Hondo's 1982 Honda CT110 Rebuild Thread

Discussion in 'Some Assembly Required' started by Hondo, Jun 14, 2013.

  1. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    I just picked up a somewhat neglected 1982 Honda Trail 110 (CT110) from a neighbor for $300.

    It ran but has been sitting outside in the elements for some years now. Total miles, 2,128.4-

    [​IMG]

    Here are a few pics-

    [​IMG]

    [​IMG]

    It will need -

    A new ignition switch-

    [​IMG]

    A right mirror mount & mirror-

    [​IMG]

    Seat covers (passenger seat not shown)-

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    and this laundry list of replacements & maintenance items-

    - new battery
    - oil flush & change
    - inspect & rebuild brakes if necessary
    - soak, lube & replace drive chain (if necessary)
    - get new helmet lock or key the old one
    - clean & rebuild the carb (or replace)
    - replace the air filter element
    - clean everything
    - possible paint the bike & replace all decals
    - inspect & lube the swingarm bearings
    - replace the fork seals & fork oil

    This will be a slower build than the KLX450R, so standby for updates!
    #1
  2. sanjoh

    sanjoh Purveyor of Light

    Joined:
    Feb 13, 2007
    Oddometer:
    5,397
    Location:
    Mountains of Central Florida:)
    Nice bike for a restore/rebuild:clap
    #2
  3. Crisis management

    Crisis management Latte riders FTW!

    Joined:
    Feb 14, 2007
    Oddometer:
    1,511
    Location:
    New Zealand
    Thats a tidy looking CT, I picked up a $20 CT90 a month ago but it has been a farm hack so is in nowhere near the condition yours is in, but with some fresh fuel and an oil change it's running perfectly!
    It's now in a few hundred pieces getting repainted and all the seals etc being refreshed, total budget is $200 to get it back to being "road legal"..... as long as the police don't take a close look!
    They are a fun little bike, mine is being assigned to be the beach bike for getting groceries and going fishing at our beach house. :clap
    #3
  4. swoody126

    swoody126 Been here awhile

    Joined:
    Aug 26, 2008
    Oddometer:
    425
    Location:
    denton, America
    what a cool find!

    dad had one that he logged nearly 30,000 miles on

    & he never got much more than 30 miles from the house/RV

    have fun w/ your quest

    sw
    #4
  5. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    As I'm taking the kids on a 10 day RV trip in my ADV Jamboree in a few weeks, and I want to take the CT110 along for the trip, I ordered these parts today-

    - new carb
    - fork seals
    - main seat cover
    - buddy seat
    - air filter
    - ignition switch
    - front brake pads
    - right switch control
    - one mirror

    With the buddy seat I ought to be able to get both kids on the 110 if we need to run into town..... :D
    #5
  6. CA_Strom

    CA_Strom Cunning Linguist

    Joined:
    Jan 13, 2005
    Oddometer:
    2,331
    Location:
    The Temples of Syrinx (So. CA)
    Nice find and a great deal. I bought this vintage 1965 ct200 back in Feb. and just finished a moderate restoration. Starts first kick and is a blast to cruise around town. It's amazing, everyone had or knew someone that had a CT! I grew up with a 67, so this old girl is helping me relive my youth and tune up the wrenching skills. This site is your go to for anything CT related:

    http://hondatrailcts.yuku.com

    [​IMG]

    [​IMG]
    #6
  7. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    I have got a lot of work done since receiving the parts that I ordered.

    The fork seals were needing to be replaced and I found one side really rusty-

    [​IMG]

    After removing the rusty snap ring I cleaned up the fork tube, replaced the seal & the fork oil. I found the brake cable to be completely seized up so I ordered one from Beatrice Cycle .

    Looking good now-

    [​IMG]

    The front brake drum was also rusty from sitting outside, but it cleaned up well with a bit of sandpaper-

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    New pads & springs ( Beatrice Cycle ), ready for installation-

    [​IMG]

    Just need to install the brake cable-

    [​IMG]
    #7
  8. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    I also installed a new carb, fuel lines & small, inline fuel filters. After replacing the oil, I got it running but have to tune it as I found that it won't hold it's idle.

    Also found that the headlight, brake light and horn do not work. I suspect corroded connections as it was left outside in the weather by the previous owner..... :hmmmmm
    #8
  9. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    I bought a seat cover for the main seat & a passenger seat on ebay.

