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Table of Contents
Related Manuals for Honda XR190L 2017
Summary of Contents for Honda XR190L 2017
- Page 1 Shop Manual XR190L 1. General Information 2. Fuel & Engine 3. Frame & Chassis 4. Electrical System 5. XR190CT Addendum This book is Specific Shop Manual. XR190L-H (2017) Refer to “Basic Shop Manual” for basic and common maintenance instructions. XR190CT-H (2017)
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Page 2: Table Of Contents
5. XR190CT-H ADDENDUM A Few Words About Safety ···················· 5-2 BODY PANELS ······································ 5-16 How To Use This Manual························ 5-3 RIGHT SIDESTAND ······························· 5-18 MODEL IDENTIFICATION ······················· 5-4 FRONT WHEEL······································ 5-19 SPECIFICATIONS ···································· 5-5 FORK ······················································ 5-21 TORQUE VALUE······································ 5-7 STEERING STEM···································... -
Page 3: A Few Words About Safety
Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. -
Page 4: How To Use This Manual
PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. -
Page 5: Model Identification
XR190CT-H ADDENDUM MODEL IDENTIFICATION • Model name: XR190CT-H Code/Type Destination Latin America Australia, New zealand, South Africa VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER COLOR LABEL... -
Page 6: Specifications
XR190CT-H ADDENDUM SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2,103 mm Overall width 842 mm Overall height 1,127 mm Wheelbase 1,369 mm Seat height 827 mm Footpeg height 292 mm Ground clearance 237 mm Curb weight 137 kg Maximum weight capacity 95 kg FRAME Frame type... - Page 7 XR190CT-H ADDENDUM ITEM SPECIFICATION DRIVE TRAIN Clutch system Multi-plate, wet Clutch operation system Cable operating Transmission 5 speeds Primary reduction 3.136 (69/22) Final reduction 3.467 (52/15) Gear ratio 2.785 (39/14) 1.789 (34/19) 1.368 (26/19) 1.090 (24/22) 0.928 (26/28) Gearshift pattern Left foot operated return system 1 - N - 2 - 3 - 4 - 5 ELECTRICAL...
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Page 8: Torque Value
XR190CT-H ADDENDUM TORQUE VALUE • Each fastener should be tightened to the standard torque value except the fasteners specified torque value. • Q’TY: Quantity, DIA: Thread diameter (mm), TRQ: Tightening torque (N·m) STANDARD TIGHTENING TORQUE FASTENER TYPE FASTENER TYPE 5 mm hex bolt and nut 5 mm screw 6 mm hex bolt and nut 6 mm screw... -
Page 9: Special Tool List
XR190CT-H ADDENDUM SPECIAL TOOL LIST TITLE TOOL No. TOOL NAME 07406-0040004 Fuel pressure gauge 070MJ-K260100 Fuel pressure gauge attachment 070MF-KVS0300 Fuel pump case remover 070PZ-ZY30100 SCS short connector 07708-0030200 Locknut wrench, 10 x 12 mm 07908-KE90000 Tappet adjusting wrench, 3 x 4 mm 070MG-0010100 Tensioner stopper Fuel &... -
Page 10: Cable & Harness Routing
XR190CT-H ADDENDUM CABLE & HARNESS ROUTING COMBINATION SWITCH WIRE LEFT RIGHT HEADLIGHT HANDLEBAR HANDLEBAR WIRE SWITCH WIRE SWITCH WIRE RIGHT HANDLEBAR LEFT SWITCH WIRE HANDLEBAR SWITCH WIRE TURN SIGNAL MAIN WIRE LIGHT HARNESS WIRE INSIDE BOOT CONNECTORS: · LEFT HANDLEBAR 9P ·... - Page 11 XR190CT-H ADDENDUM THROTTLE CABLE A 2 – 4 mm THROTTLE CABLE B SPEEDOMETER CABLE WHITE IDENT MARK AREA (15 mm) WHITE IDENT MARK 5-10...
- Page 12 XR190CT-H ADDENDUM INSIDE BOOT CONNECTORS: BATTERY · REAR BRAKE LIGHT SWITCH 2P NEGATIVE (–) NEUTRAL · ALTERNATOR 3P CABLE SWITCH · ALTERNATOR 2P WIRE · NEUTRAL SWITCH WIRE CONNECTOR To be butted. SENSOR 2P CONNECTOR ALTERNATOR WIRE EOT SENSOR 2P CONNECTOR ECM 33P CONNECTOR STARTER...
- Page 13 XR190CT-H ADDENDUM NEUTRAL NEUTRAL SWITCH WIRE SWITCH WIRE DRIVE SPROCKET COVER NEUTRAL SWITCH WIRE DRIVE SPROCKET COVER DRIVE SPROCKET COVER BANK ANGLE SENSOR 3P CONNECTOR IGNITION COIL WIRE 5-12...
