness.

A more complete way is a bit more work. As you will be working with dissimilar metals (the aluminum of the barrel; the ductile iron of the sleeve), there will be compromise. Use heli-arc to fill the o-ring recess and come as close to the sleeve as you feel comfortable. Roughen the head gasket recess and fill it with brazing rod (bronze). Mill to flatness and remove an extra .6mm. Run a head gasket meant for a Virago 1000, or make one from copper.

The best solution is to run Virago 1000 or 1100 cylinders. Either will fit; the deck height, the stud pattern, and the sleeve OD are the same once you add in the thickness of a compressed head gasket. Then you would have a stable basis from which to work.

More to come . . .

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