[TemeculaTim]

Thanks Semlin, I will soon be starting a restore of my two Z50's and this info will be helpful.

Tim

[yooper]

I recently bought a stainless steel bolt replacement kit for my CT90.

Source: Burks Motorsports, Motorcycle Parts

Here is what is in the kit.

Most of the bolts are 6mm x 0.1 pitch. All are Allen head.

• 5 45mm bolts, 25mm is threaded
• 14 40mm, 25mm is threaded
• 1 30mm
• 12 25mm
• 3 20mm
• 3 15mm tapered head
• 2 15mm tapered head 5mm x 0.8 pitch

How I measured:



The entire kit:

[semlin]

awesome bolt list. the diameters and pitches match my measurements of individual bolts.

thanks yoop

[semlin]

a link to a restorer site with some useful information on resto tricks

Marbles Motors

[semlin]

link to modern PPG paint formulas for some honda colours

Honda ATC90 / US90

[semlin]

some possible modern paint codes for the honda scarlet and trim cloud silver taken from a forum dedicated to restoring 60s era honda twins. The scarlet was also used on the cl72/cl77 models

Originally Posted by hond305 forum

Red:
EMO/LM likes Imron 6543UM, and this actually crosses to three different PPG codes, 71977, 71650, and 74359. The shop only had the chip for PPG 71650, and I compared it out in sunlight to the original part from my bike and it was a match, by all eyes in the area that saw it, including mine. The suggestion of Ditzler DPL71654K (from the Silver book?) crosses to PPG 71654, but it looked a little darker. It would probably look good on the bike, too, but I think the 71650 would be closer to stock.

Silver:
EMO's Imron 45040U crosses to PPG 33283, and while they didn't have a chip for this, the formulation is a very basic medium silver made up of black and silver flake, so should make a good match

edit: looks like that silver is for trim pieces like fenders/battery covers, not for engine or fork parts

[semlin]

site for getting new sprockets and chains.

SPROCKET SPECIALISTS-Sprockets for all makes of bikes.

[Hugh Heifer]

Received my shifter and foot peg mount to replace those bent on my '70 90 tonight. Stoked to work on it. Hope to do some on Saturday.

[Hugh Heifer]

The 90 is running. All brakes replaced, rear foot pegs, front foot pegs, did some re-wiring, painted all the plastic as recommended on the Beatrice site with some rattle can gray, took two links out of the chain and replaced the rear sprocket. Replaced all the cables and cleaned the throttle. Changed the oil and replaced some buggered hardware. Adjusted the clutch. I think it all cost me about $200 from the Beatrice site. Sweet.

[gladly]

Originally Posted by semlin

ct90 valve adjustment and clutch replacement write ups

| Adjusting Valves

http://www.ct90.net/ct90.nsf/84c3aaced2522fc880256a9e003b8911/cff028e88db9bfa480256a9e007e97e5!OpenDocument

horizontal honda engine valve adjusting video here

IIRC it's windows media player format, some folks had trouble viewing it

it's on youtube, too (lower quality IIRC)
try this:


or this: YouTube - How To: Adjust your valves

[Jman]

Honda manuals can be found here:

honda repair manuals

[Jman]

I had some snowy weather on Monday, so I decided to take a crack at swapping the front tire, tube, and rim strap. The old Yokohamas are the original tires, and the rubber was quite non-gummy. Not ideal for road use.



I had purchased some Michelin Gazelles 2.5 tires for the bike, since it probably would see about 90% street and only 10% unpaved.

It was about as easy as changing a tire on a mountain bike. The old tire levered off really easily with the tire irons, and I didn't even need a rim protector.

To put the new stuff on, I first put on the rim strap, then I put the tube into position inside the new tire, and started putting the tire on at the part where the valve passes through the rim. Remember to take that first nut off the valve before passing it through the hole! Fasten the nut back onto the valve before continuing to make sure the valve doesn't move around while you are working the tire on.

I actually managed to get to the 180 degree point without much trouble, but then the tire began gripping the rim and wouldn't budge, so I put some soapy water on the edge of the rim, and the tire slid onto the rim, both beads at once! For this, I was using the flat, tapered end of the irons--this was great for stuffing the tube into the tire as I worked along. That last bit, however, went on by hand--it was that easy.

Once it was all in place, I used my bike pump to get it up to 1/3 full, then struck the tread of the tire all around with a mallet to get the tube to seat properly, with no pinches, twists, or bends. Then, I pumped it up the rest of the way.



While I had it off, I also opened up the hub, cleaned out all the caked on old grease (even at room temp, it was like candle wax!), and lubed everything up. The wheel bearings still were pretty uncooperative, so I've ordered all new bearings and will be replacing them shortly. But that's another story.

BTW, the tire irons were the Motion Pro Enduro set, from Motorcycle Superstore. They were $19.95, and worked like a charm. Since I ordered the tires at the same time from MS, the price of the total package was pretty cheap. I think it was under $70 for two tires, the irons, and shipping.

[FJ40_owner]

Keep on gathering those vintage motorcycle parts. They seem to be Gold plated these days. The one on this link looks to be mint.

1979 Honda CT90, ultra clean!

I sold my 110 in 84 for $800.

