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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Dealing with Old Hard Rubber CT90 Carb to Air Cleaner Boots

I have had a couple of CT90's where the rubber boot between the carb and air cleaner and also the rubber elbow in-between the end of the air cleaner and the rack on the back of the bike have been almost rock hard and very difficult to deal with when trying to disassemble or reassemble these installations.  I have found that if I take a hair dryer and heat up the rubber that it will become pliable and enable easier removal or installation.  The softening effect is not permanent and the rubber will go back to being rock hard when it cools, but it does make things workable until you have a chance to go out and buy new rubber boots.

I have mad another post on a permanent way to soften up old rubber parts at this link that works very well and recommend you take a look.


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