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...

Honda CT200 Engine Fasteners

I put this post together as reference for the length of the fasteners used in a 1964 Honda CT200 for assembling the engine cases and covers, but also for some of the fasteners used internally within the engine.

Screw size convention
Example: M6 x 1.00 x 20
M6 - is the diameter of the screw, which in this case is 6mm
1.00 - is the thread pitch of the screw in threads per millimeter
20 - is the length of the screw, which in this case is 20mm

On a few items like pins and a washer I provide dimension in inches instead of mm.


Clutch Cover Screws
Four  M6 x 1.00 x 20



Clutch Cover Side Case Screws
Three  M6 x 1.00 x 60
Five    M6 x 1.00 x 50
One     M6 x 1.00 x 40



Clutch Basket Cover Screws
Two  M5 x 0.8 x 11 Countersunk Head




Shift Ratchet Pins on Shift Drum
(dimensions are in inches)
Four pins 0.475 long and 0.055 diameter with head
One pin 0.100 long and 0.055 diameter with head
Each pin has a head that is 0.106 long and 0.194 diameter




Center Case Screws
Seven  M6 x 1.00 x 60
One     M6 x 1.00 x 45
One     M6 x 1.00 x 40



Oil Screen Cover Bolts and
Four  M6 x 1.00 x 24

Small Drain Bolt on Left Center Case
One  M6 x 1.00 x 8
One  M6 Aluminum Crush Washer




Generator Side Cover Screws
Two  M6 x 1.00 x 28
Two M6 x 1.00 x 22



Generator Stator Screws
Three  M6 x 1.00 x 28




Oil Pump Screws
Four  M5 x 0.8 x 18
Two  M5 x 0.8 x 10




Spark Advancer Bolt
One  M8 x 1.25 x 68




Timing Cover Screws
Two  M5 x 0.8 x 17 Countersunk Head




Drive Sprocket Retainer Screws
Two  M6 x 1.00 x 8




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

Link to page with listing of CT90 and CT200 parts available on Amazon



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