The story of a wet dream, with pictures...............

[Shaft]

A bit of back story:

Some months ago, I started looking for a hack of some sort, without too much of an idea what I was looking for; probably something 250ish, probably older (for classic insurance and ease of fiddling) and maybe an off roader, because I had it in mind that, as a winter bike/commuter, it would likely be dropped at some point, so I wanted something that crashed quite well.

The budget was small, somewhere around £500 all done, but not including insurance, so the hunt began; scouring auction sites and small ads, I found a few things that took my fancy, but they all seemed too expensive; I started looking at bikes that I reckoned wouldn't have much of a following, stuff that wasn't well loved when it was new, or bikes that needed a fair bit of fettling, but even these ended up going for mad money.

I was getting close to the point where I was going to give up, because I clearly didn't have the required budget; even if I found something, it was so far away, it wasn't worth the cost of getting it home.

Then, last Friday, a break through; a classified ad on the bay turned up a bike I knew and loved, having despatched a few in the early 80s, so, after a couple of calls, the deposit was paid and it turned up a couple of hours ago............................


https://img18.imageshack.us/img18/6607/dreamrear.jpg

https://img32.imageshack.us/img32/2496/dreamfront.jpg

https://img24.imageshack.us/img24/1534/dreamside.jpg


Yep, it's a tad tatty round the edges, but nothing that can't be fixed with a bit of spit and polish.

Comes with tax and ticket until July, but it's a non runner; apparently, it was OK until it was stood for a couple of months, now it spins easily enough, but it won't fire and the carbs overflow, so I'm guessing sticky float valves or similar, so first job is to attack the carbs with copious amounts of carb cleaner and an airline.

Assuming that gets it running, a service and a new rocker cover gasket to fix the one that leaks now and she'll be right!!

Long term, my plan is to turn it into a replica of my favourite Dream, a bike I rode for about a year and put shed loads of miles on and, in fact, until today, the last Super Dream I'd sat on for 28 years; although it was the same age as this one, it had been slightly 'Deluxed', so a ducktail seat cowl and a set of reverse Comstars will be sourced, then the whole thing goes black.

Anyway, that's for the future, next installment will be sorting the fuelling......................hopefully
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[mysterious_rider]

Nice little bike. Good luck gettting her running, although being a honda im sure you wont need luck.

[nisp]

seems to be a bit of a theme here with the old hondas..
____________________
Suzuki TS 50 1999 Honda CB 125 t2 1981 Yamaha XJ 600 s Diversion Honda cx 500 MZ ETZ 250 1985 Yamaha FZR 400 1981 Suzuki TS 185 1984 Triumph bonneville 790 2001 MZ TS250 1979 Suzuki sv 650 1999 KTM exc RFS 450 2007 Hercules mx 125 1976

[Shaft]

[Shaft]

While I'm waiting for my carb rebuild kits to arrive, I thought I'd check other potential barriers to starting, so I whipped the plugs out and did a spark test; looked good enough to me (I put new ones in anyway) and they were bone dry, so unless both inlet valves are jammed shut, the problem definitely lies with the jets.

As I had nothing better to do, I began Operation Tart Up (forgot my camera, so pics tomorrow) starting with straightening the badly deformed headlamp bracket, caused by the bike falling over on the previous owner's driveway.

Unbolted the lamp, attacked the bracket with a large pair of grips to get the twist out, then finished it off with a few wacks with a dead blow against a dolly; job done, headlamp now points at my side of the road

Cleaning next, in my view the best way of getting to know a new bike.

Although it's only done 29k (which I think is genuine) it obviously hasn't seen a bucket of soapy water for a lot of it's 32 years, so all the alloy casings and fork sliders are caked in dried/baked on dirt; my preferred method of cleaning this material is Scotchbrite pads, lubricated with Duck oil, which gets through the grime and gives a smooth, uniform finish.

As I indicated at the beginning, the aim is not build a show pony, just to get it tidy but used looking, so I'm not going overboard with the polishing.

I've only done one side so far and I haven't gone mad, but it's already a huge improvement, as the before and after pics will show.

What I have discovered is a few bits and pieces that need derusting and painting, so that's what my weekend has in store for me, if the carb kits don't turn up in time................
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[Fladdem]

Ahh, i was close with a cb125t then. I nearly bought a superdream 250 when i was 14 to get ready for my test but you know paper round money, by the time i had saved enough for it, it was gone. That was a blue one as well. Can't remember the year it was nearly 4 years ago. Hope it goes well!
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.

