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Showing posts from February, 2026

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 Cl...

A 3D Printed Functional Front Air Filter Housing for use on a Honda CT90 K2 and Later

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One thing I have had on my list of things to do is to design a functional front air filter housing that can be 3D printed to go along with the rear air filter housing I designed several years ago and that I made a post on here at this link .   Related Posts:  CT90 K2 and Later Air Filter Housing 3D Printed Seal  After some effort I was able to create a functional 3D printed design of the front portion of the air filter housings used on K2 and later CT90's.  The picture below is of the final configuration that I designed and then printed (in orange) and installed on one of my bikes along with my previous rear air filter design (in grey).