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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For Sale - The Original Made in the USA CT90, CT110 & CT200 Clutch and Headset Nut Tool

As of 4/4/2022 I have decided that I will no longer make these clutch holding tools.  I have provided a file of my design that would enable you to make you own copy of the tool here at this link.

As of May 26th of 2021 I am now out of stock of my tool.  I am looking into making another batch, but the outfit I use to laser cut my tool has increased their prices significantly to where it may not be worth the effort to continue to try and sell my tools, especially given how cheap the knock off of my tools are coming out of China.  I'll update this post if I do end up producing another batch.

I do want to thank everyone who has purchased one of my tools as it has been an enjoyable experience (except for the knock off's from China...) and I hope you have found the tools useful. 

When working on a Honda CT90 two of the most frustrating things can be trying to hold the clutch basket while loosening the nut that holds it on and also loosening the special headset nuts on the front forks.  Like most people I have found ways to get the job done and even made a post about using plumbers tape to hold the clutch basket, but I really wanted a nice tool since I plan on working on CT90's as a hobby for a long time, so I decided to design and produce my own.

 After a couple iterations, I ended up with the tool design shown in the picture below that works on a CT90 and CT200's in addition to some other Honda models, and I am currently selling them on eBay for $26.00 plus $5.35 for shipping.  


Here is a picture of the tool being used on a CT200 engine.

Instead of just having the tool be good for holding the clutch basket, I added some openings on the handle and one edge of the tool that can be used to loosen the headset nuts on the front forks of a Honda CT90.

 The largest opening on the handle fits the lower headset nut found on most K2 and newer CT90s and fits as shown below.

The smaller opening at the end of the handle fits the smaller upper headset nut on most K2 and newer CT90's in addition to the headset nut found on K0 and most earlier CT90's and fits as shown below.

And last, but not least, I added a feature along the edge of the tool that fits the headset nut on the K1 version of the CT90 and is shown in the pictures below. 



Again, if you are interested in picking up one of these tools I am selling them on eBay at this link.  I currently am selling these within the USA, but due ship outside the USA using the eBay global shipping program.

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


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