Postie bike rebuild

Posted by jerry on March 5th, 2007 — Posted in Journal, Motorcycling

Progress! The Honda CT110 oversize piston kit arrived and the cylinder has now been rebored to fit the new piston.

piston kit

And with Sharon starting to be on the mend I took the opportunity during her sleep to start reassembly of Eve’s bike. First the new piston went on smoothly – the new piston pin slid neatly onto the connecting rod and the pisoton was secured with the new piston clips.

ct110 piston

After fitting the piston rings it was time to start on the barrel – there was a lot of rust and dirt on the barrel so I cleaned the exterior using kero brushed on and then a drill-mounted bronze wire brush.

CT110 cylinder

Then the tricky bit – fitting the cylinder without breaking the piston rings. After fitting a new bottom gasket I tackled the fitting. Not having a piston ring compression tool I used finger pressure to squeeze the rings closed as I gently lowered the barrel over the piston. This requires patience and eventually got it ride smoothly over the piston.

CT110 cylinder

taking care to thread the cam chain through. Then I fitted the cam sprocket to the cam chain and held it all in place with some thin wire.

Now for the head. I cleaned the carbon out of the combustion chamber and the valves, and removed the remnants of the previous gasket, before cleaning the outside of the head thoroughly and fitting a new head gasket.

I lowered this gently in place and then, after making sure the crankshaft was at top dead centre, I installed the cam through the cam chain sprocket and bolted it in place, using a small 10mmsocket wrench. I set the other socket wrench on the timing end of the crankshaft to stop the cranckshaft rotating when I tightened up the sprocket bolts.

Once in place it was a relatively quick process to install the covers with their respective new gaskets, so it looks nearly complete.

CT110 engine

Next step was to refit the carburettor inlet manifold – with its new gasket – and then the exhaust.

CT110 engine

Looks like a new engine now! And in many ways it is – it will need running in of course. But before I can test start it I want to get the footpegs and bash-plate back on – so more to come on this rebuild 🙂



Comment by alan

great stuff i want to up the capacity of my postie just put a 16 tooth front sprocket it now cruises at 90 but i’d like to rebore it as well what did you take it up to? thanks alan

Posted on May 28, 2008 at 3:32 pm

Comment by jerry

I just bought the first oversize – enough to overcome the wear marks in the cylinder but not enough to radically increase the capacity. But you can buy big-bore kits to take it up to 150cc, but you may need to check whether or not the crankcase may need additional machining to accept the bore sleeve. Good luck with it 🙂

Posted on May 28, 2008 at 5:48 pm

Comment by matthew white

i have a 2006 model how much would it cost to get some go out of it cheers matt

Posted on May 15, 2010 at 12:33 am

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