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

Product Review - Small In-Line Fuel Filters

Most if not all the CT90's that I have picked up have been non-running project bikes that usually have been sitting out in the weather, which in almost every case has meant that the gas tank had some amount of rust.  While I think I do a pretty good job now that I have some experience under my belt at de-rusting tank, in the end there is always a little bit tucked away in some corner that I didn't get, so I always install an in-line filter on both the reserve and primary gas lines going to the CT90's carburetor.

Given there is not a lot of space between where the gas lines exit the opening in the frame and the carburetor, I went looking for a nice small in-line filter.

The first filter that I tried was a nice compact filter that I picked up off of Amazon.




The picture above is of a used filter from a CT90 where the gas tank still had some very fine rust particles.

At Amazon the filter is a Visual-Filter Slimline Compact Body Filter - 3/16in. -1/4in. FF701C and they cost $5.54 for a package of five.

While I like the size of this filter (about two inches long and 3/4 of an inch in diameter) what I have found with time is that the bronze filter element used in this filter worked well for large particles, but very fine rust particles were making it through and were clogging the jets on my freshly rebuilt carb.  Given the fact that the filter doesn't' have the capability to filter very fine particles that can clog your jets on a CT90, I wouldn't recommend using this filter.

Given that the Visu-Filter wasn't really getting the job done, I went looking for another filter to use on my CT90's.

The filter that I ended up with is also from Amazon and it is the Wingsmoto Fuel Filter Universal Motorcycle Dirtbike ATV Moped Scooters that only costs $6.70 for a pack of ten which I though would be a great deal if they worked.

Here is a picture of the filter:


While the filter is a little larger in diameter at 1 1/8 inches, the length is the same at two inches.  The reason I selected this filter is that I wanted to find something that would perform better with the very fine rust particles I was dealing with and I liked the paper filter element that looked much better then the bronze element on the Visu-Filter.

Here is a picture of the two filters together:


One very slight issue with the Wingsmoto filter was that there was flash left over from the molding process at one end of the filter (the right hand end in the picture above) that was easily removed before use.

Here is a picture of the pack of filters that I received from Amazon minus one that has already been installed on one of my bikes.



Overall I like the Wingsmoto fuel filter and would recommend it if you are looking to add in-line filters to your CT90 which I think is a smart thing to do to help prevent future carb problems.

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

Link to page with listing of CT90 parts available on Amazon

Comments

  1. What size fuel line do you use from tank to carburetor?

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    Replies
    1. Its 5/16 and what I keep in my shop is a roll of Stens 115-335 Tygon 5/16-Inch by 50-Foot Yellow Fuel Line

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  2. Just followed your advice and got the two filters. How dif you set them up as they are much wider. Did you put longer fuel lines?

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    Replies
    1. Hi, When I use these filter I stagger them so one is in front of the other and use a slightly longer length of fuel line between the rear most filter and where it attaches to the carb. The length of the fuel line from each from the tank to each filter is cut a little long which helps in position the filters with and excess pushed back into the frame

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