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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CT90 Engine Exposed!

I was finally able to get around to doing a project that I have been wanting to do for some time and that was to take a bunch of extra CT90 engine components and build an engine using cases that I had machined to end up with an engine that would enable you to see all of the internal components.

Related Posts:
CT90 Engine Reassembly
CT200 Engine Reassembly

Here is a picture of how the final engine turned out.




Once I had the engine built up I decided to make a video and share it on YouTube.  In the video I show the engine running and also provide detail views showing the changing gears, operating the clutch, and how the piston and valves interact.  I also included some slow motion video that really provides insight on how the internals of a CT90 engine work.

Below is a link to the video on YouTube:



I hope you find the video interesting and informative as I enjoyed really enjoyed pulling together this project.

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

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


Comments

  1. UnknownFebruary 2, 2021 at 2:21 PM

    Thanks for taking the time to do this. Very interesting.

    ReplyDelete
  2. UnknownSeptember 16, 2021 at 6:22 AM

    All of your videos and information are done very well and extremely informative.

    ReplyDelete

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