Cant say for the new Gas Gas models,but this thread brings up some interesting issues.If its plastic Jim,Ive never seen a plastic cover on any dirt bike that didnt have those problems eventually.The covers warp,the gaskets harden and even though some manufacturers reinforce the area on the cover where the mounting bolts seat;you just cant get the bolt to the right tension and have the plastic carry that load to the next fastener.The gasket eventually rolls over the edge of the case eventually anyway. ktm ignition covers have been the biggest problem for us in the past.With any of the plastic covers weve gone to the lots of goop method, basicly glueing the the things on there as opposed to trying to fasten and seat the gasket.The cast covers are better for sealing because they carry the load between fasteners and you can glue the gasket to the cover and then seal cover and gasket to case with some quality grease.
Plastic covers take the big hits better,they will absorb alot of the blow,whereas a metal cover can transfer that load to the case,which is very thin with little support in the ignition cavity.Still havent decided which one Im going to use on this gasser project,the cases are tougher on these gassers so we will probably use the cast one and rubber wrap it on the bottom leading edge.
For those of you having some clearence issues with these 23 ounce flywheel weights,if it was me Id fire that baby up and use a quality file that can be cleaned and turn that flywheel and nut down,starting with the nut,and then knocking that sharp edge down,and finishing with a face cut if you had too.The bike is your lathe.
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