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Showing posts with the label Electrical

A new Batch of Honda CT90 and CT200 3D Printed Parts

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 I'm continuing to find and endless number of opportunities to utilize my 3D printer to make useful parts for my also endless number of CT90 project bikes that I am working on, so I thought I would share a few of the latest CT90 parts that I have designed and printed. All of the designs I share below, I first modeled using my ViaCad 2D/3D modeling program. Related Posts: More 3D Printed Honda CT90 Part Designs 3D Printed CT90 K1 Rear Airbox Snorkel CT90 K1 3D Printed Carb to Air Filter Boot A 3D Printed Valve Spring Compression Tool Speedo Light Bulb Socket Caps On almost every older CT90 I work on (I guess they are all old...) the little rubber caps on that cover and help hold in the bulbs on the base of the speedo are cracked, disintegrating before my eyes or are just missing. I modeled up both a short cap that has a hole for one wire and a taller cap that has a slot in its base that allows two wires to pass through as shown in the pictures below.

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.

Making a CT90 Internal Battery Bracket

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A common item that is missing on a lot of old Honda CT90's is the sheet metal bracket that helps cradle the battery in the opening on the side of the frame.  When the battery is removed there really isn't anything retaining the bracket, so it can very easily get left out and ultimately lost. You can sometimes find a used inner battery bracket on eBay, but lately when I have needed one I just make one as it is a very simple part and if you own a pair of tin snips and are a little bit crafty, you can make one in a few minutes. I made the attached drawing below to help others who may be in a situation where they need a inner battery bracket and would like to fab one up, but are looking for the overall dimensions of the bracket. The drawing does not have the dimensions for the depressions stamped into the original Honda designed bracket that add stiffness to the part, but the design on the drawing will give you a good functional part. I hope this post was helpful and ha

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 Wire Harness Detailed Information

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I recently had a number of CT90 main wire harnesses that I had to do some minor repairs on, so I thought I would do a post to share some detailed information that might be beneficial to someone else  working on their CT90's wire harness or maybe even someone wanting to build one from scratch. At the beginning of this post I'll explain some of the differences between the wire harnesses and then later in the post I will show the 1971 version of a CT90 harness completely disassembled so you can see what the individual wires look like and I will detail the process I follow to reassemble that harness back into an installable configuration. I also included detailed information on the measurements related to the harness and a table of how long each of the individual wires are in case someone decided they wanted to build a harness from scratch. Wire harness Differences Here is a picture of the three harnesses I was working on.

How to Test Your Honda CT90 or CT200 Rectifier

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One part on the CT90 that can degrade with time and also cause a variety of issues that don't seem to have an obvious cause is the rectifier. Links to Related Posts CT90 Rectifier Upgrade Basic Test of a CT90 Condenser Basic CT90 Ignition Coil Check If you have an old CT90 that you are trying to bring back to life, I would recommend just going ahead and upgrading your rectifier to a newer more modern solid state design and I made a post here on how to do that yourself .  But if you would like to use the rectifier that came with your bike or if you are really trying to restore your CT90 back to the original configuration, I'll show you how to test your rectifier to see if it is good or bad as it's really a very simple test to do.

How to Test Your CT90 Condenser

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One item often overlooked on a CT90 when trouble shooting is the condenser that is mounted with the ignition coil.  The primary function of the condenser is to prevent arcing at the ignition points when the points open which results in a spark being generated at the spark plug.  The condenser also to a lessor degree, helps maintain the spark at the spark plug. Links to Related Posts CT90 Rectifier Upgrade Basic CT90 Ignition Coil Check How to Test Your CT90 Rectifier Unlike CT90 ignition coils which can be 50 years old and still be in great shape, a condenser is really just a capacitor and capacitors can and will degrade with time, so its always worthwhile to take the time to test the condenser, especially if you have gone to the trouble to remove the coil/condenser assembly from your CT90. There are a couple of different ways you can check your condenser to determine if it is performing correctly. The first approach is to make a couple of subjective observations on your CT

Product Review - Harbor Freight Cen-Tech 7 Function Digital Multimeter

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One of the things I am known for is being a little cheap, so I don't have any problem taking advantage of the free items that Harbor Freight lists in their weekly adds.  One of the best free items they have is a low cost digital multimeter made by an outfit called Can-Tech. Here is a l ink to the Harbor Freight website where you can purchase the multimeter for around $4.49 if you don't take advantage of when then list it in their weekly add as a free item with any purchase. The multimeter comes with a basic set of instructions and a set of leads.

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;

How to check a Honda CT90 Ignition Coil

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How to Check a Honda CT90 or CT200 Ignition Coil Here is how I perform a basic check of the primary and secondary coils on a 6 volt CT90 ignition coil.  It's also a good idea to check your condenser while you have the coil assembly removed from your CT90 and I outlined how you can check your CT90 condenser at a post here at this link . The coil in the picture below is from a 1969 CT90 I picked up recently.  To check the primary coil I set my meter at the lowest setting to measure ohms and then connect the leads from the meter to the ends of the red and green wires and look at the reading. For this coil the reading is 3.3 ohms which is a little higher then the 2.3 ohms that is used as an upper limit, but should be just fine and is understandable given the coil is 48 years old.

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:

Figuring out wire colors on a CT90 stator when colors have faded or are not present

I have a 1971 CT90 I am working on and had an interesting electrical problem when I went to reattach the connector from the main with harness to the wires coming from the stator within the crankcase.  While the one wire for the neutral switch was correctly colored, the other three wires had a cloth overboard and did not have any color. The answer to how you can figure out what the colors should be on a stator with faded colors can be found by joining the Honda 6 Volt group on Facebook. In the file section of this group, John Pardue was kind enough to share a very simple test you can perform that will identify what wire is what color.  Here is a link to that file in that group, but you will most likely have to join which is very worthwhile as there is a lot of great information shared. The Pardue Brothers web site also has a lot of useful electrical related information and products to help with your CT90 restoration project. Helpful Links   (Shop Manuals, Wire Diagram, Model

Soldering a Wire

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A lot of times when you pick up an old CT90 some part of the wire harness may be damaged and need to be repaired.  While everyone who works in their shop or on bikes and vehicles knows how to solder to some degree, I thought I would provide a little electrical help and share how I go about soldering two wires together to repair a wire harness. The first thing I will say is that if you plan on bringing old CT90's back to life on a regular basis keep an eye out for old partial wiring harnesses and pick them up when you can.  Being able to salvage sections of wire in the right color and with a pin or socket at the end always makes for a much easier and cleaner repair. Some people may ask why not just use a crimp style butt connector to join two wires.  While a butt connector would work and be functional, it's not that clean and over the life of a bike I feel a nice soldered joint will hold up much better and less likely to give you a problem when your 10 miles up an old loggi

Honda CT90 or CT200 Rectifier Upgrade

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One of the most common items to find not working on old CT90's is the rectifier.  While a CT90 may start with a poor rectifier the rectifiers primary purpose is to take the alternating current from the genorator in the engine and convert that to direct current or voltage to charge the battery. If you are looking for information on how to test your existing CT90 rectifier, I made a post at this link that includes a step by step process for performing the test. While you could always purchase a new rectifier from any one of the outfits that carry replacement CT90 parts, one of the cheapest ways to go is to get a rectifier from Radio Shack that will only cost about four dollars, but does require some minor modifications to the wiring on your CT90.  If your looking to do a complete restoration by all means go out and spend the $15.00 to $30.00 for a replacement rectifier, but if you looking for a cheap but very robust solution, go down to your local Radio Shack and pick up the fo