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 use on a Honda CT200

 Recently someone on my Facebook page commented about a post I did where I shared information about a 3D printed air intake boot I designed for K0 CT90's and asked if I could design one for the CT200 and even offer to let me borrow an old CT200 air boot that had some issues to use to help construct a design.

Related Posts: A 3D Printed Honda CT90 K0 Air Intake Boot

Well I've actually had an old CT200 air boot on my desk for over six months as creating a 3D printed design has been on my list of things to do for quite some time. With the encouragement from the comment I received on Facebook, I sat down and created an initial design using my ViaCad 2D/3D Pro modeling software that I'm pretty happy with.

Here is a picture of the 3D printed design I came up with and printed next to the stock Honda CT200 air boot.

The design is actually composed of three pieces like the stock design is. There are two end pieces that were printed using SainSmart TPU and a center sleeve that connects the two end pieces that was printed using PETG.



I kept the initial design simple and didn't include the raised rings that help to retain the hose clamps at each end of the boot so I wouldn't have to deal with the printing issues associated with overhangs, but may look to include them on a future design.

When I did print this design I tilted the parts  at the base which required supports so that the end of each boot had overhangs that didn't require supports as shown below.


I don't have a completely assembled CT200 at the moment to mount the boot too (I need to get back to building bikes...), but I did take one of the frames I have and the top of one CT200 carb that is on my bench waiting to be rebuilt and dry fit them as shown below.


If you would like to try and print this CT200 air boot for your bike the .stl files are available to down load at Prusa Printables here at this link.

I hope you found this post useful and I would like to hear how the design works out for you if you print one up for your bike.


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


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