[Ed Case]

Always a good bet if it comes at thr 'right' price, the CB250RSA, lighter, quicker, better handling, much simpler, much less 'hocus-pocus' going on under the tank, cruise comfortably at 70. Mine's got 52000 miles on it now and still going great.

[Shaft]

I was looking at a couple of those when this came up, but I didn't really like the RS when it was new, it just felt a bit too light and twitchy for me and, after all these years of riding much bigger bikes, the SD feels like a moped, so I'm not sure I'd be real comfortable on something even smaller.
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[Shaft]

No time for any progress today, so just the shots from yesterday's efforts.

Before.............

https://img252.imageshack.us/img252/5889/dscf0862.jpg


https://img827.imageshack.us/img827/752/dscf0863i.jpg


After.............

https://img832.imageshack.us/img832/676/dscf0864a.jpg


https://img69.imageshack.us/img69/6073/dscf0866ya.jpg


I really didn't put a lot of effort into the polishing and I will do a bit more but, as I've said before, this is going to be a working bike, so there's no point in going OTT.

The good bit about using Duck oil (you can substitute WD40) as the lubricant, is that while you're cleaning, you're also giving all the fixings a damn good soak, so it should prove a bit easier to take some of this stuff off, which I'll be needing to do to paint some of it.

In case you're wondering, that isn't dirt on the downpipes, it's real rust, so they're beyond saving (as are the silencers really); I'll replace the whole system at a later point, but for now I'll just be brushing off the surface rust and giving them a coat of paint.

Which might well happen tomorrow, as my carb kits definitely won't be here by then.
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[Ed Case]

[Shaft]

I'm quite sure the RS is a fine machine Ed, DataPost thought so, they had a whole fleet of them, it's just not really for me, hence why this a thread about a Superdream

Meanwhile, was late getting to the workshop yesterday, so didn't have time to do much, sorted my priorities as doing something about the rusty battery tray and rear mudguard.

Battery tray was dead simple, just two bolts to undo, which came out easily to leave me with this sorry looking thing:

https://img600.imageshack.us/img600/9205/dscf0868x.jpg

And the Black Hole of Calcutta:

https://img824.imageshack.us/img824/3148/dscf0867q.jpg

Battery tray is a piece of cake to sort, as it's only a few bits of bent metal, spot welded together; a quick whizz over with a belt sander and three coats of aerosol Hammerite Smooth, and we get this:

https://img40.imageshack.us/img40/1151/dscf0872c.jpg

Should last for a while; similarly, the resulting hole was cleaned up with Duck oil again, which revealed a swing arm that was better than I first feared, but will probably get pulled at some point in the future, for painting or powder coating, before it goes beyond the point of no return.

Now for this:

https://img688.imageshack.us/img688/7127/dscf0869h.jpg

Frankly Mr Honda, this is a dumbass design; why link two pieces of plastic with a lump of pressed tin, that's going to get covered in everything the rear wheel can throw at it?

It's not strong enough to provide any structural rigidity and it's only purpose in life seems to be to act as a mounting point for the helmet lock, which could easily have been put on the main frame.

Anyway, despite spending two days soaking in penetrating fluid, 4 of the 6 mounting bolts (tiny things made of cheese) sheared off, but I suppose that's par for the course; getting it off showed what happens when you bolt a thin piece of steel, hard up against a much thicker piece of steel and some plastic, which act as water traps:

https://img841.imageshack.us/img841/2165/dscf0870g.jpg

https://img29.imageshack.us/img29/4833/dscf0871dg.jpg

The sheared bolts left enough behind to get a pair of molegrips on, but despite further treatment from some freeze fluid, they still wouldn't shift, so I'll be removing the captive nuts (another idea conceived by a total genius ) and replacing them with some tougher nuts and bolts.

Had similar difficulties removing the helmet lock, which is held on with a more substantial 15mm nut on the end of a splined pin; more penetrating fluid, more freeze spray, but the thing wouldn't shift, even with an electric impact gun on it. Resorted to a 3' breaker bar and only succeeded in snapping the body of the lock, then stripping the splines off the locating pin, so now I've got a nut that spins and a busted lock still firmly in place.

I'm determined to save this infernal lump of bent tin, mainly because I saw an NOS part rising rapidly towards three figures on the bay, with a day to go, which indicates they are rare and sought after, so getting a decent used one will be a challenge.

Anyway, I was running out of time, so I treated the topside to a going over with a paint removal wheel, to give me this.........

https://img822.imageshack.us/img822/2962/dscf0873py.jpg

.........which I then covered in a couple of coats of paint, to stop it rusting even further.

