Originally Posted by
Bikerider007
I gave it a go just now to double check and the pin pretty much disappears, I can almost push it through by hand and then the threads stick so far out that nut won't tighten down or it would take several washers. The other pin diameter appears the same.
Oh, I get it... sorry, I had not considered that. What you need is not a longer cotter, but one with a different taper. I don't know how you're going to find that, though. Therefore:
I would cut a shim the size of the taper on the cotter. Steel from a coffee can might be thick enough; or you might need two or three layers, I don't know. Make sure it's smooth and flat and fits perfectly in the flat spot between the cotter and the spindle., then proceed as normal.
Yes, this is a cheesy workaround, but as long as the cotter is inserted with enough pressure, it should be okay. Especially if you don't expect to ride the bike a great deal. I'd carry the cotter tool with me when going on long rides.