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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Simple Method to Check if the Holes are Clear in your CT90 Carburetor Emulsion Tube

One of the most important steps when you are rebuilding or just cleaning your CT90 carburetor is to make sure that you check that all of the small holes along the side of your emulsion tube are free and clear. One simple way that I check my emulsion tube before reassembling it back into my carburetor is to use a LED flash light.

Here is a picture of a typical emulsion tube showing the very small holes that exist along the length of the tube above the o-ring.




What I'll do is take a LED light that is setting on my work bench and hold it close to the emulsion tube.


With the light shinning on the holes along the side of the tube, I look down the end of the tube and verify that there is light shinning on the inside wall of the emulsion tube for each of the holes being checked.


I repeat this check for each of the four sets of holes that exist around the perimeter of the emulsion tube.

I find that this is a quick and easy check to make sure all of the holes are free and clear before reassembly of the emulsion tube into the body of the carburetor.

I hope you find this useful.

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

Link to page with listing of CT90 parts available on Amazon


Comments

  1. -NateOctober 12, 2021 at 11:09 PM

    Don't forget the O-Ring ! .

    It's critical and often gone missing or damaged, causing poor running .

    -Nate

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