I don't think there's anything wrong with the Tenere clutch, what you are suffering is not a common complaint. It has cropped up before, but only once in a blue moon and there are loads of members who ride really hard off road and haven't had any trouble. JaumeV rallies his competitively on a weekly basis, and a couple of Zs have done the Heroes Legend Rally a number of times and it doesn't get any harder than that!

What you've got to remember is that any clutch is going to get too hot, do odd things and eventually fail if it given a hard time. How much of a hard time it gets depends as much on riding style as anything else.

HD clutch plates aren't going to help, they just bite harder so as to avoid slip under power. In fact, they are going to make feathering the clutch more difficult and generate even more heat due to the higher friction levels when doing so. Fitting a hydraulic clutch isn't going to help either as you've still got the push rod and pressure plate in the system.

As I mentioned, for cheapness, try a 14T gearbox sprocket and if you want a total solution the perhaps consider a Rekluse clutch?

http://www.xt660.com/showthread.php?t=20601

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