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 Air Intake Boot for a use on Honda CT90 K0

 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.


The part was a challenge to model, but eventually I was able to create a model that was very close to the stock Honda part.

Printing was also a little bit of a challenge, but once I figured out I needed to print it in the orientation shown below and use supports it printed fairly easily.


I printed the air intake boot using TPU which seems to work well.

Here are the links to the .stl files:

Here is the link to the .stl file for the CT90 K0 air intake boot at Prusaprints


 I hope you found this information useful.


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