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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Alternative Spring Configuration for CT90 Brake Switch


A while back I was working on one of my basket case K1 CT90's and needed a spring for the brake light switch that is actuated by the rear brake lever and brake pedal.  At the time DrATV/Beatrice was out of stock of the spring so I decided to find another spring to do the job as I was more focused on getting something that worked and less on having be a picture perfect restoration.

Here is a picture from one of my other CT90's on what a stock spring looks like in this application.




My goal was to find a replacement spring that had the same stiffness as the stock spring and I ended up finding a spring on Amazon that had the right stiffness and looked like I could make it work. iIt was only $2.89 for two springs, so I decided to give them a try and added the springs to my next Amazon order.

Since the spring from Amazon was not the same length I had to add a section of bailing wire to get a final configuration that would fit in the same location as a stock spring.  Here is a picture on the new spring next to a stock spring.




I installed the new spring on my K1 CT90 and while it may not be pretty, it's been working great.



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

Link to page with listing of CT90 parts available on Amazon


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