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

Make Your Own CT90 Clutch Holding Tool using My Tool Drawing

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 drawing that you will get a good part from the the laser cutters I've listed below or any other laser cutter that you may use and that you use this file at your own financial risk.


My Clutch Tool .dxf Drawing

With the disclaimer out of the way, here is the the link to the Clutch Tool V4F.dxf  file for my clutch tool. The .dxf file format is what most of the laser cutters require for any parts that you would like them to cut.


Laser Cutting Suppliers

I have been using the two laser cutting sources below for most of my orders:

OSH Cut - Seems to have good pricing (before COVID), especially on larger quantities 

Send Cut Send - Has a number of options and can have good prices during special offers they send out

To order a part from either of the above companies you would have to log in and create an account.  You would then up-load the .dxf file I shared above, select the material and quantity, and then the website should provide you a quote/cost of how much you order will be.

For the parts that I was selling I used 0.135" (10 Ga.) thick,  A1008 Cold Rolled Steel for the material.

Each of the above laser cutting companies offer a variety of materials that they can cut parts from, so if you wanted try a different material or thickness you're free to do so, but you'll also see a corresponding change in the price on your order.

The parts you receive back from the laser cutter will have burrs on one side that you'll need to remove.


I hope you found this information useful.  If you do use my drawing and have success (or not...) with a particular laser cutter supplier, then it would be great if you could leave a comment below so others can utilize or avoid that same resource.


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






Comments

  1. Hello...I'm a long term me fan of the trail 90 and both a 64 and 65 models. Am wondering if anyone knows of an engine rebuilder close to Charleston WV? Shipping costs are quite prohibitive right now. Thnx. Tom

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  2. This tool is the bees knees ! I was a Honda Mechanic back when CT90's were current bikes and I love this tool, THANK YOU for making the original batch and for sharing the files .

    Apparently me new laptop can once again get me into this fantastic site .

    -Nate

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