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

Product Review - Memotronics ELF33-6 Turn Signal Flasher

I have a 1975 CT90 that I have never had the turn signals work all that well even though I replaced all the bulbs, picked up a new stock flasher, and cleaned the truncates signal switch and also went through and checked and cleaned all the grounds.

While I did get some improvement after taking all of the steps described previously, they still didn't work like they should, so I decided that I would take the next step and look at converting my turn signals to LED bulbs.

In making the change to LED's I knew it couldn't't be a straight swap of the bulbs only and that I would need to change the flasher to a configuration that wouldn't be dependent on the resistive load of the bulbs to cause the flasher to function like with a stock CT90 flasher.  So I figured I would do the upgrade in stages and first buy a new flasher that works with LED's and with a little searching on Amazon I found the Memotronics ELF33-6 Turn Signal Flasher that had good reviews.




Here is a link to the flasher on Amazon:


The flasher is different from a stock flasher in that it contains a ground wire that must be grounded to the frame of your CT90 and also contains an extra output blade that gives you the option to drive the turn signal indicator light in your speedometer directly if you so choose.

Since my goal at this point was to just change my stock flasher with this one to see if it made any improvement I decided to make a couple of simple modifications to the flasher.

The changes I decided to make were to add a change the connector on the end of the ground wire to a closed eye and also to add a short section of shrink tubing to the extra output blade that provides the optional method to power you indicator light.


Here is how the flasher looks after I made the changes.


The photo below is of the bottom of the flasher and shows the labeling of the blades that are used to connect to the wiring on your CT90.


The blade on the right with an "X" above it is what connects to the wire providing power to the flasher on you CT90 and that wire is generally black in color.

The lower blade that I have applied heat shrink tubing too and that has a "P" label to the right is the optional output from the flasher that can be used to drive the turn signal indicator lamp in your speedometer.  I may use this output when I finally change my bulbs to LED and I'll do an additional post at that time to explain how I run and hook up that wire.

The blade on the left with an "L" below it is the output that will actually drive your turn signal lights and that connects to the grey wire on you bike that was connected to your stock flasher.

Here is a picture with the flasher connected to the flasher wire on my CT90, but not not installed in its rubber holder and the ground wire not yet installed.


And here is a picture of the final installation with the flasher in its holder and the ground wire installed.


With the Memotronics ELF33-6 Flasher installed my turn signals now come one much quicker, flash a nice rate and are brighter then they were before, so it was a noticeable improvement.  The flasher isn't cheap at $17.99, but is needed for LED's which I plan on using in the future and a definite improvement over the stock flasher.  So if you are having issues with your turn signal lights on your CT90 you might consider using this flasher.



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




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