I am refurbishing a 97 EV and have found the upper suspension mount thread to be worn. Parts List says that it should be M6 * 35, but these do not hold. Either corrosion or previous-owner brute force has opened the holes up. The earlier Cali1100i/EV 8mm screw will not fit and I suspect that the suspension mount is smaller diameter than the earlier frames. (Can anyone confirm?).
Oddly enough, a good-old British Association (OBA) will screw in and hold. I know that OBA is nominally the same as M6, being 1mm thread pitch, but with slightly different thread form and outside diameter. (6mm OD instead of M6’s 5.794mm-5.974mm OD).
I know that the screw does not, in fact, do much other than retain the suspension unit on the mount, but I don’t want to unnecessarily weaken the mount post.
I could (I know) simply tap out to M7 * 1.0, or alternatively I could drill deeper and then re-tap M6 * 1.0 with longer screws.
I would appreciate any suggestions or prior experience.