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Showing posts from July, 2017

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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Making a Basic Vinyl CT90 Seat Cover

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I am always looking for a way to save a few bucks and I get a lot of enjoyment out of doing things myself, so I have a few CT90's that need seats and in a previous post I showed an approach to make your own seat foam/cushion , so I decided to go on and make covers for the CT90 seats I previously made a cushions for. While I have used a sewing machine a time or two in the past, this will be my first time trying to make a seat cover, so I look at this as a learning experience (i.e. I don't plan on my first seat cover being perfect...). Here is a picture of one of the seats I will be making a cover for.
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Two Quick Tips When Installing the Bearings in your Frame Headset

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I was working on one of my CT90's this week and I had pulled the front forks to do some work that was needed and when reassembling the forks to the frame I thought I would share a couple of tips that I have found that help make the job go that much easier. The first thing is to use a magnetic tool tray to hold the loose ball bearings.
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