Not sure how I'm going to fix the missing metal, either sandwich the holes between two steel plates, or maybe experiment with some dense nylon, but it will get sorted.

Meantime, I'm considering using the tin as a buck for a GRP replacement, if I can be bothered.
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[Ed Case]

Yes, there's a contraption just like that on my RS, and that's in 'shit order' too. What a piss-potical bit of kit. One place where plastic would be ideal and they used thin tin.....divvies !.

[Shaft]

Made a little bit of progress, starting Tuesday with beginning the repairs on the mudguard.

First of all removed the captive nuts with their very captive bolt ends, using an angle grinder/belt sander combo, then tried to get as much rust cleaned off as possible.

Made up a plate from flat steel, bent at right angles at each end, to fit inside the guard, then used panel adhesive to bond it; here it is clamped up, waiting for the glue to cure.........

https://img543.imageshack.us/img543/1661/dscf0877m.jpg

This is something of an experiment, insofar as we normally use this stuff for bonding totally clean steel, so I wasn't sure if it would work with this much rust around.

However, after 15 minutes it had gone off and showed no signs of giving way, as I pressed down on the plate to re drill the bolt holes.

I can recommend this stuff, which would be especially useful if you haven't got access to welding gear; it comes in the form of a two part epoxy with an application gun (similar to bathroom sealant) and the mixing takes place in the nozzle, so you don't have to do anything, just squeeze and stick.

The downsides are, it's relatively expensive and it goes off very quickly, so you must make sure you know exactly where your repair panels are going to go, because you have very little working time; the upsides are, it will stick both metal and plastic and it's stronger than welding, obviously with no risk of distortion.

I also removed the (now broken) helmet lock, by the simple expedient of cutting through the retaining pin with an air saw.

I'll be repairing the other end tomorrow and finishing off with more smooth Hammerite, but brushing this time, as I'm not overly happy with the coverage of the spray.

In other news, my carb kits turned up today, so I'll be taking a deep breath and stripping the carbs, with a view to getting the sucker running by the end of the week......................fingers crossed!

Yesterday was a bit slow at work, so time to roll up the sleeves and get this fuelling issue sorted.

First thing, tank off and I was pleasantly surprised at what was waiting underneath:

https://img546.imageshack.us/img546/6233/dscf0878c.jpg

Bit of dirt, flaky paint and some light surface rust, but I reckon it could be a lot worse. I'll probably throw some paint on a few brackets, but there's nothing really pressing to deal with.

Carb removal next and Mr Haynes says that because of the limited space, this job "requires some dexterity and care" and he's not joking!

I was amazed at how many tools I accumulated around me, for what should be a really simple task; a variety of different types and sizes of spanner, screwdrivers and little hooky things, for extracting nipples from sockets.

Anyway, after much fiddling and faffing, plus a blast from a hot air gun, to soften the airbox rubbers, the offending instruments were set free:

https://img804.imageshack.us/img804/4467/dscf0880i.jpg

On to the bench and I elected not to take Mr Haynes' advice and split them up; I would have if I were doing a full on rebuild, but this is just a clean up and besides, I've never heard this running, so I decided leaving all the settings as they are, would probably help me at the start/setting up stage.

So, off with a float chamber and it was immediately obvious what the problem was:

https://img41.imageshack.us/img41/671/dscf0884w.jpg

https://img829.imageshack.us/img829/875/dscf0883e.jpg

Barely a whiff of petrol, just lots of silt and rusty water; hardly surprising it didn't want to fire, I doubt that mixture is even 20% fuel

Having gotten rid of that, everything appeared to be in good shape; stripped out the jets and cleaned with intake cleaner, then blew everything through with compressed air and reassembled, using a new float valve, bowl seal and a new fuel pipe, to replace the rather tired looking original.

Much better:

https://img687.imageshack.us/img687/5586/dscf0885z.jpg

Now, to replace them which, as we all know, is a straightforward reversal of the removal procedure, except in this case, it wasn't; as I moved everything out of the way, to offer up the carbs, the bottom half of one of the throttle cables fell out, where it had completely rusted through.

So now I'm 22 quid lighter and waiting on new cables, which probably won't turn up 'til next week

Still, better to find out now, than have it let me down on the road, so I guess there's a silver lining somewhere in there.

Looks like I'm back to painting and fettling for the weekend, but it will give me a chance to finish off the mudguard and have a go at fitting an accessory......................
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[Carvel]

Thats more like it, looking good
____________________
2002 Aprilia RSV1000R, Cbr600Fs, Mk1 B12, Vfr400 NC30...

