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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Favorite Cleaners

Whenever I am working on an old CT90 that I have just picked up, I initially spend most of my time just working to get everything clean so I know what I am working with.   My two favorite cleaners for this phase of the process and just in general are Simple Green and a hand cleaner like Fast Orange.




I really like both of these cleaners because they work well, are not harsh to where you need gloves and are relatively inexpensive. The Simple Green can be pricey is you buy it in smaller amounts, but it is pretty cheap if you buy it by the gallon at Lowe's.

I use the Simple Green the most and generally stay it on and let is soak for a while on greasy areas and it works great on slightly rusty chrome if you first spray it on and then take a brass brush to the rusty areas.

I use both of these on CT90 wire harnesses and its nice to first remove the complete harness from the bike and then use either cleaner and the wire harnesses will come out looking like new (or really close).


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








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