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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...
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Aftermarket Honda CT90 Carburetor Drain Modification

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Relocating the Drain on a Aftermarket Honda CT90 Carburetor  I recently picked up an aftermarket carb for one of my CT90's off of eBay that is very similar in design to a Klein 556A carburetor except for one detail and that was the orientation of the drain fitting.  The drain fitting pointed straight down verses straight back and is a common issue with aftermarket CT90 carbs. Related Posts: Adjusting and Jetting a Honda CT90 Carburetor  Here is a picture with the old carb on the left and the new carb on the right.
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Honda CT90 and CT200 Gas Cap Teardown

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Honda CT90 and CT200 Gas Cap Teardown One of the most over looked elements of a Honda CT90 or CT200 fuel system is the gas cap used on the gas tank.  The gas cap plays a critical role and is designed to allow air to enter the tank and prevent a vacuum from forming as fuel is used by the engine as the CT90 uses a gravity feed fuel system.  While allowing the tank to vent air the gas cap also utilizes a labyrinth design to minimize the gas fumes that can escape from the tank. 
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Adjusting the Clutch on a Honda CT90

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I recently did the video at the link below on how to adjust the clutch on a Honda CT90.  The method I show in the video would apply to Honda CT200's and many other Hondas that have an automatic clutch. I hope you find the video helpful. Helpful Links  (Shop Manuals, Wire Diagram, Model Information, etc.) Link to page with listing of CT90 and CT200 parts available on Amazon
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Registering a Small Motorcycle in the State of Vermont

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UPDATE: Recently the State of Vermont eliminated the method I describe below for registering out of state vehicles, which is very  unfortunate (it really sucks!).  I don't know of another option that is comparable to what was available with Vermont, but West Virginia just implemented a new program that allows out of state businesses to register vehicles in that state, so hopefully in the future that process will be expanded to include out of state individuals also. Registering a Honda CT90 in Vermont This post shares in detail my experience in going through the process to register a Honda CT90 in the state of Vermont and then take that registration and use it to get a title here in the state of Washington.  I'll explain the process and then share actual copies of the my completed application and what I received back from the Vermont DMV. I have purchased a number of CT90's that didn't have a title and with the ones that I planned on keeping, I have gone through the...
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For Sale - The Original Made in the USA CT90, CT110 & CT200 Clutch and Headset Nut Tool

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As of 4/4/2022 I have decided that I will no longer make these clutch holding tools.  I have  provided a file of my design that would enable you to make you own copy of the tool here at this link . As of May 26th of 2021 I am now out of stock of my tool.  I am looking into making another batch, but the outfit I use to laser cut my tool has increased their prices significantly to where it may not be worth the effort to continue to try and sell my tools, especially given how cheap the knock off of my tools are coming out of China.  I'll update this post if I do end up producing another batch. I do want to thank everyone who has purchased one of my tools as it has been an enjoyable experience (except for the knock off's from China...) and I hope you have found the tools useful.  When working on a Honda CT90 two of the most frustrating things can be trying to hold the clutch basket while loosening the nut that holds it on and also loosening the special headset...
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Product Review - Memotronics ELF33-6 Turn Signal Flasher

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I have a 1975 CT90 that I have never had the turn signals work all that well even though I replaced all the bulbs, picked up a new stock flasher, and cleaned the truncates signal switch and also went through and checked and cleaned all the grounds. While I did get some improvement after taking all of the steps described previously, they still didn't work like they should, so I decided that I would take the next step and look at converting my turn signals to LED bulbs. In making the change to LED's I knew it couldn't't be a straight swap of the bulbs only and that I would need to change the flasher to a configuration that wouldn't be dependent on the resistive load of the bulbs to cause the flasher to function like with a stock CT90 flasher.  So I figured I would do the upgrade in stages and first buy a new flasher that works with LED's and with a little searching on Amazon I found the Memotronics ELF33-6 Turn Signal Flasher that had good reviews.
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CT90 Engine Exposed!

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I was finally able to get around to doing a project that I have been wanting to do for some time and that was to take a bunch of extra CT90 engine components and build an engine using cases that I had machined to end up with an engine that would enable you to see all of the internal components. Related Posts: CT90 Engine Reassembly CT200 Engine Reassembly Here is a picture of how the final engine turned out.
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