346-351-1404
CT90-ST90 Auto to Manual Clutch
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The manual clutch lever in place. One on the top is from a CT90 and the bottom one is from a CL90. Notice the difference in the oil dipstick location. Closer look at the CL90 Manual Clutch Cover. The Clutch Oil passage is exactly in the same place as the CT90 cover.
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The original CL90 clutch cover was painted with the center polished. The cover is one piece, just like the CT90 cover. The earlier S90 had two piece clutch cover, with removable center. Closer look at the clutch lever. This cover is powder coated black for my custom CT90. The manual clutch center is removable with the clutch plates installed. CL90 uses different clutch plates than the CT90. You cannot use the CT90 auto Clutch in this conversion.
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The center bearing and the clutch cover are the same as the CT90. The manual clutch plunger fits in the same place as the CT90 auto clutch mechanism. This is the shift lever on the CT90. This part has to be shortened, in order to fit the manual clutch cover. To avoid cutting a CT90 Shifter shaft, get a shifter shaft from a CL90 or S90 Engine.
On the top are the CT90 auto clutch parts. Everything is replaced by the plunger assembly in the bottom of the picture.
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The shorter lever is from a CL90. Almost identical levers. Use a cutoff wheel to cut the shifter shaft.
Leave about 3/8" stub (to be finished later)
Caution: Always wear eye protection while using power tools Install the shifter in the case and use a straight edge to make sure the cutoff part does not protrude above the side of the engine case.
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Trial fit the manual clutch cover and make sure everything fits. Install the clutch using clutch nut tool. OEM Honda clutch holder shown in this picture. You can use any method to hold clutch in place. Install clutch cable with the lever on the left side of handlebar.