Matt B: I can deal with crushed nuts to beat Ollie.

[pepperami]

I am liking this thread much detailed photos please with little pointy things pointing to the bit you`re talking about
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[Shaft]

Sorry pepperami, no pointy things, but I hope it's fairly self explanatory.

Managed to get a couple of little jobs done today, mainly on the tarting side of things.

Started with finishing the rear mudguard.

I'd already cleaned up the area as best I could and cut out a patch, so time to glue it in:

https://img201.imageshack.us/img201/3659/dscf0888h.jpg

As mentioned previously, you don't get much working time with this gear, so it's straight to plate fitted and clamped:

https://img42.imageshack.us/img42/6817/dscf0889j.jpg

Then whizzed off the worst of the crud and applied a liberal coat of the black stuff:

https://img7.imageshack.us/img7/3460/dscf0896t.jpg

Job jobbed!

While I had the paint out and having nothing better to do, I thought I would tonce up some the bits that aren't always accessable, namely the top frame rail and a few brackets.

https://img651.imageshack.us/img651/6115/dscf0891gc.jpg

https://img694.imageshack.us/img694/3931/dscf0892r.jpg

As always, there's no cosmetic imperative behind this, just a desire to save what's there; obviously, should I ever begin suffering from early onset dementia and decide to do a more thorough job, the frame will get stripped and powder coated.

For now though, I consider it like giving the old girl a new Winter coat:

https://img687.imageshack.us/img687/4941/dscf0895u.jpg

https://img543.imageshack.us/img543/7346/dscf0893s.jpg

https://img593.imageshack.us/img593/4308/dscf0894e.jpg

Pukka, as people from my part of the world apparently say.

I also mentioned earlier the possible fitting of an accessory.

Ive been looking for a set of grabrails, or a rack, as mine are missing and, apart from wanting to fit a box, I haven't got anywhere to put the rear indicators.

It turns out the seller had removed a rack and sold it separately (doh!) but he did say he might have something that may do the job; the deal was, he would post it to me and, if it worked, I would send him a tenner, if not, no money changes hands, which seemed very fair.

At this point, I must heap some praise on the seller; the deal was done very swiftly and efficiently, he delivered pretty quickly, for a bargain price and tried to help out with the rack, plus he seems a thoroughly decent bloke, who's also a long term biker.

If you ever find yourself dealing with a seller called garrysbikebits, he's one of the good ones.

Anyhoo, the rack apparently came off a 250 Nighthawk and it looked like it would go, with the added bonus that it came with a box and indys fitted.

Offered it up and it's nowhere near; I could make up some brackets to make the bolt holes line up, but it's way too wide and I don't think there would be enough clearance to remove the seat, so I'm back on the hunt for something designed for a Superdream, if anyone can help.

Next installment (I hope) will be the fitting of new throttle cables and bunging the carbs back on, then it's the moment of truth.............
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[Shaft]

OK, after an illness enforced break, it's time to crack on again.

First off, let's deal with the throttle cables; with apologies for the poor close up, this shoulder is the issue, it's just too big for the hole it has to fit in.

https://img859.imageshack.us/img859/1973/dscf0902r.jpg

No problem, wack in a vice, fettle with a fine file and Robert's your Father's brother.

Moving on, when I got back to work, a little parcel from David Silver was waiting, included in which was a new rocker cover gasket.

While I was doing that job, it made sense to check the valve clearances and give the cover a quick tickle with the plastic wheel, to remove the worst crud and corrosion; I'm sure you've all seen a set of feeler guages and a ring spanner before, so I didn't bother with pictures of that, but here's the exposed valve train, just to prove I was there.

https://img85.imageshack.us/img85/509/dscf0903c.jpg

Next was refitting the carbs.

Ran into a small problem here, because I assumed the inlet stub O rings would be of a standard size, so I could just go to the box of stock spares and pick out a couple of replacements for the hard, flat originals; unfortunately, I failed to follow some advice given to me early in life (to assume, just makes an ASS out of U and ME) and I didn't have anything that would do the job.

So, bodgery required in the form of a bed of silicone sealant and plenty of crossed fingers, because if I thought taking the carbs off was awkward, putting them back was one of the most annoying bits of fiddle arsery I've come across; suffice to say, having got them back in, I'm not in a rush to take them out again!

https://img638.imageshack.us/img638/8470/dscf0908g.jpg

At this point, I was fed up with doing twiddly bits, so I thought I'd chuck some of the bigger stuff back on, namely the rear mudguard assembly; all my holes lined up perfectly and, apart from having to chase out a couple of paint filled threads, it all went together easily, this time with zinc plated hardware.

https://img19.imageshack.us/img19/1725/dscf0905x.jpg

Something else that was waiting for me, was a little package from Scotland, so that went on next.............

https://img32.imageshack.us/img32/1295/dscf0906te.jpg

Needs a clean up (probably a repaint, in truth) but now I've got somewhere to put my top box and, most importantly, my new set of repro indicators, courtesy of DS.

