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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Checking Your Rear Wheel Hub Rubber Dampers to See if They Are Worn

Something that is often overlooked when someone picks up a used CT90 is the condition of the rubber dampers in the hob of the rear wheel.  These rubber dampers are important in that they help reduce the loads generated in the drive system when they are in good condition and can generate significant loads in the drive system if they are worn.

You can do a basic check of the condition of these dampers without having to disassemble anything on your CT90 and it really only takes a few seconds to do.  I have prepared the video below to show a CT90 which have dampers in good condition and all a CT90 where the dampers are worn and need to be replaced.







I will provide another post in the future on how you would go about replacing these dampers if they worn.

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

Link to page with listing of CT90 parts available on Amazon