Front end swap

[Scottie1]

I have just swapped out the front end for a 1992 complete front and the axel bolt fits good but I can't get a cotter pin through the end as the bolt doesn't stick all the way out. I have all the spacers in and everything fits like it should. Am I missing something somewhere as everything lines up like it should and it rides good.

[red]

I have just swapped out the front end for a 1992 complete front and the axel bolt fits good but I can't get a cotter pin through the end as the bolt doesn't stick all the way out. I have all the spacers in and everything fits like it should. Am I missing something somewhere as everything lines up like it should and it rides good.

Scottie,

Check again that you do not have one spacer too many, and if you have any extras, maybe a thinner one (from the original front end) will do the trick.  If you can see into the holes for the cotter pin, you may be able to use a "safety ring" there, as is.  They come in all sizes, and you can make your own from "extension-type" steel springs (the type like a screen door would use).

To cut a spring, file a notch in the steel, and bend both sides of the notch with pliers back and forth, to "cut" the spring.  Springs will usually destroy most "wire cutters." 

The inner part of the spiral is to make it easier to start the ring into the pinhole.  Safety rings do not rust where bent, like cotter pins, because you never need to bend them.  Practice "rotating" the ring to install it, as you would rotate a small wheel in your fingers.  It's legal to cheat by rotating the ring into the pinhole with pliers, if needed.

[racerrad8]

The axle for the FJ is the same for all years. the early FJ's used an axle nut and cotter pin to secure the nut.

The later model forks are threaded and don't use a nut. Thus there is no reason for a cotter pin.

The pinch bolt at the bottom of the forks clamps on the axle to prevent it from loosening.

You do not use a cotter pin on your upgrade forks.

Randy - RPM

[Scottie1]

That's great thank you I have done it right then. I thought I would ask before I actually done some proper riding with it like it was.

[krusty]

Been there, done that.