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 Clutch P
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Figuring out wire colors on a CT90 stator when colors have faded or are not present

I have a 1971 CT90 I am working on and had an interesting electrical problem when I went to reattach the connector from the main with harness to the wires coming from the stator within the crankcase.  While the one wire for the neutral switch was correctly colored, the other three wires had a cloth overboard and did not have any color.

The answer to how you can figure out what the colors should be on a stator with faded colors can be found by joining the Honda 6 Volt group on Facebook. In the file section of this group, John Pardue was kind enough to share a very simple test you can perform that will identify what wire is what color.  Here is a link to that file in that group, but you will most likely have to join which is very worthwhile as there is a lot of great information shared.

The Pardue Brothers web site also has a lot of useful electrical related information and products to help with your CT90 restoration project.


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



Comments

  1. Jon PardueApril 22, 2017 at 2:49 PM

    Glad that was helpful. I tried to make the test effective using common items.

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