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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 Cl...
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More 3D Printed Part Design that can be used on a Honda CT90

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I've been having fun modeling a number of Honda CT90 parts and then printing them on my printer. and I thought I would share them here along with links to .stl files in case others wanted print parts for their own individual use. To create all of the parts I share below, I first created a 3D model in my ViaCad 2D/3D modeling program. Ignition Switch Access Hole Plug The first part I will share is my design for the rubber plug that goes in the hole where the wires from the ignition switch exit. I have printed this plug using SainSmart TPU filament which is flexible enough so the plug can be installed, but it is not near as flexible as a new stock rubber plug, but much more flexible than a 50 year old rock hard stock rubber plug. Here is the link to the .stl file at PrusaPrinters for the ignition hole plug.
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