Honda CT90 Engine Reassembly

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I have one 1971 CT90 where I was going to rebuild the clutch because the kickstarter just wasn't turning over the engine like it used too,  and I also had a Big Bore kit from DrATV that I wanted to install. My intent was to just do the top end and rebuild the clutch with new disks, but when I opened up the cases to rebuild the clutch pack I found a slick black slime in the bottom of the case.  I didn't like the idea that there could be black slime in the rest of the engine, so I decided to disassemble the entire engine to make sure I cleaned everything out.  Since I was tearing everything apart I thought I would document step by step how everything goes back together in this post in case others were interested in knowing what the inner workings of a CT90 engine look like. Links to Related Posts: My Honda CT90 Clutch and Headset Nut Tool Cut Away of a CT90 Engine - CT90 Engine Exposed! Repairing Damaged CT90 Spark Plug Threads Using a Time-Sert Thread Insert CT90 Cl...
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My Blog on my Experiences Restoring CT90's

I pulled together this blog to share some of what I have learned and continue to learn through my ongoing efforts to restore a number of Honda CT90's.  I retired back in 2015 and I always enjoyed working on vehicles and was looking for another project and didn't want to take on another car restoration at that point in time and I started to look for something physically smaller where I wouldn't have to use a engine hoist or lift to work on the vehicle which got me looking at doing a motorcycle.

When I was younger I always liked CT90's, but never owned one and started to think it would be nice to have a CT90 up at our second home up on Camano Island in Washington state, so I set out to find a  project CT90's to bring back to life and ended up running into a guy who had three non running project CT90's he wanted to get rid of and offered me a deal I couldn't refuse.

Along the way I found that I really enjoyed working on these bikes and have now somehow managed to buy a number of parts bikes and bikes that were close to complete but not running, but as of early 2017 I have five running CT90's and three more non running bikes I have just started working on.



I look at my CT90's as a retired guys "Lego's" and up until now my focus has more or less just been on getting the bikes up and running to where everything on the bike functions the way it was intended.  In the future I plan on taking one or two of my best bikes and go through a complete restoration where I'll do a complete teardown, repaint, etc. and bring them back to be as close to new as possible.

There is a lot of great information on CT90's out on the web and what I have tried to share in my blog is additional information in the following areas:

1. How to actually do the work on your CT90 and do it in a way that won't break the bank.

2. I'll try and share information on the tools, techniques, materials, etc. that work for me so you'll have a head start with your project.

3. I'll also share the specific resources I have found for getting good information to help you with your build and also the best resources I have found for buying parts.

4. And as I lean something new I plan on writing a post to share that information.

I hope the information I share is useful and I would be interested in hearing what you're experiences have been if you've also been working on a CT200, CT90 or CT110 project of your own.

Thanks,

Mike


Helpful Links  (Shop Manuals, Wire Diagram, Model Information, etc.)

Link to page with listing of CT90 parts available on Amazon

Comments

  1. UnknownDecember 25, 2020 at 5:13 AM

    Dear Mike, you might be my biggest inspiration I have several bikes now. I am rebuilding a old hunting bike I traded for an outboard motor. It ran when I got it but as they say run hard put away wet. Your detail in rebuilding is astounding . So I'm finally getting around to attacking this bike top to bottom to learn as much as I can. So a huge thank you... Dave from Whidbey

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