Clutch rebuild parts list DrATV

[joel1234567]

Lots of little parts to remember when doing a CT90 clutch rebuild, and I always end up going back through old order emails and other locations to piece it all back together on what is needed. Hopefully this shopping list will be of use to others (and myself) in the future when doing a clutch rebuild. A couple of the item numbers changed since my last clutch order but it's nice to get all of this stuff from one place in one order. Probably a few things you don't necessarily need- shift drum stopper, inner clutch cover, some of the spare screws, for example- but better to have a spare than get in there and discover that you need them. It costs me about $10 just to ship the order so ordering a spare is worth it to not have to place another order. Whole order shipped for a little less than $90, can't beat that.

This also assumes you've got the tools needed to get that clutch out already.

Shopping Cart
Item	Unit Price	Qty.	Cost
NEW_CLUTCH DISK_SET FIBER ALL 90 & 110'S ATC125M_84/85 1/22W (317K)	$22.49	1	$22.49
EBC REDLINE CLUTCH KIT HONDA_90's_110's_125's W/_SEMI_AUTO_CLUTCH REPLACES 22201-121-690 22201-121-306 1/22W (317K): CT90_ST90_CT110 ATC90_ATC110 ATC125M_84/85 HEAVY_DUTY CLUTCH_SPRING_SET (4EA_SPRINGS) 1/21W (157J)	$12.59	1	$12.59
*SHIFT_DRUM_STOPPER CT90_CT110_ATC90 (ATC110_THRU"1985") (ATC125M) 24430-459-950 1/22M (268N)	$12.99	1	$12.99
CLUTCH COVER SCREW KIT CT90 ATC90 K0/79 (77W)	$5.99	1	$5.99
CLUTCH COVER GASKET ALL_90'S ALL_90'S CT_ATC_ST_S_SL_CL replaces 11393-028-306 7/21G (CT9G7)	$7.58	1	$7.58
*KICK_START_SHAFT SEAL_ALL_CT90'S ALL_ST90'S ALL_CT200'S 91251-ZW5-003 1/21A (67A)	$3.99	1	$3.99
**CT90_ATC90 CT110_ATC110 ALL_THRU_1985 INNER CLUTCH COVER 22111-028-010 1/22M (216D)	$9.99	1	$9.99
**CT90_ATC90 CT110_ATC110 ALL_THRU_1985 INNER CLUTCH COVER 22111-028-010 1/22M (216D): *SCREW" "NEW" 5X12 FLAT TAPERED 1/18A (68H)	$0.76	2	$1.52
CLUTCH NUT COVER GASKET (CT9G8)	$1.75	1	$1.75

 

[ktheake]

Thanks - im not much involved in ct90 s but are st90 clutch sets the same ? I did see a few part #s and The fitment to st90 - just thought i would ask up

 

[joel1234567]

That's a good question but I cannot definitively answer. I've got a couple ST90's in the pipeline but haven't popped em open yet.

 

[-Nate]

I don't think I've ever seen a worn out shirt drum stopper, several broken ones though .

The inner clutch cover piece too is a non wear part .

I applaud you replacing all the various screws but using the proper tools negates the need .

This is a great post, I hope some newbies pay attention to it .

 

[-Nate]

A BIG thing = soak the new friction discs in clean motor oil overnight before you install them ! .

Failure to do so will often result in a locked up clutch .

The other thing is : after you've assembled the clutch, hold it in one hand and turn the small drive gear with your other hand ~ it MUST turn one way but *instantly* lock up when turned the other way .

if it takes a 1/4 turn to lock up it's mis assembled , stop and go back, post pictures, there are five different auto clutches and who knows what's on your bike now .

Moat of the old Hondas that come to me have serious shifting issues and almost all are caused by improper clutch assembly or allowing the clutch pedal on the left side of the bike, touch _anything_ as you're re installing the linkage and clutch cover again .

 

[joel1234567]

Thanks. Yes there are probably extras here as I mention but a spare never hurt if you have a few bikes goong. Shift drum stopper breakage isn't uncommon. I've got all the proper tools but getting that inner clutch cover off can be tricky. You're trying to use an impact driver on something that's spring loaded. Getting shims into position that hold the spring from collapsing and work reliably without having four arms is somewhat reliable but not foolproof. Last attempt I stripped a screw, had to score the screw head with a Dremel to get a flathead screwdriver in there and it cut into the inner cover. I guess if you're perfect at it with all the perfect tools and techniques then you don't need spares... I have a ways to go.

 

[-Nate]

I see you're where I was in 1971 or so ~ almost no tools , I learned by doing things and agree that spares are important .

The tiny screws holding that pesky cover on are #1 Phillips IIRC, DO NOT use a loose fitting impact bit there or anywhere else ! .

The outer side cover screws are #3 Phillips, you can also be rich (I wish) and buy $$ JIS special tools but not necessary .

Remember : MAZDA still uses JIS threads and head sizes on every thing so you can get good correct hardware from junkers at Pick-A-Part or the MAZDA dealer .

Oh boy ~ do I ever have miserable memories of damaged / stripped screws .

I once found a $10 set of reverse twist drill bits, those and my $5 yard sale electric drill (reversible) saved my bacon more than once .

It seems few machines come to me before they've been mangled by others so I feel your pain .

I'm still working on the four arms thing, so far no luck and my Sweet won't go near any Motocyle .

 

[OLD CT]

Definitely a good idea to pick up a spare of any of these parts. That beats one day needing it and finding out they are discontinued or simply out of stock.

 

[-Nate]

I do highly recommend a clutch holding tool there are several made by Honda enthusiasts who make a better AutoClutch holder than Honda ever did....

About $30 IRC . look on E-bay .

 

[joel1234567]

Definitely a good idea to pick up a spare of any of these parts. That beats one day needing it and finding out they are discontinued or simply out of stock.

Or paying another $10 in shipping for $4 worth of screws.

I've got the clutch holder and all the jis bits. But like you say, it seems few machines come to me before they've been mangled by others.

 

[-Nate]

This is why we choose HONDAS ~ because in spite of terrible DPO's / DPM's they're well designed and even better built making them very hard to ever truly be junk .

 

[mkhpalm]

if it takes a 1/4 turn to lock up it's mis assembled , stop and go back, post pictures, there are five different auto clutches and who knows what's on your bike now .

Click the image, I think 1/4th turn is supposed to be normal: http://dratv.com/clutchtesting.html

 

[-Nate]

Suit your self .

I've been riding & working on these since 1971 .