So, back to looking something like a bike again.

https://img864.imageshack.us/img864/4499/dscf0909.jpg

Still need a couple of bits; rather annoyingly, while I was away the bike was moved and, somewhere in it's journey of twenty feet, one of my freshly painted engine top mounting plates went missing

Also, at some point in it's life, one of the screw mounts for the rear light lens has been broken off; I tried to stick it back on with my whoopdedoo epoxy glue, but it didn't work on that type of plastic and the offending part pulled straight off, as soon as I put some torque on the screw.

Other than that, I need to adjust the throttle cables, refit the battery and tank, then fire it up.

Sounds easy enough...............
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[pepperami]

MOAR NOW , WE NEED MOAR
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[Shaft]

[waynenoonan12...]

great project, always been a big fan of the early Cb250's polish your engine this is what my engine looked like when i got it

https://i199.photobucket.com/albums/aa288/waynenoonan1234/PICT0038.jpg

after a clean

https://i199.photobucket.com/albums/aa288/waynenoonan1234/DSC00631.jpg

and after a good few hours polishing
https://i199.photobucket.com/albums/aa288/waynenoonan1234/PICT0057.jpg

[Shaft]

Very nice Wayne, but not the look I'm after.

Anyway, I'm kinda at the home straight stage really.

It's started pretty much first punch of the button every day, even from cold, not absolutely happy with the tickover though; I don't know if it's the pattern pipes or my imagination, but it doesn't sound quite right, slightly 'chuggy', if that makes sense.

The exhausts aren't blowing, I've checked for air leaks and it sounds fine at anything above minimum revs, so I'm wondering if the tickover is set a little low; I'm pretty sure the carbs are synched well enough and it doesn't help that the rev counter seems wildly inaccurate, so I'm going to put it on our gas analyser and use it's inductive pickup to check the revs and see if I can improve things.

Anyway, pictorial evidence that it's a goer............

https://img811.imageshack.us/img811/9803/dscf0911fo.jpg

Managed to get the new indicators on, except I'm missing the proper screw clip for one of the rears, which has lead to a serious piece of bodgery and I'm really not happy with it; I'll be putting an appeal up elsewhere, but if anyone is reading this and has a spare, please let me know because I don't know how long the indy is going to stay on for.

So, here's Thunderbird 1, more or less done............

https://img526.imageshack.us/img526/2154/dscf0913mx.jpg


https://img267.imageshack.us/img267/9885/dscf0910l.jpg

Once I've sorted out the tickover and done an oil and filter change, I'll be on the road, although something tells me this bike might never really be finished, but then I guess that's part of owning old vehicles, there's always something to play with
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[Hobgoblin]

good work Shaft, its looking well!
____________________
Plodding along on my CG

[Shaft]

[Shaft]

Bollox!

Reset the tickover and traced the chugginess and low rev flat spot to a poorly set spark plug; entirely my fault, I didn't check them when I put them in, one was OK, the other virtually closed, regapped and all was well, so I went for the inaugural spin round the block.

Everything was just fine, except the forks are twisted (probably as a result of the falling over incident that prompted the last owner to sell) and the front brake feels like it's made of lignum vitae, so a caliper rebuild will be taking place, but neither issue is a big deal.

Got back to the workshop, got off with the engine running and the bloody carbs are overflowing again

I'd measured the float heights when I stripped the carbs and they were within tolerance, but having read several tales of this being a recurring problem, I'm wondering if the most easily available published settings (the Haynes manual) are correct.

We have similar problems on a particular classic car we deal with, where the published factory settings for the float heights don't work, so I'm going to do what we do with them and try setting the SD floats a little lower.

Apparently, they fitted non-adjustable floats on later models and swapping them in cures the problem, but at £44 per carb, plus carriage, I'll be making the originals work if it kills me!

Not happy
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[pepperami]

A good job , well done. .

It`s always the little niggly things that hold up a project.

I did a Sachs XTC 125 last year and it was the same in that the bulk of things were fairly straightforward, but all the little finishing touches to get it "right" took the longest.
____________________
I am the sum total of my own existence, what went before makes me who I am now!