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...

Helpful CT90 & CT200 Cable Info

CT90 and CT200 Cable Information

I have a number of CT bikes and I always am looking for new project bikes that in almost all cases need new cables, so I put together the table below so I have a quick reference to all the latest and past cable part numbers.  I also made hot links for the cable part numbers that I know are available at Dr ATV or Everett Powersports where I buy a lot of my CT90 parts.

I hope this is helpful to others and if you have any comments or see any errors please feel free to let me know.

Year
Model
Serial Number
Throttle Cable
Front Brake Cable, Right Lever
Rear Brake Cable, Left Lever
Speedo Cable
1964 - 1966
CT200
CT200-100001
17910-107-671, 2FM-MC-3928
45450-GB4-600, 45450-033-000, 45450-053-000
43460-033-000
44830-159-000, 44830-061-810
1966 - 1967
CT90K0
CT90-100001
45450-GB4-600, 45450-033-000, 45450-053-000
43460-053-000, 43460-102-000
44830-159-000, 44830-061-810
Late 1967 - 1968
CT90K0
CT90-122551
45450-GB4-600, 45450-033-000, 45450-053-000
43460-053-000, 43460-102-000
44830-159-000, 44830-061-810
1969
CT90K1
CT90-200001
17910-077-000
45450-077-000
43460-077-000
44830-GF4-000, 44830-011-101, 44830-077-000
1970
CT90K2
CT90-300001
43460-053-000, 43460-102-000
44830-GF4-000, 44830-011-101, 44830-077-000
1971
CT90K3
CT90-400001
43460-053-000, 43460-102-000
44830-GF4-000, 44830-011-101, 44830-077-000
1972 - 1973
CT90K4
CT90-1400001
43460-053-000, 43460-102-000
44830-GF4-000, 44830-011-101, 44830-077-000
1974
CT90K5
CT90-1500003
43460-053-000, 43460-102-000
44830-GF4-000, 44830-011-101, 44830-077-000
Late 1974
CT90K5
CT90-1520002
17910-102-770, 17910-128-000
N/A
44830-GF4-000, 44830-102-730
1975
CT90K6
CT90-1600003
17910-102-770, 17910-128-000
N/A
44830-GF4-000, 44830-126-940, 44830-102-730, 44830-102-770

After S/N 1709298
44830-459-671
1976
CT90-76
CT90-1700004
17910-102-770, 17910-128-000
45450-169-000, 45450-102-770, 45450-KA9-680, 45450-102-771
N/A
44830-459-671

1977
CT90-77
CT90-1800008
17910-102-770, 17910-128-000
45450-169-000, 45450-102-770, 45450-KA9-680, 45450-102-771
N/A
44830-459-671

1978
CT90-78
CT90-1900010
45450-169-000, 45450-102-770, 45450-KA9-680, 45450-102-771
N/A
44830-459-671

1979
CT90-79
CT90-5000011
N/A
44830-459-671

1980
CT110
JD01-5000001
N/A
44830-459-671

1981
CT110
JH2JD010-BS100002
N/A
44830-459-671

1982
CT110
JH2JD010-CS200001
N/A
44830-459-671

1983
CT110
JH2JD0102-DS300003
N/A
44830-459-671

1984 - 1985
CT110
JH2JD010-ES400001
N/A
44830-459-671

1986
CT110
JH2JD010-GS400001
N/A
44830-459-671



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

Link to page with listing of CT90 parts available on Amazon

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