A Few More 3D Printed Parts for use on a Honda CT90

Here are a few more Honda CT90 3D printed parts I modeled and printed recently. Two of the designs were successful while one never got to the point of being acceptable enough where I would share the .stl files.

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

Throttle Hinge and Cable Holder

While working on one of my bikes recently I had the throttle assembly apart and it got me thinking about the feasibility of modeling and 3D printing the throttle hinge and cable holder. While these parts are not hard to find, they would make a nice challenging part to design and 3D print.

The first part I made was the cable holder which is a pretty straight forward part to design. The gray part below was printed with PLA and the orange one with PETG.

The holder actually worked well with a stock Honda throttle hinge. The loads on the holder are only the force of the carb slide spring and any friction in the cable assembly, so there actually quite low and the one I printed using some gray PLA has held up well and I haven't had any issues.

The throttle hinge was much more difficult and in the end I never did get a part I thought was acceptable. The picture below is of a throttle hinge and holder I printed using PETG.

While the throttle would work when both of my 3D designed parts were installed, the throttle would never return on its own without a little assistance. An unintended benefit was a very nice "cruise control" feature, but overall I didn't think it was acceptable. I did make several versions of the throttle hinge to try and reduce the friction down to an acceptable level, but was not successful at getting to a design that I thought was acceptable. The picture below is of several of those design attempts.

I found the throttle cable holder to work well but maybe not well enough to share .stl files at this point.

Carb Top Gasket

Another part that I decided to model up and print is the small gasket that goes inside the cap that retains the slide on the later model CT90 carburetors. I don't know why this gasket isn't included in carb rebuild kits, but I find it missing a lot of the time when I pick up a project bike, so I designed one up printed it using TPU which has some level of gas/fuel compatibility.