Honda S90 - Restoration
April 16, 2012 - Bike is For Sale!
It's been a long, long time since I've had the time or motivation to work on my languishing Honda S90 restoration project. I've revived this project, with the intent to sell the bike, since I don't really have much interest in keeping or riding it.
Recently, I've recovered the seat (the old one was pretty beat with some tears), charged the 6v battery and started on rewiring everything with the new wiring harness.
If someone wants to buy it before it's fully back together again (engine and all systems work fine!), with many spare/new/original parts, manuals, ownership, etc.then I'll let it go
for $1500 CDN for the whole kit and kaboodle.
You can reach me at email@example.com if you are interested.....
July 24, 2005
Finally had some time and inclination to resume the work on the S90 yesterday afternoon. I replaced all the cables with new grey ones (throttle, clutch, front brake and speedo) and installed the NOS handlebar grips instead of the aftermarket ones the bike came with. The throttle grip took a bit of elbow grease, but I finally managed to get the old one off with some persuasion using a rubber mallet. When it doesn't work, get a BFH! ;-) Reassembled the petcock with some newer parts, so hopefully that will cure the final gas leaking issues that keep plaguing me.
Dropped the engine (again) and pulled out the old hacked wiring and replaced it with the new harness that had arrived courtesy of some eBay'ing. Had to pull the pins and replace the connector housings with the older ones, since the new ones were a bit too tight, but that was an easy task. Fished the front harness connectors to the front of the frame with a handy straightened coathanger wire. Took a bit of fishing of wires, but finally reinstalled the battery. For fun, I installed the horn (another eBay find), turned on the ignition key and hit the horn button. Lo and behold, the horn sounded! Kind of whimpy, but cute and appropriate for a 6V, 40 year old bike. Very cool.
Next step will be to start connecting all the other switches/lights on the handlebars and running some wires for the taillight, then re-install the engine to test to see if it still runs with the new harness. All the wire colours matched so I don't expect any issues with running the engine, but one never knows! Then again, I might decide to test the engine first, before getting too deep into the auxiliary wiring issues. That would probably be a smart thing to do.
Still searching for a flasher (winker) relay and some rear indicator lights to complete the restoration project.....ping me if you have any leads or know where to find any of these items!
April 13, 2005
Pulled the gas tank off to make it easier to augment the wiring harness to include cables for the headlight, horn and turn signals.
While I was at it, disassembled the petcock, to see what is causing it to have a slow leak. Looks like there is a small hole in the bottom resevoir,
The first pair of turn signals (winkers for the Pommies tracking this blog) have arrived. I'm waiting for the new headlight bucket/speedo, brake cable
April 4, 2005
As promised last week, I've posted pictures of some of the used S90 parts that I have for sale here as a result of me replacing items
Today was "thread the wires through the bars" day. Wasn't too bad, but then doing all internal wiring on my '96 Wide Glide
Here's what the new housings look like...very nice!
Next up will be wiring them all in, but that has to wait till the new headlight bucket and turn signals arrive in the mail. Not much point futzing with
Front view of the triple tree with the new wiring exiting the bars.
Still no leaks from the carb float bowl! Yay! Just for fun, I also installed the new kick starter and footpeg rubbers. Gotta practice
Closeup of the non-leaking carb!
But now I've noticed that there is no side stand on this bike, so I'll have to keep an eye out for one on eBay. As you can see from the above photo,
March 30, 2005
Carb float bowl was still leaking slowly, so I fabricated a new gasket out of thicker cork/rubber material.
Took off the old switch housings and put on the new levers. What that means is that I have a set of older ones available. The
Got a new headlight housing coming with a four bulb speedo unit, so I'll be selling the existing 3-light housing/speedo as well.
The brake cable seems a bit too tight and the end connector doesn't quite fit the levers right, so I've ordered a NOS one
March 27, 2005
Today was mainly spent scraping ice on the driveway with the blade on the ATV, in the hopes that it will melt faster and that I can get
Dana came down for a beer to the garagemahal, and wanted to hear the S90 running, so I dropped the lift, and kicked her over (the bike...not Dana).
Pulled the float bowl...bone dry! Guess that is the problem. Turns out the new gasket I fabricated was holding back the float, so
But now I have a very slow gas leak out of the carb again. Might need a second layer of gasket material, but wasn't inspired to
Needed a fix, so I topped up the oil and gas, then took the dirt bike across the ice flows and down the shoulder to a nearby dirt road.
It was great to be in the wind again for the first time after a long, cold winter, and has me wanting to take one of the Hawg's out
Felt guilty, not really giving the S90 much attention, so I tried a technique recommended by a member of the
March 26, 2005
Carburator has been leaking badly for some reason, so tonight's task was to try and figure out what the problem was and fix it.
I had put some RTV gasket maker on the float bowl, but that seemed to make things worse. I picked up some rubber gasket material sheets
The rest of the time was spent setting up the MIG welder (finally....after way too long). Love the electronic helmet.
Snow is melting fast in the driveway, so rather than install the new switch housings and do lots of wiring work, I think I'll reinstall the
March 24, 2005
Spent some time playing with the S90 in the garage tonight.
Reinstalled the engine, hooked up the carb, added gas to the tank and
Lift the bike, pull the plug, check for spark. No spark. Hmmmm...that
Checked for battery power....nothing from the fused lead. Turns out
Drop the lift, kick the bike. Nothing! Damn. Oh yeah...turn the
Lift the bike, and pull the plug. Check for spark. Got spark, but it
Turn on ignition and gas, twist the throttle and kick the bike, and
Shut it off. Kick it again....she starts like a charm and runs fine.
Didn't test the tranny, since I still have the sprocket and chain off,
Gotta love the internet! 10 years ago I don't think I could have proceeded
with getting the
Special thanks to Fred in the Netherlands for scanning/posting/emailing
Service and Parts
Yeeehaaa! It lives, Igor! ;-)
March 18, 2005
Back in the garage this evening working on the Honda S90
Took the new battery (yet another eBay acquisition) to a local battery
Installed the coil and condenser (eBay parts yet again). The coil
Spent some time digesting the wiring diagram, and hooked up the battery
Speaking of which, where does the rectifier usually get mounted?
Grounded the key housing and the spark plug, since the engine is
YeeeHaaa! That is a good thing!
Now I have to reinstall the engine in the frame and hook up the carb.
Pretty good progress tonight, with some serious steps towards making
March 7, 2005
Finally spent a bit of time in the garage this afternoon.
Cleaned up some
So the Honda S90 is now on the lift. I dropped the engine, and
I would say that was pretty good progress for an afternoon. ;-)
Now I'm cruising eBay for some of the little parts I need to do a good
We had initially gone to a friends to get some "free" plants from her garden. Saw the Yamaha RT180 and the Honda S90 for sale on the side of the road on our way there. Still there on the way back, so had to stop and check things out. That was a mistake! So I picked up some new toys. Always wanted a dirt bike for playing around but not enough to spend the moola to buy a new one. The cute Honda S90 was bundled in the deal and cost me $200, so I couldn't pass it up. Damned good shape for the price, I think. The owner said the prior owner had it running fine, but had pulled the coil and condenser for some other use, so these parts are missing.
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