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

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.

Spare Gas Tank Helmet Lock Cover

The next part is the little cover that goes on the helmet lock on the spare gas tank bracket. Here are a couple of pictures of the cover and these were all printed using PTEG.





Here is a picture of the 3D printed cover next to a stock cover.


Here is a link to the .stl file at PrusaPrinters for the cover shown above


Replacement Skirts for K0 & K1 Steering Stem Nuts

The last two parts are the skirts that go on the steering stem nut on both the K0 and K1 versions of the CT90.

I have printed these skirts in both SainSmart TPU and PETG. I like the flexible chemical resistance of TPU and it also makes makes installing the skirts easier on the steering stem nut, but the PETG is closer to the hard plastic of the stock skirt, but does require more force when installing to overcome the detent feature I added on the skirt to secure it to the groove in the nut.

Here is a picture of the TPU printed skirt for a K1 next to the skirts from a stock Honda K1 CT90 steering stem nut.


Here is the link to the .stl file at PrusaPrinters for the skirt for the CT90 K1 steering stem nut.


The skirt on the K0 steering stem nut is very similar to the the K1, except the skirt is longer.


Here is a link to the .stl file at PrusaPrinters for the skirt for the CT90 K0 steering stem nut.


I hope you found this interesting and maybe this will spark a few similar designs from others who have 3D printers.


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


Comments

  1. UnknownApril 7, 2021 at 5:24 AM

    That is fantastically. Although I don't have 3d print or ct90 (have s90 and cl90), I appreciate your love for the ct90 and generosity for sharing the print files.

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