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Showing posts from July, 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 Piston Holding Tool for a Honda CT90

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Maybe I'm just getting old, but when I am rebuilding a CT90 engine one of the things that can be a little bit of a pain is holding and compressing the rings on the piston when you're sliding on the cylinder.  Sometimes its not to bad, but other times I fuddle around before I can get it to all come together. Related Posts: CT90 Engine Reassembly I decided to design a removable tool that I can 3D print, that helps support the piston, so I can focus more on compressing the rings while installing the cylinder.  The tool is also nice as a way of closing off the opening to your crankcase to keep dirt and crud out if your engine is going to have the cylinder off for an extended amount of time. Here is what the tool looks like installed.
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More 3D Printed Parts for Use on Honda CT90 & CT200 - Hard to Find K1 Parts and Others

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I'm continuing to find and endless number of opportunities to utilize my 3D printer to make useful parts for my CT90 project bikes, my fishing float tube, and other hobbies that I have.  I thought I would share a few of the latest CT90 parts that I have designed/modeled and printed. All of the designs I share below, I first modeled using my ViaCad 2D/3D modeling program. Related Posts: A New Batch of Honda CT90 and CT200 3D Printed Parts More 3D Printed Honda CT90 Part Designs 3D Printed CT90 K1 Rear Airbox Snorkel CT90 K1 3D Printed Carb to Air Filter Boot A 3D Printed Valve Spring Compression Tool CT90 K1 Front Fork Cover Side Reflector Base On almost every older CT90 I work on (I guess they are all old...) the little rubber caps on that cover and help hold in the bulbs on the base of the speedo are cracked, disintegrating before my eyes or are just missing. I modeled up both a short cap that has a hole for one wire and a tal
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