honda ct90 not shifting

1

1heybuddy

New Member
I just finished putting in a new clutch in my ct90 and now it won't shift into any gear. The shift lever moves but won't go into any gear....What happened???
 
Did you soak the fiber plates in oil for 24 hours prior to the installation? What did the metal plates look like? Any warped or discolored?

And the clutch does need to be adjusted after reassembly. The procedure is in the shop manual and is easy but the rebuild can be quite technical and tricky if you have not done it before.

Rick
 
Maybe its your sub tranny in between L and H. My CT90s all have a big "neutral zone" on that little arm under the subtranny
 
+1 on CT's advice. Been there, done that.

And you know you have rebuilt that clutch correctly when you can grab the gear on the back of the clutch and are able to easily turn it one direction but it quickly locks up in the other direction. It takes two hands to do this and is the best pre-installation test that I know of.

Rick
 
My CT 110 died and when I went to shift it into neutral to re start it I could get it to shift...I shifted it into the HI/LO neutral position and was able to push it home. Does anyone have in put on this issue. Could this be related to the clutch as well?
 
jbarnes said:
My CT 110 died and when I went to shift it into neutral to re start it I could get it to shift...I shifted it into the HI/LO neutral position and was able to push it home. Does anyone have in put on this issue. Could this be related to the clutch as well?
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You likely have a shift drum stopper problem. Very common on these bikes. It is the star-shaped plate bolted to the side of the shift drum that is likely loose - the Phillips head screw needs some Loctite and a good tightening. The roller on the end of the shift drum stopper is also known to break off. Less likely is that the star is worn or that the "claw" that engages the shift drum is worn. If your bike has many thousands of miles you might have worn shift forks but this is very unlikely.

You will need to remove the riders right side engine cover, then the clutch, and then the main drive gear to even begin to expose what is actually wrong. This will require an impact driver, a clutch nut socket and a clutch holder to get the cover and the clutch out. Figure you will need a side case gasket and an outer clutch cover gasket as well. And those outer clutch cover screws are also a major chore to remove without a good set of JIS screwdrivers. Then you will need a set of snap ring pliers to remove the drive gear c-clip. You will need a torque wrench set to 28-33 ft pounds to put the clutch nut back on.

This is an easy job once you get the right tools. It also is good to have a helper to hold the engine when you are tightening that clutch nut. All in all, it is not a hard job and we can talk you through it.

Rick
 
Thank you Rick, So from what you are saying I have to pull the cover off and the clutch to even get to the shift drum stopper? I am hoping to start pulling it apart this weekend.
 
i started to dig into the issue. when I open the case i could see the issue right away. the shift drum was able to slide out and hit the gear directly in front of it. I pushed the drum back in and this seemed to stop the binding issue. My question is what keeps the drum from being able to slide out that far? you cane see were the philips screw had been rubbing against the gear.
 
I'm not familiar with the 90's but on the ct70's the bolt that holds the drum in place is under a rubber plug on the left side of the motor under the stater cover. shift all the way down before you tighten the bolt. Use the shift lever while spinning the trans to spin the drum until it stops. Then tighten the bolt. You may want to check the phillips screw also as they tend to loosen also and should have some loctite on the threads to keep it in place. You may also want to service the clutch while you are in there and clean the oil spinner and oil screen. ....I just looked back, sorry, you just rebuilt the clutch.
 
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Let me see if I can look at the shop manual a little more closely for you. I'm thinking the bolt for the shift drum is missing on your bike. There are several free manuals at http://ct90-ct110.com/ or the ct90 Yahoo Group if you need one.

Rick
 
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This chat has me hopeful of fixing a non shift issue. I have gathered all the tools and the rain will keep me out in the garage later today. Will gave to see what is unhappy with that plate or back side bolt on the left side. I am also about to split the cases on another CT90 engine soon. The clutch plate fastner with the two screws in the middle of the clutch pack had a tab broken off....also found what I think is 3rd gear tooth missing. Splitting the cases is the safer way of clearing any remaining metal pieces from the damage. AND YES there is a bolt that holds the backside of the gear assembly in the left side case and a locking ring also.
 
Flying Wrenches said:
This chat has me hopeful of fixing a non shift issue. I have gathered all the tools and the rain will keep me out in the garage later today. Will gave to see what is unhappy with that plate or back side bolt on the left side. I am also about to split the cases on another CT90 engine soon. The clutch plate fastner with the two screws in the middle of the clutch pack had a tab broken off....also found what I think is 3rd gear tooth missing. Splitting the cases is the safer way of clearing any remaining metal pieces from the damage. AND YES there is a bolt that holds the backside of the gear assembly in the left side case and a locking ring also.
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I need to pay attention to the dates on these posts. What year is your CT90?
 
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