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

CT90 & CT200 Components Available on Amazon

CT90, CT110 & CT200 Parts and Components Available on Amazon

I don't know about you, but about 90 percent of all my online purchases are done on Amazon.  While there are a number of great places to purchase CT90 parts online like DrATV/Beatrice Cycle (and I still buy parts from DrATV), I am on a regular basis making an order on Amazon and usually will add CT90 stuff to the order.

While Amazon may not carry the difficult to find CT90 hardware, they do carry much of the basics needed to bring a old CT90 back to life.  While Amazon may have just about everything, they don't always make it easy to find what you are searching for so I thought I would put together this page as a quick reference to a majority of the CT90 parts available on Amazon.

Also with Amazon you really need to spend the time looking at the information included with each part to make sure that it is going to fit your application. Sometimes the pictures included don't match the part description, so take your time and read the description.
I have tried to group the parts under common themes and include a link to the Amazon page.

Engine Components

4 into 1 NE Brand Complete Gasket Set plus case seals - Honda CT90 (Note: this set does not have gasket for dual range transmission cover)

Athena P400210600092 Top End Gasket Kit

Vesrah Complete Gasket Set - Honda CT90 VG-168

Athena Complete gasket set HONDA CT90 K1 / K2 / K3 / K4 66-79 P400210850092

Clutch Side Cover Gasket

Stator Cover Gasket

Engine Oil Seal Kit

Standard Piston Ring Set for CT90

CT200 Engine Gasket Set

Replacement Valves for a CT90

Valve grinding compound

Stainless Allen Screw Bolt Set for CT90 Cases

Stainless Allen Screw Bolt Set for CT200 Cases


No. 1 JIS Crosshead Hex Drive Bit

No. 2 JIS Crosshead Hex Drive Bit

No. 3 JIS Crosshead Hex Drive Bit

JIS Crosshead Hex Drive Bit Set

Hozan JIS-4 Screwdriver Set

In case you have an engine that won't seal with a paper gasket alone the following sealants will help
Yamabond 4

ThreeBond 1184

Engine Oil

Clutch Lock Nut Tool

Generator Rotor Puller Tool

D8HA Spark Plug

Splice that allows you to add new spark plug cable to your coil

Nippondenso Points and Condenser Set

Kokusan Points Set

Kokusan Points and Condenser Set

CT200 Points

Contact Cleaner

Genuine Honda Carburetor Gasket Set for CT90 - Gaskets only and you need to check for which models it supports, but has the screen and fuel selector gasket.

Genuine Honda Carburetor Gasket Set for early 1969 K1 CT90 - Gaskets and fuel screen only

KIPA CT90 Carburetor Rebuild Kit for Honda CT90br />
Carburetor Rebuild Kit

66-68 Honda CT90 K0 and earlier Models Carb Rebuild Kit, but you may want to take a look at DrATV or Out West to see if there kits are cheaper

CT90 K1 Carb Rebuild Kit for early K1 that used an o-ring for the bowl seal. You may want to check DrATV or Out West to see if they have this kit at a lower cost

Keyster Carb Rebuild Kit for early 1969 K1 with o-ring for the bowl seal

CT90 K1 Keyster Carb Rebuild Kit for Late 1969 Model

Carburetor Rebuild Kit - 1970 thru 1975

Carburetor Rebuild Kit - 1978 thru 1979

Deluxe Carburetor Rebuild Kit with Float - 1978 thru 1979

Keyster - 1.7 Float Needle Valve Assembly

Option 1 - Carburetor Intake Manifold Insulator

Option - 2 Carburetor Intake Manifold Insulator

Genuine Honda 5.5 mm Fuel Line

Honda 46mm Carburetor Clamp

Honda 56mm Carburetor Clamp

Berryman Carb Cleaner

Berryman Carb Cleaner in a can so you can soak your carburetor

Early Model CT90 Air Filter Element

Honda CT90 Air Filter Element

Honda CT110 Air Filter Element

UNI Air Filter Element for the CT90

Straight Style Aftermarket Kick Start Lever

Curved Style Aftermarket Kick Start Lever

CT90 and CT200 Kick Start Arm Rubber

Aftermarket Ignition Switch

6 Volt Sealed Beam Headlight - Check fitment for your year of CT90

6 Volt 3 Watt Speedo/Instrument Light Bulb 5 Pack

A good basic 6V Turn Signal Flasher to replace a stock Honda Flasher

Memotronics ELF33-6 Turn Signal Flasher Relay, LED Compatible, 3 + Ground Wire Prongs, 6 Volts
This is not a direct stock replacement, but I found that it works great. See my post on this relay if interested in using on your CT90.

Fire Power 6N5.5-1D Battery and Electrolyte

Yuasa 6N5.5-1D Battery (you'll need to provide electrolyte)

Battery Electrolyte Pack

Six Volt Battery Charger

Exhaust Gasket

CT90 Exhaust Pipe - 1976 - 1979 Honda 183A0-102-650

Chrome CT90 Exhaust Pipe - Check fitment for your CT90

CT110 Exhaust Pipe - 1980 - 1986 Honda DP 0433-403

CT200 Exhaust Pipe

Front Brake Cable for 1976 thru 1979 CT90

Brake Shoes
Front and Rear Brake shoes for K1 - K3 CT90

Front Brake Shoes for 1976 -1979 CT90

Front Brake Shoes for 1976 - 1979 CT90

Front Brake Shoe for 1975 CT90

Bearings Rear Wheel

Individual sealed wheel bearings - Size 6301 12mm/37mm/12mm

Here is another bearing optionn

Bearing set for Front and Rear Wheel

Chains and Sprockets

Drive Chain for CT90 K1 - K5

Chain Wax

Chain Degreaser

Rear Axel Chain Adjusters

Option 1 - Shinko SR241 2.50x17 Tire

Option 2 - Shinko SR241 2.50x17 Tire

Set of Tires and Tubes for CT90 and CT110

Set of Shinko SR241 Tires, Tubes for CT90 and CT110

Kenda 257/300-17 TR-4 Motorcycle Tube

IRC Rim Strips for 17" Wheels

CT200 Aluminum Rims

CT200 Black Aluminum Rims

Steering Fork Bearing Set - Check fitment for your bike

Honda Front Fork Seal (this looks to be a single seal and not a set)

Front Fork Seals

Option 1 - Swing Arm Bushing

Honda Rubber Foot Pegs

Reproduction Tail Light Lens - Check Fitment for your bike

Reproduction Tail Light Lens - Check Fitment for your bike

Reproduction Tail Light Lens - Check Fitment for your bike

Reproduction Tail Light Lens - Check Fitment for your bike

Reproduction Tail Light Assembly - Check Fitment for your bike

ed Reflectors for License Plate Bolts

CT90 and CT110 Downtube Cover

Honda Seat Assembly

8mm Right Hand Thread Mount Generic Mirrors

8mm Right Hand Thread Mount Generic Mirrors

Generic Tool Kit #1

Generic Saddle Bags for your CT90, CT200, or CT110

Book about Honda 90 Motorcycles

Metal Rescue Rust Remover

Evapo-Rust Rust Remover


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