Honda CT90 - Shop Manual

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Foreword2
Contents3
Features8
Specifications9
Product View S9017
S90 Performance Curves18
S90 Engine Performance18
Product View CL 9019
CL90 Performance Curves20
CL90 (L) Engine Performance20
Product View CD9021
CD90 Performance Curves22
CD90 Engine Performance22
Product View C9023
C90 Performance Curves24
C90 Engine Performance24
Product View CT9025
Posi-Torque (F.no. 000001A and Subsequent)26
CT90 Performance Curves26
CT90 Engine Performance26
Engine27
Tools Necessary for Disassembly and Reassembly27
Engine Assembly Diagram S90, CL90, CL90L29
Engine Description30
Power Transmission System/Diagram30
Engine Removal30
Removing the Drive Chain30
Disconnecting the Clutch Cable31
Engine Assembly31
Removing the Inlet Pipe31
Engine Installation32
Setting Direction of Chain Clip32
Adjusting the Chain32
Cylinder Head Construction33
Disassembly (Cylinder Head Block)33
Squish Area33
Removing the Starter Assembly/The Rotor33
Removing the Contract Breaker Assembly34
Removing the Point Brake/Camshaft34
Disassembling the Valves34
Cylinder Head Inspection and Repair35
Checking/Repairing Cylinder Head Warpage35
Checking the Valve Guide Diameter35
Inspect Valve Guide36
Valve Seat Contact Area36
Reworking the Valve Seat36
Valve Mechanism37
Inspection of Valve Seating37
Exhaust/Inlet Valve37
Measuring Valve37
Outer/Inner Valve Spring38
Camshaft39
Camshaft Construction39
Cam Contour39
Valve Timing40
Cam Sprocket Root Diameter40
Measuring Camshaft Height40
Cylinder Head Reassembly41
Rocker Arm/Arm Shaft41
Assembling the Cylinder Head41
Torquing Sequence of Cylinder Head41
Cylinder Construction42
Connecting the Cam Chain42
Assembling the Camshaft42
Installing the Point Base42
Piston43
Cylinder Offset43
Cylinder Disassembly44
Piston Ring44
Removing the Cylinder44
Cylinder Inspection45
Removing the Piston Pin/Ring45
Measuring the Cylinder Bore45
Measuring Piston Skirt Diameter45
Measuring the Piston Ring Side Clearance with a Thickness Gauge46
Piston Ring Groove Dimensions Ring and Gap46
Piston Ring and Gap46
Cylinder Reassembly47
Checking Piston Ring Contact47
Assembling the Piston47
Cam Chain Tensioner Construction/Detail Diagram48
Cam Chain Tensioner Disassembly/Inspection/Reassembly49
Removing the Cam Chain Tensioner49
Removing the Tensioner Push Rod49
Component Parts of the Cam Chain Tensioner49
Construction and Operation of Clutch50
Clutch Mechanism S90, CL90, CL90L, CD9050
Clutch Mechanism C90, CT9051
Clutch Disassembly52
Component Parts of Clutch S90, CL90, CL90L, CD9052
Removing the Clutch Outer Cover52
Clutch Inspection53
Removing the Clutch Assembly53
Inspecting the Clutch Spring53
Clutch Reassembly54
Friction Disc and Clutch Plater54
Clutch Outer and Drive Plate or Clutch Plate54
Clutch Center Guide54
Flow of Lubricating Oil55
Oil Pump Construction/Disassembly56
Gear/Trochold Oil Pump56
Oil Pump Inspection/Reassembly57
Gear/Trochoid Type57
Gear Shift Mechanism Construction58
Gear Shift Mechanism Disassembly/Inspection/Reassembly59
Removing the Primary Driven Gear/The Gear Shift Spindle59
Assembling Shift Drum Stopper59
Crankshaft Construction/Disassembly/Inspection60
Removing the Crankshaft60
Measuring Crankshaft Alignment60
Crankshaft Reassembly61
Measuring Axial Clearance61
Connecting Red61
Reassembling the Crankcase61
Transmission Construction62
Raduction and Torque Ratios62
Number of Gear Teeth, Indicate CD9062
Low Gear62
Second/Third/Top Gear63
Neutral64
Transmission Disassembly65
Removing the Kick Starter Spindle65
Removing the Gears65
Removing the Gear Shift Fork65
Transmission Inspection66
Main/Counter Shaft to Gear Clearance66
Shift Drum Groove66
Transmission Reassembly67
