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Evaluation of structural durability has always been a key issue in product development. It is a time consuming element in the development cycle. Exploring fatigue life prediction analysis capabilities, using computer based digital processing techniques, at an early design stage can reduce the development period dramatically. Fatigue sensitivity is an analysis tool to evaluate effect of a design parameter on durability of the component or product under study. The technique was effectively used to analyse parameters like stress concentration, welding geometry, loading environment, etc. The paper discusses how fatigue sensitivity analysis was carried out on different structural components of two wheeled vehicles like chassis, engine link, mounting accessories, welded components, etc. It also describes how the methodology was useful in pinpointing causes of the likely failure, in arriving at simple but very effective modifications, etc.