The distance front-to-back of the holes in the top cover seem to vary, Jouni - imprecise factory machining? I never used wire for years on my SF1 and had no problems, and even with wire I didn't need to elongate the holes. I have a different cover now, but as cheap insurance I always fit the thin wire to any twin motor I build anyway. Because there are no dowels to position the top cover onto the head precisely it is random where the studs will end up relative to the top oil-feed channel. Covers that require elongating - we're talking very small amounts here - just to enable the thin wire to be fitted, were obviously on the risky side when fitted without the wires.
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You mean that the distance of the holes on the cover vary from cover to cover? Front-back, but not sideways?
As the cover has no dowel pins and should find a some kind of average condition how the studs are leaning on the tight holes.
The oil channels are not inline with the stud holes:
-On left and front the stud should be leaning left and back
-On left and back the stud should be leaning left and front
-On right and front the stud should be leaning right and back
-On right and back the stud should be leaning right and front
I was thinking:
1. How many of them could do this at the same time? I guess possibly just one. The passages should then be blocked on both sides, because on the analyzed damages in Finland the valve trains had always similar damage on both sides. No cases with damages on one side only.
2. The difference in stud diameter vs. hole diameter should keep the channel open even if the stud is leaning against the passage. However, this can form a narrow slot, that could get blocked if there is sludge. The damages are also known in very clean engines. I once tried to calculate this blocking, but I did not had all of the real components with actual dimensions on hands at that moment. My approximation was that the area was still bigger than the area of the oil spray holes - when a stud is leaning against the passage with the cover tightened in place. Also the oil channels not being inline with the holes widens the passages.
3. How the wire solution was actually tested? My understanding is that in Finland the damaged cases cut sharply off, and success for decades for dozens of bikes.
-Jouni