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Showing posts from October, 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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Make Your Own CT90 Clutch Holding Tool using My Tool Drawing

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While I enjoyed making and selling my design of a CT90 clutch holding tool that I shared in my original post at the link below, with all the latest price increases it just didn't make sense from a time and cost standpoint to try and compete with the knock-off's of my tool coming out of China. My Design of a CT90 Clutch and Headset Nut Tool I been receiving a number of request from people asking me to make another batch of tools which I don't plan on doing.  Since I'm not going to make any more tools I think the next best thing I could do is provide a copy of the .dxf file that I created and used to produce my tool, so anyone can order a tool at their own cost and personal use, or to make to sell to others.  People can order tools from the laser cutter outfits at the links below or from any other laser cutters that people may be aware of. Disclaimer: I want to be clear that I am not making any guarantees that if you use my .dxf draw
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A 3D Printed Air Intake Boot for a use on Honda CT90 K0

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 I actually created the model of the CT90 K0 air intake boot and 3D printed a part some time ago, but I never shared the .stl files so I decided to make a short post to provide links to those files at Prusaprints. While this air intake boot isn't to hard to find, I decided to model and print it as an overall effort to develop models for all the early CT90 and CT200's so people have an option over buying a very high priced air intake boot or using a section of radiator hose. Here is a picture of my 3D printed part next to a stock Honda air intake boot for the CT90 K0.
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