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

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.





I hope you found this information useful!

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

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