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Showing posts with the label Assy

Honda CT200 Step by Step Engine Reassembly Guide

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I recently picked up a CT200 that wasn't running, but seemed to be in decent shape where the engine would turn over and had signs of good compression.  I had rebuilt one CT200 a couple of years ago and sold the bike and since that time I started this blog and because I have had such a good response with the post I did on reassembling a CT90 engine, I decided to take the time to go through the engine of my new CT200 and document the reassembly in this post.  Another reason I am going through this engine is that this may end up being a bike I will keep for a while and it seems like all old CT's that I pick up have slime in the engine and the clutch will end up slipping sooner or later, so now is as good a time as any to tear it apart, clean, and then reassemble the engine to avoid any problems in the future.  I plan on taking the same approach I did with the CT90 engine reassembly post where I document in detail the step by step process on how everything goes back together in ca

Listing of Honda CT90 Parts available on Amazon

I have mixed feelings about Amazon as in some respects they are really taking over the world, but in the end they have become the simplest and quickest way for my family and I to get what we need. While Amazon may not always the cheapest place to buy things and some of their third party sellers are kind of questionable, I have generally always had a good experience purchasing item from Amazon. Since I tend to make a lot of my purchases on Amazon, I have also started to buy much of what I need for a number of the Honda CT90 projects I am working on. While Amazon may not have many of the small unique CT90 parts like what is available on DrATV, they do have most if not all of the general parts you end up replacing on a CT90 project bike that has sat on the side of someones barn for the last twenty years. Since it's not always easy to find things on Amazon, I decided to make a page on my blog at the link below where I have collected together a number of the CT90 related items pe

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 Clutch Pack Assembly Detail Build-up

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All CT90's at some point in their life will have the clutch start to slip and require the clutch assembly to be rebuilt. Links to Related Posts: CT90 Engine Reassembly Making a Low Cost Clutch Holding Tool for Your CT90 Shift Drum Stopper Replacement When Doing a Clutch Rebuild I have one CT90 where I could tell the clutch was starting to slip because the kickstarter just wasn't turning over the engine like it used too, so I decided to rebuild the clutch.  I don't normally tear the whole clutch pack apart when I install new clutch disks, but when I opened up the cases on this bike I found a slick black slime everywhere, so I decided to disassemble the entire clutch assembly (and actually the rest of the engine...) to make sure I cleaned everything out.  Since I was tearing everything apart I thought I would document how everything goes back together in this post in case others were interested in knowing what the inner parts of the clutch pack look like. I have als

The Basic Sequence and Process to Set or Adjust your Honda CT90 Timing

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The primary goal in setting the timing on your CT90 is to have a spark occur at the spark plug due to the points opening up when the piston is at the ideal position before top dead center with both the exhaust and intake valves closed. In the write up below I will share how I go about adjusting the timing on a CT90 and I will be doing this on an engine setting on my bench, but everything I share below is equally applicable for an engine mounted on a bike. Related Posts Cut away of a CT90 Engine - CT90 Engine Exposed! My Process to get a CT90 that won't Start to Start Adjusting and Jetting a CT90 Carb CT90 Engine Assembly Honda CT200 Engine Reassembly Building a static timing light from a free Harbor Freight LED Light To set the timing on a CT90 there are four main steps: 1. Making sure that the timing chain sprocket that drives the overhead cam is installed at the correct position on the timing chain relative to the crank/piston assembly 2. That the valves are adjuste

Honda CT90 Sub-Transmission Reassembly

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Updated 11/11/17 to correct the section on installing the high range gear where I left out the step to install the splined washer and retaining ring after the high range gear is installed. I was building an engine for a project CT90 and was reassembling the sub-transmission and thought I would capture the build of that assembly here as a post for future reference and for anyone else to utilize if they happen to be working on this portion of a CT90's engine assembly. Here is an overall picture of all of the parts that go into the sub-transmission assembly

Honda CT90 Spark Advancer Assembly Build-Up

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When someone picks up their first CT90 (and they will soon find its hard to own just one...) and its a barn find that doesn't want to run, one of the things they tend to overlook in trying to get the bike running is the spark advancer.  On most older CT90's that haven't been run in a number of years, the spark advancer is usually frozen solid due to corrosion or dried grease and this prevents the bike from running well at anything other than idle. I was in the process of building up an engine for one of my project bikes and had to go through and clean up the spark advancer, so I thought I would share some detailed photos of the spark advancer assembly and the process for building it back up. While I don't plan on providing any details on how to get an old spark advancer assembly apart and clean, I will offer up that solvent, penetrating oil, and a lot of patience will eventually do the trick. Here is a shot of a clean and assembled CT90 spark advancer.  There are

Step by Step Instructions for the Reassembly of a Basic Two Screw Honda CT90 Carburetor

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Anyone who ever buys a CT90 will at some point in owning the bike have to disassemble, clean and reassembly a CT90 carburetor.  The focus of this post is really just on the reassembly of the carburetor.  So after you have disassembled and cleaned all of the parts of your carb and picked up a new gasket set (or reused your old gaskets) you're ready to reassemble your carb.  The terminology I use in my descriptions below is my own and may not be exactly the same as what is called out in a Honda manual, but I hope it is clear enough for you to understand which parts I am working with. Link to related Posts: Adjusting and Jetting a CT90 Carb With respect to a new gasket set, I generally wait until I have disassembled the carburetor before I make the decision to buy a new gasket set.  I have found that most of the time the condition of the old gaskets are just fine and I'll apply a little RuGLYDE to freshen up the elastomeric parts and seals and just really make sure all of t

Trials and Tribulations with Rebuilding CT90 Speedo's

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I currently own a number of CT90's and a few of the bikes have a loose indicator light lens in the speedometer assembly that I need to fix.  I have never opened up a CT90 speedo, but I have speedo's off of three 1969 CT90 project bikes I picked up a few months ago that all have loose indicator light lenses that needed to be fixed, so I figured their as good as place as any to start building my knowledge and experience.  I'll also admit that things didn't go as well as I would had liked and I definitely have learned a thing or two that I won't forget anytime soon. Here is a shot of the three speedo's off of my 1969 CT90's that I will be rebuilding;

1970 CT90 Turn Signal and Horn Button Brakedown and Assembly

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I was going through and cleaning up the left lever lever assembly that retains the turn signal switch and horn button and thought I would share a few shots of the detail parts and how it is assembled. If you are missing or have a rusted detent ball I have found that a 5/32 ball bearing that you can get at a bicycle shop of good hardware store is a good substitute. Here is an overall shot of all the components:

1970 CT90 Headlight Switch Breakdown and Assembly

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I was going through and cleaning up the right lever lever assembly that retains the throttle grip and also the headlight switch and thought I would share a few shots of the detail parts of the headlight switch and how it is assembled. Here is an overall shot of all the components: