77 WR250 back from the dead

You have to "un-stake" the end to dismantle. It's a PITA to do it without breaking something, and nearly as much to re-stake after.

Maybe I'll just use the new one I got.
On another subject I got the tank primed

Update on the whole bike. It's coming along well. I got the seat on today but no pics of that yet.

During the course of cleaning the rear brake plate I found the steel fork had worn an outline into the magnesium. The bushing and rubber had shifted inboard also.
I ground the damage flat and parallel then took a stainless washer of the correct thickness and reamed the center to match the housing. I used JB Weld to glue it on and sanded the match the contour. I Painted it flat black and now I never have to worry about wear as long as the epoxy doesn't fail.

GOT MUD.? Lol

rich, I could not get my VDO one apart, but I did not try too hard. In pumping grease in it, the center did seem to separate a bit.

Is the center domed bolt the grease fitting? it looke like theres a ball in the middle.

Ok I got it apart and here's what's inside.
It was cruddy, rusty, and gummed up.
I used a dremel with a metal cutting bit to get the peened part shaved.
I'm not taking the large wheel apart because it's pretty free to move.
what type grease did VDO use? Maybe some type of graphite.
That stuff sticks to everything and must have been super quality to have lasted that long.

Well after all the work to get the wheel sensor going I discovered the cable end that goes into it is sheared off inside the housing. I can hear the frayed end spinning inside the jacket and there's no square drive. Ughhh
Anyone have a spare?

I've got an automotive speedometer specialty shop locally that was able to fab up a new core for me, FYI.
They were able to also able to put together a cable for my '85 speedometer (the '86 they couldn't do, but I believe some Harley Dyna's from the '80s use essentially the same cable, sheath and all, though once I found the above, I stopped looking).

Thanks Eric I think NAPA carries cores.
They didn't have it.
I sent it to West Valley Instruments in Reseda CA for a rebuild.

MY VDO drive did not have that tabbed washer thing....where does that piece sit? Mine mates directly to the pins in the wheel hub.

The washer is the coupler between the hub and VDO unit.
the small tabs fit in the notches in the VDO and the others fit into notches in the hub.
I'm sure there were different designs over the years.

That washer is used on Leleu hubs.The husky hubs use the pins.

Affirmative, I have Leleu

Got the new chain on today and the 120 length was way off.
I followed the manual procedure of getting all three bolts lined up with the suspension weighted and having 5-10mm slack.
Presuming the "link" length is actually the roller count, I ended up cutting off 14 rollers meaning a 106 would have been fine.
Now I have extra if I need it.

you'll never need it...ive got a box full of those tail bits....ive kept them "in case" for 30 odd years...nearly enough to make a full chain!

I know I have an extra master link from 1990 still. I just can't throw it away.

Funny I was just organizing some old parts and found a bunch of those tail pieces. I said, if I throw these out, I will need one the next week, but otherwise my relatives will be throwing this out when I'm six feet under.

well extra master link might be a different story...good to stash those.