How do you replace the cover that has the spring-band chain break? I can't seem to get it over the clutch. There must be a trick.

You need to load the brake, it has obviously activated and the band is now smaller than the drum, if the hand guard is connected to the brake, clamp the side cover in a vive, be carefull not to damage the cover, now pull the hand guard fully back, it will take some force as it is compressing a large spring, it will click when the brake loads, if the hand gaurd is on the machine not the brake, remove the hand guard from the machine and use this as a tool to fit into the brake, with the cover in a vice pull the hand guard fully back until it clicks. the cover should now fit back onto the saw.