Front sprocket cover fractured = no clutch

[BEAR]

I think the general design is a bit piss poor. I'm sure the bolt dias are probably OK. But the spacing is fairly bad and with a flexible cover, I'd say most of the clutch load is already on only a couple of bolts. So a stiffer cover would reduce some bolt loads. Then add stiffer springs and you're probably still better off. Since not many complain about covers breaking with standard springs, except Chris who started the whole debate, the covers must be very close to failure anyway. Statistically a few will fail from fatigue, most won't. Stiffer springs and you slide down the curve and more failures. Add a bracket and maybe you're back to standard rates of failure.
But I'd still like a stiffer cover simply for the better feel. I've never had a bike that has such a spongy takeup. If you're going stiffer again, helicoil the bolt holes just to stop thread damage in the ally case and as a bit of insurance. I think 4 x 6mm bolts are fine for the sort of loads the clutch can generate.
What have I started here!!! Hope I haven't offended anyone, oh gosh oh golly....bugger! <i></i>