1972 CT-90 rebuild

Discussion in 'Battle Scooters' started by sailah, Aug 24, 2010.

  1. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,864
    Location:
    Turning expensive metal into scrap
    First off to the traditionalists, this is not a museum piece. I didn't match the color or keep the rack chrome. If you can live with that, read on...:lol3

    So I bought these 2 CT90's (yellow is a 1970 I think, orange is a 72) on a whim for $300. I had no idea what one looked like or what was missing. I figured it would be a part swapper marathon and kick it to life. The more I got into the project, the more I was interested in restoring it.

    I knew from the outset that it was missing the entire airbox, battery cover and a bunch of other stuff.

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    The status of the mechanicals was not great. Piston was rusted to the cylinder and had to get whacked with a hammer to free up.

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    Head wasn't much better.:cry

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    So there goes the idea of just a tune up. Decided to strip it all down and see where I stood.

    Engine out

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    Frame and forks

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    Parts, hope I remember how this all goes back together

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    Started to polish the covers

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    Cylinder after I honed it. Wasn't going to go with new rings but just ordered a 20 over piston kit and going to get it bored out.

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    Lapped the valves and got a good seal. The engine bore guy said to hold the valve in with my finger and spray brake fluid. If you get any leaks, redo. Seems to be holding great. Not bad for my first time.

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    Getting deeper

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    My first attempt at lacing wheels. Wish someone told me that the spokes are specific to the inside/outside:deal Think I did each one 5 times.

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    Think this will hold?

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    Tried polishing an entire cover. I think this will end up being a nightmare to keep clean and polished. Messy to do as well..

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    I had 3 fenders. 2 bad frames and one bad tin. So I swapped the tin over and pop riveted it.

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    Hard to tell the difference on the old vs new wheel but I polished the chrome rim, and sanded each and every spoke. Nightmare. Wheels will get new bearings and have Michelin Gazelles as I won't be off roading. I bought another set of rims I will put some knobs on

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    Clutch rebuilt with new fiber discs, steels were fine.

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    I'm going to paint the engine cases semi gloss black. Read on to see what I did with the covers...

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    New exhaust, the old one was completely shot. The guards are in pretty decent shape, so I'll reuse.

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    Well look what Santa brought us:freaky

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    Powdercoating is sweet. I had the the orange pieces powdered orange obviously. The skid plate & rear rack were done in chrome powder with a topcoat of clear. Looks more like silver really. Oh well, at least it is consistent.

    The engine covers and gear/brake stuff were done in silver. The center stand and footpeg bar was done in semi gloss black.

    Really happy with the way it came out, not cheap, but the time it would have taken to really clean that frame out vs sandblasting and coating was worth it.

    I'm going to assemble the engine with SS button socket screws from Fastenal. The soft stockers were all pretty much junk when I took it apart. I think I used the EZ out more than a screw driver.

    Also putting in all new bearings for the engine save the crank bearings. By the time I washed the cases 100 times, I was getting a little grit in the smaller ones. Also got new bearings for the wheels. New oil seals and the engine should be ready to go.

    Engine should be done next week, then I get to reassemble. I have a bunch of loose ends like speedo cable, seat recover, POR the tank, new wiring harness, battery box & cover, frame cover ($$$$), decals, new cables, brake lever.

    This is my inspiration, although I recognize that I won't be total original with the powdercoating vs chrome. I'm also hunting down an aux tank from a member here.

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    Comments and advice from those who have been down the road appreciated.

    When completed, this will be the first CT-90 I will have ever ridden. Funny story on the trip home from Ohio, first gas station, guy comes up to me and launches into how he used to ride these all the time, can climb anything etc. I can't wait to join the scooter mafia. After owning expensive and powerful European V Twins, this bike has me more excited than any of them.

    Also my first restoration so take it easy:lol3
    #1
  2. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,864
    Location:
    Turning expensive metal into scrap
    spooge tank hooked up for rust removal

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    #2
  3. wanna bECO

    wanna bECO Been here awhile

    Joined:
    Jul 3, 2008
    Oddometer:
    727
    Location:
    Third stone from the sun
    :lurk.. nice work! Can't wait to see the finished product :clap. I want one of those so bad!
    #3
  4. Speedo66

    Speedo66 Transient

    Joined:
    Jan 14, 2010
    Oddometer:
    6,970
    Location:
    Cin City, OH
    Great pics, nice the way it's coming along. Looks great, and you picked the nicest color in my not so humble opinion. :clap

    Waiting for the engine rebuild story.
    #4
  5. fullmetalscooter

    fullmetalscooter Let me take this duck off

    Joined:
    Apr 28, 2009
    Oddometer:
    3,306
    Location:
    BC
    nice if you clear coat the metal your save your self some trouble of reploshing it.
    #5
  6. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,864
    Location:
    Turning expensive metal into scrap
    The engine covers were powdercoated. The polishing looked good for about 5 minutes.:lol3

    No story on the engine rebuild other then the frozen piston. One thing led to another and I had every component taken apart.

    I'm going to Vegas this weekend and will get the bike finished next week.
    #6
  7. DirtDriven

    DirtDriven Not Cheap,Thrifty

    Joined:
    Mar 11, 2009
    Oddometer:
    299
    Location:
    True North, GA
    Great job so far! I done one of these last winter and when I finished I turned around and sold it and have kicked myself ever since for it.
    These things are awesome little bikes. Ok that's it now I have seen yours I want another one now :lol3 The search begins!

