Honda CT90 K0 "Trail 90" Joining the Case Halves - And Some Broken Bits

1968 Honda CT90 KO
Frame #: CT90-154895
Engine #: CT90E-155049
This video covers joining the the two halves of the main engine case. Along the way I learned the kick starter limit had been broken off inside the case and the spline on the kick starter was completely rounded off. See my prior videos for the start of this motorcycle rebuild and other parts of the engine tear down

[@bobcranberries5853]

Thank you for the high-quality video it’s easy to see everything.

[@duacot6633]

Having manuals and parts make it ready for me to follow. It's good to hear comments and explanation of the process for the means to gain new knowledge. Thanks for sharing!

[@SuperS780]

So, I just started working on my ct200 engine. Had the EXACT SAME PIECE break off in my case as well, and oddly enough just put my case halves together, making a poor assumption that the piece I found broken off was not essential...glad this video popped up and I was able to watch it when I did. Anyways, I guess there is no solution other than buying a new right side case half/welding the piece back on?

[@DaBombDotCom77]

Did the engine run? I believe it isn’t essential and is just the kicker stopper

[@SuperS780]

@@DaBombDotCom77 great question. Had I actually used that case without fixing the issue I believe with great confidence that it would have run. That peice definitely serves to STOP the kick stopper at a specific place. However...if you rotate that peice 360°, you will notice that the kickstarter lobe can and will make contact with one of the transmission gears. It will only make enough contact to get rotated the rest of the way around, NOT bind. But over time? How much damage will it do over time?... That is the question I am not able to answer.

[@garygullikson6349]

Enjoying your videos, wonder where you are sourcing all the parts for your KO. I have the same '68 with low/high range.

[@claytongerber]

I will have more videos soon. Parts are tough. I use DrATV. CMSNL for a lot of OE parts and eBay. CMSNL has the best website that lets you cross reference to other models and search the original Honda parts numbers.

[@garygullikson6349]

Re: Broken piece, I missed what the piece does, looks like it's supposed to stop something from rotating in a counter clockwise direction, you didn't show this detail with new case. Also, would a weld repair have been reliable and cost-effective?

[@claytongerber]

The broken lug prevents the kick start lever from rewinding too far. I debated trying to run with the broken case, but sourced a replacement. Honda seems to have strengthened the casting in that area in later designs. This bike was pretty rough and I wondered if the kick start level hit a tree or something. I suppose it could have been welded if you could successfully weld the alloy (I assume it’s aluminum).

[@snagle45]

Hello, did you ultimately remove the ratcheting piece from the kick start? I’m currently reassembling a KO engine and I’m slightly confused as you show the kick start with the ratcheting piece moving the gears, then show the right side with stop being broken then show the left side with the kick start spinning the gears without the ratcheting piece before reassembling the sides

[@claytongerber]

I did not remove the ratcheting piece. I just did that to show how it swings in the case and what the stop is for. Since my stop was broken I ended up getting another case half off eBay. Later generations had a stronger stop so this must be common.

[@kturn5953]

Where do you like to purchase parts? I’m rebuilding a Honda ST90 and am worried about finding replacement transmission parts. If DrAtv doesn’t have it, where do I turn to next? Thanks for the vids!

[@claytongerber]

Besides DrATV (Beatrice Cycles), I have gotten parts from CMSNL.com in the Netherlands. Their shipping is a little slow but they are reliable and have original Honda parts. Also you can use the Honda part numbers from CMSNL and search eBay for people who have NOS parts.

[@kturn5953]

@@claytongerber Thanks so much! See, I had no idea about that other website from the Netherlands. Awesome!

[@garygullikson6349]

Why no spoken comments, describe what part is and what is wrong with it.

[@claytongerber]

Thanks for the feedback. I am new to this and trying different options.