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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One of my favorite things - Dental Tools

Over the years I have found that having a few dental tools around can really come in handy working on my CT90's either for cleaning little nooks and crannies or for trying to install or remove little tiny o-rings, or really for any one of a million other cases where something else just won't do.




If you keep you eye out you'll find old dental tools at garage or gun shows, and you might even try asking your dentist the next time you go in for an appointment. I'm lucky in that my dental hygienist usually can find two or three tools they are ready to throw out each time I go in for a visit, so it never hurts to ask.

If your dentist isn't all that nice, then you can pick up a set of six dental tools at Harbor Freight for only a few bucks.

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

Link to page with listing of CT90 parts available on Amazon



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