    Keep us updated
    #7
  8. AustinJake

    AustinJake TE450-KLE-FXDWG

    Joined:
    Aug 20, 2010
    Oddometer:
    3,913
    Location:
    Austin, TX
    Enjoying your build, is that KTM orange??
    #8
  9. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,864
    Location:
    Turning expensive metal into scrap
    Thanks for the comments. It's been fun tearing it apart,now the wait begins for parts. The cylinder is at the machine shop and once I get the new bearings, I'll put that together. I think I have everything to get a roller once that happens.

    Bunch of little stuff I'll wait to the end to order from DrATV.

    The color is just "orange" at the powdercoaters. I thought about trying to get it matched, but said what the hell. All the chrome has been done chrome/silver powder so it'll never be original. I just want it to look sweet.

    I have another one I might make into a frankenbike. Throw some XR forks on it, rattle can the colored parts and use that for a beater. It gets pretty expensive when you have to buy the hard to get parts like an exhaust, frame cover, airbox etc. I'm guessing I'll have 1200-1500 into the project when all is said and done.
    #9
  10. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,864
    Location:
    Turning expensive metal into scrap
    Well it's been longer than I thought to get this hoss back together. I keep having the battle to go all out and replace things like bolts or just shine stuff up on the buffer. I think if I was to do it again, I wouldn't have spent the money on powdercoating. Yeah it looks great, but a decent job with a rattlecan can pretty much get almost the same result esp if you bake the paint and harden it.

    Anyways, I'm pretty much in the home stretch. It was a fun project and lessons learned for my next rebuild. That's right, on the lookout for the new project. Not sure what I'll do with the trail 90. Most likely get it registered in Maine and ride it.

    Frame, swing arm, and shocks assembled.

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    Motor which took forever to rebuild mostly out of laziness. I trashed all the seals taking it apart then forgot to order new ones so that delayed the entire project. I put all new bearings in except the crank bearings. It's hard to tell but I painted the case halved with duplicolor aluminum wheel paint which looks almost identical to the powdercoat. For the money, I'll def paint them myself next time. The covers are powdercoated. Piston and cylinder are fresh from the machinist along with new rings.

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    The unobtanium sub tank. Basically a canteen for spare gas. I bought a ton of parts from a guy in VA including a spare set of rims, drive hub, air box and the sub tank for $100. They usually sell for that just for the tank. I don't know why I really wanted it, but whatever, it looks cool. I painted the air box and the sub tank with rustoleum charcoal grey. For some reason I was getting runs, so I'll wait a week, sand the runs out and reshoot.

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    As it sits today. I need to redo the forks, should be easy I hope I don't need seals. I'm getting sick of ordering shit for this thing!! The engine needs a countershaft seal for the low range box. I also need a speedo cable, headlight and probably a few odds and ends. I want to assemble as much as humanely possible before I put the next order in to get everything at once

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    The guy I bought the parts from threw in a complete wiring harness so along with mine and the schematic I should be able to get it running.
    #10
  11. redhandmoto

    redhandmoto Been here awhile

    Joined:
    Aug 25, 2008
    Oddometer:
    689
    Location:
    People's Democratic Republic of Tarsnakestan
    Beautiful.

    Sweat, toil, and no stitches, either. Da-yum, Dude!
    #11
  12. robertjludwigsr

    robertjludwigsr Adventurer

    Joined:
    Dec 13, 2009
    Oddometer:
    89
    nicework I restored a k5 ct90 couple year ago lots of fun to ride. Where in Ohio are you
    Bob in Cincinnati
    #12
  13. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
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    Turning expensive metal into scrap
    Pittsburgh:deal
    #13
  14. MT Don

    MT Don Been here awhile

    Joined:
    Sep 18, 2005
    Oddometer:
    124
    nice job..................do you have a budget you are working to and/or, how much do you think you will have into this project when completed?

    Don
    #14
  15. SCQTT

    SCQTT Zwei Kolben

    Joined:
    May 16, 2005
    Oddometer:
    5,470
    Location:
    Mike's Sky Rancho
    #15
  16. D0N

    D0N Banned

    Joined:
    Jan 3, 2011
    Oddometer:
    280
    Location:
    upstate NY
    Nice job! I don't know if it's your camera or not, but your orange looks more like a red. :huh

    Here's my original 72 with 600 miles.

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    #16
  17. GypsyWriter

    GypsyWriter Sarah

    Joined:
    Aug 28, 2009
    Oddometer:
    1,827
    Location:
    Visalia CA
    Nice bikes you guys! I thought that the reserve tanks in the back didn't come standard until the later 70s though? Still, less than a thousand miles each - you guys need to go ride those babies more!!!
    #17
  18. wanna bECO

    wanna bECO Been here awhile

    Joined:
    Jul 3, 2008
    Oddometer:
    727
    Location:
    Third stone from the sun
    Wow, good thing we aint neighbors, i'd be buggin ya all the time!! And I think in a way you are right about the powder coating, but the rattle can might look the same at first, but you are gonna appreciate the money spent on powder over the long haul. This paint will stand up better, you'll see.

    And to Don and Scott, you just aint riding enough.... Put me in your will for your bikes.
    #18
  19. SCQTT

    SCQTT Zwei Kolben

    Joined:
    May 16, 2005
    Oddometer:
    5,470
    Location:
    Mike's Sky Rancho

    Long line already......no kids, so there will be a lucky friend or two.

    Several are VERY spoken for. :D
    #19
  20. White Tenere

    White Tenere Look a moose

    Joined:
    Jan 14, 2007
    Oddometer:
    729
    Location:
    SoCal
    I made reservations for us to go sky diving, I packed your chute myself...:wink:
    #20