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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Handy Tool - Brass Brush

One tool that I really use a lot when I am going through an old CT90 is a good quality brass brush. Sometimes it is hard to find a decent quality brass brush as the lower cost ones from Harbor Freight have too few bristles and they are too soft and just bend over which makes the brush worthless.

I have found the Forney #70491 brush in the picture below to be just about perfect. The bristles are made from a brass alloy that is stiff and hard enough that it holds its shape while in use, but the bristles are soft enough that they don't tend to scratch chrome unless you really go overboard. I pick these up at a True Value hardware store near me, but I am sure they are available online or at other hardware or welding supply stores.






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




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