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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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A 3D Printed Rear Airbox Snorkel for use on a Honda CT90 K1

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One of the other parts I recently modeled and made a 3D print of is the rubber Snorkel/boot that attaches to the rear of the 1969 K1 CT90's airbox, and that resides in the battery compartment area in the frame when the airbox is installed. Here is a picture of the model I made in ViaCad 2D/3D. The following are a couple of photos of the snorkel that I printed using a flexible TPU filament next to the stock rubber snorkel that I removed from the airbox. The 3D printed snorkel has a nice snow fit when it is mounted to the cylindrical feature on the airbox. Here is the link to the .stl file for the snorkel at Prusaprints I hope you found this information useful! 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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A 3D Printed Carb to Air Filter Boot for use on a Honda CT90 K1

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I recently picked up my first 3D printer and now have an endless list of things I plan on making on the printer for my CT90's and other hobbies that I have. The 3D printer I picketed up is a Prusa i3 MK3S+ and I purchased it during a Black Friday sale Prusa had run last year.  I purchased the printer as a kit and it was a fun project in itself, but since I got the printer up and running, I've found it to be very capable and I am happy with my printer choice. One of my first projects was to design and print the a replacement for the rubber boot that goes between the carb and air filter on the 1969 CT90 K1.  I've owned sever K1's and I think I had only one where the boot hadn't fully degraded and wasn't falling apart like the one in the picture below. There are replacement boot/filter holders available, but they are almost $70.00 which is pretty pricey.  Most of the time the filter holder portion of the assembly is just fine and its just the rubber portion that ha...
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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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