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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Simple CT90 Valve Spring Compressor

If you do ever get into doing work on your CT90's engine one thing you will be faced with doing at some point if pulling the valves.  I cobbled together a simple valve spring compressor using a C clamp and a piece of thick walled aluminum tubing I had setting around my garage.

I took a piece of the aluminum tubing about 1 1/2 inches long and cut an opening in the side of the tubing about half way through and about 70 percent of the length.  The tubing was a little over an inch in diameter and had about a 3/4 inch inside diameter.





The valve spring compressor tool (my modified piece of tubing) is placed on the end of the valve spring and then the C clamp placed over that with the adjustable end of the clamp on the face of the valve.


To remove the valve tighten the C clamp until the small retainers at the end of the valve can be removed (a small magnet helps with this step) and then once the retainers are removed the C clamp can be loosened and the valve spring components can be removed from the end of the valve and then the valve can be pulled out on the chamber side.


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

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