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Showing posts from August, 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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Honda CT90 Wire Harness Detailed Information

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I recently had a number of CT90 main wire harnesses that I had to do some minor repairs on, so I thought I would do a post to share some detailed information that might be beneficial to someone else  working on their CT90's wire harness or maybe even someone wanting to build one from scratch. At the beginning of this post I'll explain some of the differences between the wire harnesses and then later in the post I will show the 1971 version of a CT90 harness completely disassembled so you can see what the individual wires look like and I will detail the process I follow to reassemble that harness back into an installable configuration. I also included detailed information on the measurements related to the harness and a table of how long each of the individual wires are in case someone decided they wanted to build a harness from scratch. Wire harness Differences Here is a picture of the three harnesses I was working on.
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