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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Preferred Honda Shop Manual - 77 -79 CT90 and 80 - 82 CT110

Even though all the CT90's I own are models built before 1977, I still like to use the Honda shop manual for the 1977 thru 1979 CT90's and the 1980 thru 1982 CT110's. This version of the Honda shop manual has much better diagrams and instructions for items common to all years of CT90's and also has a great trouble shooting diagram to help figure out what is wrong with you bike. You can download a copy of this manual at the following page.

 The follow is an example of the trouble shooting chart in the manual:




Here is an example of one of the diagrams for adjusting the points that is much better in my opinion than what was included in the earlier manuals:

This manual can be found at the link on my Helpful Links page that also includes links to other information besides shop manuals, like wire diagrams, model information, etc. This version of the CT90 manual is really a well done manual.


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

Link to page with listing of CT90 parts available on Amazon

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