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Showing posts from February, 2018

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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A Way to Soften Up Old Rubber CT90 Motorcycle Parts That Works Well

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One of the most frustrating things I have found when working on old CT90's is dealing with the rock and rubber boots at each end of the air cleaner.  When these rubber parts a old, hard, and stiff it can make it a real pain to get in or remove the air cleaner and get access to the carb.  When I first started working on CT90's I found the use of a hair dryer to heat up these rubber parts which made them soften up, but it was only temporary and once they cooled down they became rock hard once again. I didn't want to buy all new rubber parts for my CT90's as I have too many bikes and I get more enjoyment out of doing things myself and learning about different techniques, so I went on a quest to see if there was a good method to permanently soften old rubber motorcycle parts and I came across the following four YouTube video's: Video 1 (I really enjoy all of Ichiban's videos), Video 2 , Video 3 , and Video 4 . After looking at the above videos and actually a
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