Rear Axle Nut Cotter Pin Replacement - Kawasaki KLR 650 Forum
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post #1 of 38 Old 05-03-2011, 12:08 PM Thread Starter
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Rear Axle Nut Cotter Pin Replacement

Can anybody steer me toward a suitable, re-useable type pin to replace the standard rear axle nut cotter pin? I experimented with some small "hitch pin" type things I found in the basement, but they don't really seem suitable.

Anybody use anything like this? Is it something that can be found at a local hardware or auto parts store?



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post #2 of 38 Old 05-03-2011, 12:29 PM
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You can get rid of the pin altogether with these:

http://www.dual-star.com/index2/Equipment/axle_nuts.htm

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 38 Old 05-03-2011, 12:37 PM Thread Starter
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You can get rid of the pin altogether with these:

http://www.dual-star.com/index2/Equipment/axle_nuts.htm
Thanks for the info. Do you know how many times they can be reused? I'm an old helicopter mechanic and one of our Golden Rules was "never re-use a self-locking nut." Not that I'm doubting they can be re-used, just curious as to how many times they recommend re-using them.



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post #4 of 38 Old 05-03-2011, 12:45 PM
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planalp -

Try a 3/16" dia linchpin.



T

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post #5 of 38 Old 05-03-2011, 12:49 PM Thread Starter
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Originally Posted by Tom Schmitz View Post
planalp -

Try a 3/16" dia linchpin.



T
Thanks for the photo, Tom. I think that's exactly along the lines of what I was looking for. I was experimenting with those hitch pins that kind of have two bumps or curves along one edge that are designed to fit around a round pin, but couldn't really get them to securely stay in place on the nut/axle. This linchpin looks like it works perfectly.



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post #6 of 38 Old 05-03-2011, 12:56 PM
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Quote:
Originally Posted by Tom Schmitz View Post
planalp -

Try a 3/16" dia linchpin.

T
I like the linchpin idea except for the fact it isn't very tamper resistant.

I know the chances of something happening are remote but what if .....

I heard about a guy who had the hitch pin clip removed from his trailer hitch in a parking lot, again remote but there are some weird people out there.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #7 of 38 Old 05-03-2011, 01:10 PM
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Quote:
Originally Posted by planalp View Post
Thanks for the info. Do you know how many times they can be reused? I'm an old helicopter mechanic and one of our Golden Rules was "never re-use a self-locking nut." Not that I'm doubting they can be re-used, just curious as to how many times they recommend re-using them.
Dual Star doesn't really specify but I think they would be reusable for the life of the bike. These are not like ny-lock nuts. Being a millwright I know what you mean about reusing locking nuts.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #8 of 38 Old 05-03-2011, 01:29 PM Thread Starter
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Originally Posted by klr4evr View Post
I like the linchpin idea except for the fact it isn't very tamper resistant.

I know the chances of something happening are remote but what if .....

I heard about a guy who had the hitch pin clip removed from his trailer hitch in a parking lot, again remote but there are some weird people out there.
Good points, but the thing looks like it's big enough that you'd definitely notice if it was gone. Figure I could always carry a spare in my too kit in case somebody swiped it.



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post #9 of 38 Old 05-03-2011, 01:41 PM
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Quote:
Originally Posted by planalp View Post
Can anybody steer me toward a suitable, re-useable type pin to replace the standard rear axle nut cotter pin? I experimented with some small "hitch pin" type things I found in the basement, but they don't really seem suitable.

Anybody use anything like this? Is it something that can be found at a local hardware or auto parts store?

Use a threadlocking adhesive like blue Loctite no pin required.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #10 of 38 Old 05-03-2011, 02:49 PM
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In truth, I think that anything in there is sorta like wearing a belt and suspenders.

72 lb-ft of torque is friggin' tight.

Even 60, so that you can get it off with the pot metal tools in your kit, probably won't back off....

T

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The kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother. -Philip Marlowe

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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