flywheel holes worn out

[johanv]

Hello,
I'm new here and i've got a xz550 offcourse. But i've got a problem: The tapped holes in the flywheel are completly worn out. (http://www.xz550.com/starterclutch.html)
Can I do something about this or do I need a new flywheel? Can I put M10 bolts (instead of M8) in it or use a helicoil?

[Humber]

In your place I would use larger bolts... I didn't mess with the magneto bolts much but I believe it can be done...

U can also weld the damn thing and forget about all the problems as I did on my bike....

[jasonm.]

A good machinest friend just marked out the proper locations for new holes. Drilled and tapped...all done. Some early flywheels had 2 sets of holes that were both usable for the starter clutch. Later ones the puller holes were set differently.