R Mark on the RH Gear Shift Lock67
Checking the Gear Shift Cam67
Crankcase Construction68
Crankcase Disassembly/Inspection/Reassembly69
Measuring the Crankcase Flatness with a Thickness Gauge69
Kick Starter Mechanism69
Kick Starter and Gear Interlock Mechanism70
Posi-Torque Mechanism Construction71
Power Transmission in the Posi-Torque Mechanism71
Earlier Series Rear Sprocket (Prior to CT 90 F)71
Low Speed Range71
Posi-Torque Mechanism Disassembly72
Carburetor Construction72
High Speed Range72
Cross-Sectional View of Carburetor73
Main Jet74
Choke74
Air/Needle Jet75
Carburetor Adjustment76
Throttle Valve76
Slow Jar76
Air Screw76
Adjustment for High/Intermediate Speed77
Adjustment for Slow Speed78
Measurement of Fuel in the Float Chamber78
CT90 Model from Frame no 000001A79
Carburetor Setting Table80
Frame/Tools Necessary for Disassembly and Reassembly81
Steering Handle Construction82
Steering Handle Disassembly83
Removing Brake Adjusting Nut83
Disconnecting the Clutch Cable/Electrical Leads83
Removing Throttle Cable from Carburetor83
Removing Handle Pipe84
Removing the Top Bridge Plate84
Removing Brakw and Clutch Cables84
Removing Throttle Cable84
Steering Handle Inspection85
Disconnect Spead and Brake Cable85
Disconnect Electrical Leads (CT 90)85
Removing Handle Setting Bolts85
Steering Handle Reassembly86
Removing Steering Handle (CD/CT90)86
Assembling Throttle Grip86
Clutch Cable Adjuster86
Steering Stem Construction87
Adjusting Front Brake87
Steering Stem Section Diagram87
Steering Stem Inspection/Reassembly88
Steel Balls88
Front Fork Construction89
Front Cushion Sectional Diagram89
Front Cushion89
Front Fork Disassembly90
Removing Headlight90
Removing Front Fork Cover90
Removing Front Wheel/Fender90
Removing Front Fork Assembly91
Component Parts of Front Fork91
Removing Headlight Case91
Disconnect Front Brake Torque Link92
Removing Steering Head Top Thread92
Front Cushion Assembly93
Front Fork Inspection94
Front Cushion Spring Table94
Damping Capacity94
Dimensions94
Front Fork Reassembly95
Fuel Tank Construction/Disassembly95
Turn off the Fuel Cock95
Removing Seat Setting Nuts95
Fuel Tank Inspection96
Removing Fuel Tank/Cock96
Removing Tank Side Cover96
Fuel Tank Reassembly97
Frame Body Construction/Disassembly97
Cross-Sectional View of Side Cover Installation97
Removing Main Ignition Switch97
Frame Body Inspection/Reassembly98
Seat Construction/Disassembly98
Removing Ball Races98
Removing Seat Mounting Nut98
Seat Inspection/Reassembly99
Loose Upper Rear Cushion Cap Nuts99
Removing Seat Hinge Pin99
Tool Box99
Brake System Construction/Disassembly100
Rear Brake Operation100
Removing Front Brake Lever100
Removing Front Brake Cable/Shoes101
Removing Brake Pedal and Stop Light Springs102
Removing 3 MM Cottor Pin102
Removing Rear Brake Rod from Rear Brake Arm102
Muffler Construction/Disassembly/Inspection/Reassembly103
Removing Rear Brake Cable103
Removing Difuser Pipe103
Air Cleaner Construction/Disassembly104
Removing Air Cleaner Mounting Bolts104
Air Cleaner Inspection/Reassembly105
Removing/Cleaning Air Cleaner105
Rear Fork and Cushion Damper Construction/Disassembly/Inspection/Reassembly106
Rear Fork106
Removing Rear Wheel/Fork106
Removing Lower Bolt106
Rear Fork Cushion Damper Construction107
Sectional View of Rear Cushion107
Rear Cushion107
Rear Fork Cushion Damper Disassembly108
Removing Rear Cushion108
Disassembling Rear Cushion108
Component Parts of Rear Cushion108
Rear Fork Cushion Damper Inspection109
Manual Operation of Rear Cushion109
Front Wheel Construction110
Component Parts of Front Wheel110
Protective Covering110
Front Wheel Disassembly111
Removing Cables/Front Wheel111
Separate Brake Panel111
Front Wheel Inspection112
Disassembling Brake Shoes112
