Okay, so my old 1968 Honda Trail 90 was running alright, kinda rough though. Felt sluggish on trails. Started digging around forums and asking guys at bike meets what parts make the biggest difference without going full custom. Everyone kept pointing at the same classic upgrades, so I figured why not give ’em a shot.
First Thing – Yanking That Old Carb Off
Got my hands dirty right in the driveway. Unbolted the airbox first – those old rubber tubes were cracked and brittle like stale bread. Then disconnected the fuel line, messy stuff, gas everywhere. Wrenched the old carb free; thing was gummed up inside, no wonder it ran like crap. Swapped in a brand-new reproduction Keihin carb, exact match for the ’68 model. Took forever getting the throttle cable hooked up right without kinking it. Cussed a bunch, but finally snapped it into place. Made sure the choke lever moved smooth.
Next Up – Electrics & Lights
The stock headlight bulb? Might as well been a candle. Dropped in a brighter halogen bulb – direct fit, popped right in the same housing. Then tackled the spark plug. Pulled the old one out; electrode was nasty black and worn down. Slapped in a fresh NGK plug, gapped it real careful with that coin tool. Tightened it down snug but not too tight, remember cracking one once. Big difference just kicking it over – sounded crisper right away.
Gears and Wheels Time
Heard skinnier tires help on loose dirt, so ordered these classic-style Cheng Shins. Broke the bead on the old ones with screwdrivers and a hammer like a caveman. Mounted the new fronts first, wrestling the rubber onto the rim. Used zip ties to squeeze the tire beads together while popping the tube in, trick I learned online. Back tire fought me hard. Had to:
- Soap the beads three times
- Jump on the dang thing
- Finally got it seated with a loud POP
Changed both tubes too cause the old ones looked rotten. Greased the axles good before sliding wheels back on.
Finishing Touches
Noticed the clutch lever wobbled like crazy. Found a shiny new lever assembly at a swap meet. Took apart the handlebar clamp, swapped the lever assembly in ten minutes. Adjusted the cable play while sitting on the bike. Also dumped fresh 10W-30 in the cases, simple stuff but the shifting felt way smoother afterward.
Test Ride Feels
Cranked her up – fired quicker than ever. Let it warm up, then took it down the dirt road behind my place. Felt like a new bike! Quicker throttle response climbing hills, way more traction in corners with the new tires. Headlight actually lit up the trail at night. Stalled twice tweaking the carb idle screw, but got it dialed in eventually. Whole project took a weekend, two trips to the parts store, and maybe four cold beers worth of frustration. Still kicks over first try every morning now.
