Everyday TR1 - V-star conversion (part 1)

The King is dead. All hail to the king.

My basic idea on how to overhaul the Everyday TR1's engine was sound, but in short the material wasn't. No way of looking at things  could hide the fact that the cylinders were just way out of spec.

The problem is, good (as in "within-spec") XV1100 cylinders are few and far between. Generally V-star cylinders are plentiful, Nikasil plated and very durable. And... they don't fit.

The reason is pretty simple: A stock V-star cylinder liner is almost 104mm on the outside...

... a stock XV1100 cylinder liner is less than 102.5mm...

... and the hole I want to stuff all that in is 103mm. 

Or in short: something's gotta give. Basically there's two options.

1. Bore out the cases to 104.Xmm 
2. Turn down the liners.

 As boring the cases would have meant removing all the bearings from the engine cases plus a rather unpleasant setup on my mill, a bit of recycled copper-pipe is fitted over the lathe jaws to prevent them from marring the bore.

The other thing that needs modifications are the camchain tensioners. V-star tensioners are thicker and closer to the tensioner, so they are a bit short and would run out of travel rather sooner than later.

An additional 5mm in thickness of the plunger should do the trick rather nicely. 

The next step was to take the engine apart to free up the crank and find out, whether the seller was honest and all the engine suffered from was a broken gearbox.