Removing Tire112
Measuring Wheel Runout/Bend of Axle112
Front Wheel Reassembly113
Measuring Brake Lining113
Seating Tube113
Valve in Line113
Rear Wheel Construction114
Component Parts of Rear Wheel114
Rear Wheel Disassembly115
Disconnecting Drive Chain115
Removing Rear Wheel/Sprocket115
Rear Wheel Inspection116
Component Parts of Final Driven Flange116
Removing Final Driven Sprocket116
Installing Rim Band116
Rear Wheel Reassembly117
Assembling Tire117
Replacing Ball Bearing117
Chain Clip Direction118
Periodic Adjustment119
Maintenance Inspection119
Engine Adjustment119
Measuring Cylinder Compression119
Tappet Adjustment120
Aligning to the T Timing Mark120
Adjsuting Tappet Clearance120
Breaker Point Servicing and Gap Adjustment121
Locking the Adjusting Nut121
Adjusting the Point Clearance121
Ignition Timing Adjustment122
Adjusting the Ignition Timing Advance122
Spark Plug Adjustment/Clener123
Measuring Spark Gap123
Fuel Supply System124
Fuel Strainer Clening124
Oil Filter Screen Cleaning124
Fuel Cock Lever124
Air Cleaner Servicing125
Removing Oil Filter Screen125
Removing Air Cleaner125
Cleaning Air Cleaner Element125
Clutch Adjustment126
Adjusting Clutch Cable126
Carburetor Cleaning and Adjustment127
Adjusting the Carburetor127
Idling Speed Setting Table127
Parts Not Requiring Periodic Oil Change or Lubrication128
Engine Oil Change128
Removing Drain Bolt128
Oil Level Gauge128
Drive Chain Adjustment129
Grease Gun129
Inspecting Drive Chain Tension129
Adjusting the Drive Chain129
Brake Adjustment130
Free Play of Brake Lever/Pedal130
Adjusting Front Brake Lever130
Muffler Cleaning131
Spoke Torquing131
Adjusting Rear Brake131
Removing Diffuser Pipe131
Battery Inspection132
Meassuring Voltage of Battery132
Battery Electrolyte Level132
Drive Chain Service133
Measuring Specific Gravity133
Operating Instructings for Service Tester, Type ST 4 B 4134
Security Inspection of Parts138
Torquing Points on Left/Right Side (CL90, CL90L)138
Torquing Points on Left/Right Side (CD90, CT90)139
Torquing Points on Left/Right Side (C90)140
Periodic Inspection and Servicing141
Daily Inspection Points on Left/Right Side (S90)141
Daily Inspection142
Periodic Inspection143
Trouble Shooting144
Main Engine Trouble144
Carburetor Trouble146
Condenser Test Method146
Measuring Condenser Capacity146
Engine Noise147
Adjusting the Idling147
Steering System148
Clutch System148
Gear Change System149
Suspension149
Brake System149
Drive Chain150
S90 General Export Type Wiring Diagram151
S90 USA Export Type Wiring Diagram152
CL90 General Export Type Wiring Diagram153
CL90, CL90L USA Export Type Wiring Diagram154
CD90 USA Export Type Wiring Diagram155
C90 USA Export Type Wiring Diagram156
CT90 USA Export Type Wiring Diagram157
CT90 (from F no 000001A) USA Export Type Wiring Diagram158
Supplement to S90ZK1159
Cam Chain Tensioner159
Kick Starter160
Carburetor160
Front Shock Absorber (Front Fork)160
Rear Shock Absorber (Rear Cushion)161
Wheel Axle Nut161
Maintenance Schedule162
Supplement to S90ZK Wiring Diagram163
Supplement to S90ZKT Specifications164
Supplement to CT90K2-K6165
Comparison of CT90K2-K3 to CT90165
Air Cleaner Maintenance165
Steering Handlebar Clamp166
CT90K3 Wheel Axle166
Comparison of CT90K4 to CT90K3167
Right Crankcase Cover168
Fuel Sub Tank168
Comparison of CT90K5 to CT90K4169
Supplement to CT90K2-K6 Wiring Diagram171
Supplement to CT90K2-K6 Specifications172
Comparison of CT90K6173
Turn Signal, Horn and Dimmer Switch174
Throttle Grip Inspection/Adjustment/Disassembly174
Side Stand Inspection175
Rubber Block Replacement175
Supplement to CT90K8 (77)177
Supplement to CT90K8 (77) Wiring Diagram178
Supplement to CT90K8 (77) Specifications179

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