Silly me

[Hugh Heifer]

Originally Posted by Jman

Honda manuals can be found here:

honda repair manuals

Link is broken

He explains why here:

http://www.manualz.info/

[semlin]

good price for fork boots
http://cgi.ebay.com/ebaymotors/Fork-...ht_2728wt_1143

[yooper]

ebay vendor of reproduction sprakplug decals

eBay Store - ReproDecals: Honda, Kawasaki, Suzuki

[semlin]

update on indicators (or as honda calls them "winkers") for the ct90

the diagram below is from an s90 which shares a lot of parts with the early ct90s, including an identical front fork layout to the 1969 k1 (for 1970 k2 and later the forks are different ). i believe is the correct setup for a k1 ct90 front, and would work on the rear for any ct90 or ct200. i have never seen oem indicators on a ct90 before a k4 and they do not appear on the parts fiche but after 1966 they are all wired for them and have handlebar switches and i think they would use this s90 setup on the rear for k1 and earlier at least since the s90 dates back to the early 60s. you can buy repros of this style of indicator on ebay by searching for s90 indicators or winkers. for the rear you also need the stay part which is honda p/n 33602028670. according to the european cmnsl site the stay part is still available.



here is an auction site for the repro winkers

eBay Motors: HONDA CB100 CL100 S90 SL100 Metal Turn signal complete (item 290302287242 end time Mar-19-09 00:08:51 PDT)

[Jman]

Originally Posted by Hugh Heifer

Link is broken

He explains why here:

http://www.manualz.info/

Damn. That was the holy grail of manuals.

I bet if you e-mail him, he'll still send you an attachment, on the sly.

[yooper]

Nice rebuild writeups on this Aussie postie bike site: The Wenga Postie Bike Project -> The rebuild

[Jman]

Here is an easy to navigate site for purchasing fasteners singly, or in bulk. They have oxide coated steel, zinc coated, and expensive chrome coatings in metric sizes with allen heads. No stainless in metric, though. I just ordered some allen head screws to replace the mashed up phillips head ones on my clutch cover.

Carpenter Creek Inc. : Screws, Nuts, and Fasteners

[semlin]

ok, here is some info on the different complete engine gasket sets available for the ct90.

there appear to be two basic sets. one is made in thailand and sells for as little as $6.00. it usually has green gasket paper but has several packages. the other is made in taiwan supposedly of "japanese" material and is sold by dr atv and others for about $20. it usually has at least some black gaskets. the easiest way to tell the sets apart though is that the thai sets are missing four small copper washer/seal things and you can usually see this in the packaging if you look hard.

the short answer is that the thai set is missing 5 gaskets including the oil pump gasket, plus those 4 little copper things.

here are photos of the two sets in the packages. thailand first. taiwan/japan second.

[semlin]

here is the taiwanese/japanese set broken out. notice it has the 4 small copper washers and also the oil pump gasket pictured separately.

[semlin]

now here are 3 of 4 photos of the less expensive thai set. notice it is missing several gaskets including the oil pump gasket.

[semlin]

here is the last photo of the thai set. i don't know what the other missing gaskets and seals do yet because i am about to order them but it seems prudent to get the more expensive set.

[semlin]

and now for the oil seals. there are two kits again. one has 4 seals, and one has 5 the 4 seal set is as little half the price of the 5 seal set and you can see here that it is the biggest seal that is missing.

the kit of 5 has the following

13225 POINTS ASSEMBLY SPINDLE
11.62410 SHIFTER FORK
31438 SPROCKET DRIVESHAFT
14267 RIGHT CRANKCASE
20347 MAIN COUNTERSHAFT

those numbers are actually the seal dimensions not a part number. looking closely at the set of 4 you can see the same numbers are printed on the package. the missing seal is the "sprocket driveshaft"

[semlin]

and the missing seal is honda part 91202-459-771 and goes on the subtransmission sprocket output

http://www.cmsnl.com/products/oil-se...8_91202459771/

[Jman]

Stainless metric socket cap screws, available here a la carte:

http://shopping.barnhillbolt.com/ind...ile=METRIC.htm

[yooper]

Originally Posted by Jman

Honda manuals can be found here:

honda repair manuals

Site's been shut down.

[Hugh Heifer]

Originally Posted by semlin

update on indicators (or as honda calls them "winkers") for the ct90

the diagram below is from an s90 which shares a lot of parts with the early ct90s, including an identical front fork layout to the 1969 k1 (for 1970 k2 and later the forks are different ). i believe is the correct setup for a k1 ct90 front, and would work on the rear for any ct90 or ct200. i have never seen oem indicators on a ct90 before a k4 and they do not appear on the parts fiche but after 1966 they are all wired for them and have handlebar switches and i think they would use this s90 setup on the rear for k1 and earlier at least since the s90 dates back to the early 60s. you can buy repros of this style of indicator on ebay by searching for s90 indicators or winkers. for the rear you also need the stay part which is honda p/n 33602028670. according to the european cmnsl site the stay part is still available.



here is an auction site for the repro winkers

eBay Motors: HONDA CB100 CL100 S90 SL100 Metal Turn signal complete (item 290302287242 end time Mar-19-09 00:08:51 PDT)

On the rear fender of my CT 90, there appears to be captured nut or nut plates to accept this kind of rear setup.

[Jman]

Hey bitches, check it.

Motorcycle



Scroll down halfway. Says it's $9.95 for the kit!