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Showing posts from January, 2021

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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A 3D Printed Rear Airbox Snorkel for use on a Honda CT90 K1

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One of the other parts I recently modeled and made a 3D print of is the rubber Snorkel/boot that attaches to the rear of the 1969 K1 CT90's airbox, and that resides in the battery compartment area in the frame when the airbox is installed. Here is a picture of the model I made in ViaCad 2D/3D. The following are a couple of photos of the snorkel that I printed using a flexible TPU filament next to the stock rubber snorkel that I removed from the airbox. The 3D printed snorkel has a nice snow fit when it is mounted to the cylindrical feature on the airbox. Here is the link to the .stl file for the snorkel at Prusaprints I hope you found this information useful! 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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A 3D Printed Carb to Air Filter Boot for use on a Honda CT90 K1

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I recently picked up my first 3D printer and now have an endless list of things I plan on making on the printer for my CT90's and other hobbies that I have. The 3D printer I picketed up is a Prusa i3 MK3S+ and I purchased it during a Black Friday sale Prusa had run last year.  I purchased the printer as a kit and it was a fun project in itself, but since I got the printer up and running, I've found it to be very capable and I am happy with my printer choice. One of my first projects was to design and print the a replacement for the rubber boot that goes between the carb and air filter on the 1969 CT90 K1.  I've owned sever K1's and I think I had only one where the boot hadn't fully degraded and wasn't falling apart like the one in the picture below. There are replacement boot/filter holders available, but they are almost $70.00 which is pretty pricey.  Most of the time the filter holder portion of the assembly is just fine and its just the rubber portion that ha
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