- Page 14 XR190CT-H ADDENDUM MAIN WIRE HARNESS INJECTOR 2P CONNECTOR MAIN WIRE IACV 4P HARNESS CONNECTOR MAIN WIRE HARNESS TURN SIGNAL LIGHT WIRE INSIDE BOOT CONNECTORS: · LICENSE LIGHT 2P · BRAKE/TALE LIGHT 3P · LEFT REAR TURN SIGNAL LIGHT WIRE CONNECTOR ·...
- Page 15 • * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. • ** In the interest of safety, we recommend these items be serviced only by a dealer. • Honda recommends that a dealer should road test the vehicle after each periodic maintenance is carried out. NOTES: 1.
- Page 16 • * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. • ** In the interest of safety, we recommend these items be serviced only by a dealer. • Honda recommends that a dealer should road test the vehicle after each periodic maintenance is carried out. NOTES: 1.
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Page 17: Body Panels
XR190CT-H ADDENDUM BODY PANELS DRIVE CHAIN COVER (U type only) MUD GUARD ENGINE GUARD 5-16... - Page 18 XR190CT-H ADDENDUM REAR CARRIER REAR CARRIER BASE • Rear center cowl 3-5 5-17...
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Page 19: Right Sidestand
XR190CT-H ADDENDUM RIGHT SIDESTAND 39 N·m 10 N·m Sliding surface • After tightening the pivot bolt to the specified torque, turn it 45 – 90 ° counterclockwise. • When tightening the pivot nut, hold the pivot bolt securely. 5-18... -
Page 20: Front Wheel
XR190CT-H ADDENDUM FRONT WHEEL 59 N·m • Wheel inspection 5-19... - Page 21 XR190CT-H ADDENDUM 20 N·m • Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft and drive out the bearing from the wheel hub. Bearing remover head, 15 mm: 07746-0050400 Bearing remover shaft: 07746-0050100 •...
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Page 22: Fork
XR190CT-H ADDENDUM FORK 20 N·m 32 N·m 12 N·m • Front fender 3-4 • Front wheel 3-14 • Front brake caliper 3-26 • Align the mating surface with the top surface of the top bridge. 5-21... - Page 23 XR190CT-H ADDENDUM 140 mm 22 N·m 20 N·m LEFT RIGHT • Remove the oil seal. Oil seal remover: 07748-0010001 • Drive in a new oil seal squarely with its marked side facing up until it is fully seated. Fork seal driver weight: 07747-0010100 Fork seal driver attachment: 07747-0010600 •...
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Page 24: Steering Stem
XR190CT-H ADDENDUM STEERING STEM TOP BRIDGE 20 N·m 103 N·m • Speedometer 4-34 • Handlebar 3-18 5-23... -
Page 25: Rear Suspension
XR190CT-H ADDENDUM REAR SUSPENSION 44 N·m 44 N·m • Left side cover 3-7 88 N·m 44 N·m 44 N·m • Rear wheel 3-21 • Drive chain case 3-7 5-24... - Page 26 XR190CT-H ADDENDUM 4.5 mm 3.8 – 4.2 mm 0.7 mm 0.7 mm 44 N·m 6.8 – 7.2 mm 0.5 mm 44 N·m 8 – 9 mm 6.0 N·m • Press the bearings with the marked side facing out. 5-25...
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Page 27: Front Brake
XR190CT-H ADDENDUM FRONT BRAKE BRAKE MASTER CYLINDER 1.0 N·m Silicone grease Silicone grease 1.2 N·m 5.9 N·m • Brake fluid 3-24 • Remove the snap ring. Snap ring pliers: 07914-SA50001 • Master cylinder inspection 5-26... -
Page 28: Electrical Starter
XR190CT-H ADDENDUM ELECTRICAL STARTER STARTER MOTOR • Starter motor 4-25 • Electric starter inspection SPEEDOMETER VS SENSOR 5-27... - Page 29 MEMO...
- Page 30 XR190CT-H (LA, U) STARTER MOTOR FUSE BOX SUB1 SUB2 STARTER TURN DC-LOAD RELAY BANK CUT RELAY REAR SIGNAL SWITCH ANGLE IGNITION BRAKE LIGHT RELAY SENSOR SWITCH SWITCH IACV BATTERY 12V 6Ah FRONT BRAKE LIGHT SWITCH STARTER SWITCH Bl/R Bl/R Bl/R DIODE Lg/R FUEL METER...
- Page 31 © Honda Motor Co.,Ltd. 2016 Book#: 62K79B0Z Published by Honda Motor Co.,Ltd. A. 2016.11 Printed in Japan...