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The last time I checked the valve clearances on my Falco I managed to shear one of the bolts which holds the rocker cover on the front cylinder. Sod's law says that it had to be the front one which is right near the headstock and virtually impossible to get an allen key to, let alone a drill. Fortunately it only causes quite a small oil leak but I've decided that after over a year of putting it off now is the time to get on and fix it.

Obviously I don't really want to have to remove the whole engine to fix the problem and I think I may be able to get the cylinder head off and onto the bench without too much of a problem. That was until the manual came along and burst my bubble by saying that you must remove the cylinder and head together and then split them which sounds a bit strange to me. Now, has anyone ever pulled one of these engines apart before and if so is there any particular reason they specify this or is it just their preferred method, bearing in mind that they expect you to be stripping the whole motor not just removing one head? If anyone does have some previous experience anything you can tell me about the job would be a major bonus, before i retire to the garage and commence swearing.

im sure if you are just checking valve clearance you only need to remove the cover

he needs to repair the cover....

Aladinsaneuk wrote:he needs to repair the cover....

..... not exactly .... he needs to remove the bolt with the sheared head from the cylinder head.

I'm wondering that if you take the cam cover off whether there is enough of the sheared bolt showing to get something on it (like mole grips) - obviously after a good soaking in easing fluid.
.... or has it sheared off level with the head?

Fortunately for me, unfortunately for you, I've never needed to take my Falco's motor apart so I can't answer your original question.

The person who will know is Griff at Aprilia Performance. Give him a ring, I'm sure he'll be happy to help you - tell him that D-Rider told you to call him.
Contact info on his website: http://www.customrestoandrace.co.uk/

Thanks for that DR, can't believe you were the onlt one who understood what I was on about. There's no way of gripping it because it is flush with the top of the head.

Having had another look at the manual I think that there are bolts running from the bottom of the barrel up into the head which would explain it.