    Before-

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    After-

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    [​IMG]
    #9
  10. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    New OEM Honda ignition switch from Beatrice Cycle-

    [​IMG]

    I also installed a new mirror from Beatrice Cycle and the lower half of the right control switch assy (mirror mount was broken) from ebay-

    [​IMG]
    #10
  11. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    Electric Troubleshooting-

    I found both the sealed beam headlight and the tail/brake light bulb to be burned out.

    Ordered the "off road" headlight from Beatrice Cycle that has a replaceable bulb and will be picking up the tail light bulb locally.

    I put the foot pegs, the skid plate and the new front rack on-

    [​IMG]

    The rack will allow me to add a basket or a place to strap anything-

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    Shot from the other side-

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    I also installed these rear pegs (ebay) onto the shock mount bolts-

    [​IMG]

    I also flushed the engine oil with Seafoam and replaced it with Shell Rotella T 5W-40 synthetic.

    After resetting the initial settings I was able to get the carb/engine tuned & it runs great!
    #11
  12. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    I just ordered a Garmin Montana gps mount for the handlebars- will be able to use my Montana 600 on it using the internal battery as it won't run/charge off of the 6 volt system.

    [​IMG]
    #12
  13. CA_Strom

    CA_Strom Cunning Linguist

    Joined:
    Jan 13, 2005
    Oddometer:
    2,331
    Location:
    The Temples of Syrinx (So. CA)
    Very nice work! DrATV (Beatrice Cycle) is the place to go! They get all my spare $$$ too. Question, why the 2nd set of passenger pegs mounted on shock bolts vs. the OEM pegs forward???
    #13
  14. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    At the end of the month I'm heading west (to Cali & up the coast) in my Rv with the CT110 on the back.

    I plan on using the CT110 when the RV is parked & we need to ride into town. With the extra seat and foot pegs I can get both kids on the CT110 (behind me) for the short ride to town. :D
    #14
  15. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
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    Oddometer:
    10,022
    Location:
    Denver, CO
    I forgot to add that I adjusted the valves yesterday- they were way out (loose).
    #15
  16. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    Got a few things done today-

    Installed the missing side reflector & fork spacer-

    [​IMG]

    [​IMG]

    And installed the new front brake cable-

    [​IMG]

    Now the only items to address are the new headlight (on it's way) and getting the helmet & frame locks either rekeyed or replaced.
    #16
  17. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    The Garmin bicycle mount with the my Montana 600-

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    another view-

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    The replacement headlight came in From Beatirce Cycle- (on the right)

    [​IMG]

    I can change the bulb for a few bucks vs $50 for the sealed beam-

    [​IMG]

    It works really well for a 6 volt headlight-

    [​IMG]

    I replaced the 32 year old spark plug wire and boot with a nice NGK boot and new 7mm cable-

    [​IMG]

    Almost complete- waiting for the new keys to come in so that I can install the sub fuel tank and frame lock. I ordered a new center crossmember cover and the correct decals as the one on the bike is cracked pretty bad & the decals are for a later year. Needs some polish too-

    [​IMG]
    #17
  18. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    Today I looked at the Aux/Sub Fuel Tank and decided to paint it- I was looking 32 years old-

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    I scraped off the warning sticker (and ordered a new one) after I took this pic-

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    After cleaning & degreasing I painted the tank with some gloss black epoxy paint-

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    As you can see the tree pollen nailed the can, so I finished the later coates in the garage.

    I also did the mount for the tank-

    [​IMG]
    #18
  19. DC950

    DC950 Microadventurer

    Joined:
    Mar 1, 2004
    Oddometer:
    2,926
    Location:
    Memphis, Motorcycle Purgatory
    very nice. I would really like to find one that good for the price you got it for!
    #19
  20. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,022
    Location:
    Denver, CO
    The new keys arrived!

    [​IMG]

    I bought the custom made keys from Armor Locksmith Lock Keys and Safes on ebay-

    [​IMG]

    He made the keys from the code that was on the back of the steering and helmet holder/sub fuel tank locks.

    Installed-

    [​IMG]

    Installed the tank & lock, just waiting on the new warning decal to come in-

    [​IMG]

    I also installed a missing shroud insultor-

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    Before-

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    After-

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    I'm just waiting on the crossmember cover & decals to come in. It will be complete after that!

    :freaky
    #20