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 Cl...
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Using a VW Lug Bolt as a Puller to Remove a Honda CT90 Generator Rotor

I had read online that the wheel lug bolt from a VW had the same thread as what is in the center of the generator rotor on a Honda CT90 and makes a good tool for removing the rotor, so I thought I would give it a try.


I went on to Amazon and found a VW lug bolt and it was only $5.00, so I added it to an order I was making.  The VW lug bolt has a 14 x 1.5 mm thread which is the same as what is in the inside diameter of the generator rotor that is intended to be used for the rotor removal.


I received my order from Amazon and instead of receiving just one bolt I actually received a box with 20 lug bolts, so I don't know if Amazon made an error, or that you actually get 20 lug bolts for $5.00, but in the end I now have a few extra lying around my shop.


To use the VW lug bolt to remove your CT90 generator rotor you simply thread the lug bolt into the threads at the center of your generator rotor and then restrain your crank so it cannot rotate by using your clutch holding tool or by some other means.



Then simply apply torque to the VW lug bolt and it will jack your generator rotor off of the end of the crank shaft.


The VW lug bolt worked well for me, so it you are looking for an inexpensive tool to help you remove your CT90 generator rotor you might consider giving it a try.

Helpful Links (Shop Manuals, Wire Diagram, Model Information, etc.)
Link to page with listing of CT90 parts available on Amazon




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