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I have two revs and found both just as you described. I dont think the bolt can go very far as the cover holds it from comming out too far. I did put blue lock tite on my bolts after finding them loose. Not sure if it has helped as I have not had the covers off since.

My 07 800r crank also broke and clutch fell off. Engine was a dealer warranty replacement for the first one that blew up 800 km on motor that broke the crank.

Send it to Trygstad. My cv tech rebuilt crank lasted 320 km, mag side rod bearing failed and rod punched a hole in the bottom of the case. cv tech fixed the crank and welded the case (big deal). engine builder had to grind down the weld as there was not enough clearance for the rod. Lots of...