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Shop Manual

XR190L
1. General Information

2. Fuel & Engine

3. Frame & Chassis

4. Electrical System

5. XR190CT Addendum

This book is Specific Shop Manual.


Refer to “Basic Shop Manual” for basic and XR190L-H (2017)
common maintenance instructions.
XR190CT-H (2017)
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··································· 5-23

SPECIAL TOOL LIST······························· 5-8 REAR SUSPENSION ····························· 5-24

CABLE & HARNESS ROUTING ·············· 5-9 FRONT BRAKE ······································ 5-26

MAINTENANCE SCHEDULE ELECTRICAL STARTER ······················· 5-27


(LA type)················································· 5-14
SPEEDOMETER ···································· 5-27
MAINTENANCE SCHEDULE
(U type)··················································· 5-15

5-1
XR190CT-H ADDENDUM

A Few Words About Safety


XR190CT-H ADDENDUM

Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. 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.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.

For Your Customer’s Safety


Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

Improper service or repairs can create an unsafe


condition that can cause your customer to be
seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.

For Your Safety


Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.

Failure to properly follow instructions and


precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.

Important Safety Precautions


Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

5-2
XR190CT-H ADDENDUM

How To Use This Manual


This manual describes the service procedures for the XR190CT-H.
Refer to XR190L-H SHOP MANUAL (No.62K79B0) for service procedures and data not included in this addendum.

Your safety, and the safety of others, is very important. To help you make informed decisions we have provided
safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you
about all the hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING,
or CAUTION. These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

As you read this manual, you will find information that is preceded by a symbol. The purpose of this message
is to help prevent damage to your vehicle, other property, or the environment.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS


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. THIS MANUAL IS WRITTEN FOR
PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES,
MOTOR SCOOTERS OR ATVS.

© Honda Motor Co., Ltd.


SERVICE PUBLICATION OFFICE
Date of Issue: November, 2016

5-3
XR190CT-H ADDENDUM

MODEL IDENTIFICATION
• Model name: XR190CT-H
Code/Type Destination
LA Latin America
U Australia, New zealand, South Africa

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER


COLOR LABEL

5-4
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 Semi double cradle type
Front suspension Telescopic fork
Front wheel travel 160 mm
Rear suspension Pro-Link
Rear wheel travel 151 mm
Front tire size 2.75 - 21 45M
Rear tire size 90/100 - 18M/C 54M
Front tire brand CM-725 (CHENG SHIN)
Rear tire brand CM-726 (CHENG SHIN)
Front brake Hydraulic single disc
Rear brake Mechanical leading trailing
Caster angle 27° 10’
Trail length 101 mm
Fuel tank capacity 12.0 liter
Fuel tank reserve capacity 3.9 liter
ENGINE Cylinder arrangement Single cylinder inclined 15° from vertical
Bore and stroke 61.000 x 63.096 mm
Displacement 184.43 cm3
Compression ratio 9.5 : 1
Valve train Chain driven OHC with rocker arm
Intake valve opens 0° BTDC at 1 mm lift
closes 25° ABDC at 1 mm lift
Exhaust valve opens 30° BBDC at 1 mm lift
closes -5° ATDC at 1 mm lift
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Viscous paper filter
Engine dry weight 29.6 kg
Emission control system Crankcase emission control system
Three-way catalytic converter
FUEL SYSTEM Type PGM-FI (Programmed Fuel Injection)
Throttle bore 30 mm

5-5
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 1st 2.785 (39/14)
2nd 1.789 (34/19)
3rd 1.368 (26/19)
4th 1.090 (24/22)
5th 0.928 (26/28)
Gearshift pattern Left foot operated return system
1-N-2-3-4-5
ELECTRICAL Ignition system Full transistorized
Starting system Electric starter motor and kickstarter
Charging system Single phase output alternator
Regulator/rectifier SCR opened, single phase half-wave rectification
Lighting system Alternator

FUEL & ENGINE SPECIFICATIONS


CYLINDER HEAD
Unit: mm
ITEM STANDARD LIMIT
Camshaft Cam lobe height IN 33.977 – 34.217 33.947
EX 33.807 – 34.047 33.777

FRAME & CHASSIS SPECIFICATIONS


FRONT WHEEL/SUSPENSION/STEERING
Unit: mm
ITEM STANDARD LIMIT
Fork Recommended fork fluid CN10 # –
Fluid level 140 mm –
Fluid capacity 420 cm3 –
REAR WHEEL/BRAKE/SUSPENSION
Unit: mm
ITEM STANDARD LIMIT
Drive chain size/link 428HO/132LE –

5-6
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 TRQ FASTENER TYPE TRQ
5 mm hex bolt and nut 5.2 5 mm screw 4.2
6 mm hex bolt and nut 10 6 mm screw 9.0
8 mm hex bolt and nut 22 6 mm flange bolt 12
10 mm hex bolt and nut 34 8 mm flange bolt and nut 27
12 mm hex bolt and nut 54 10 mm flange bolt and nut 39
SIDESTAND
ITEM Q'TY DIA TRQ REMARKS
Sidestand pivot bolt 1 10 10 5-18
Sidestand pivot nut 1 10 39 Self lock nut 5-18
FRONT WHEEL
ITEM Q'TY DIA TRQ REMARKS
Front axle bolt 1 12 59
Front brake disc bolt 5 6 20 Pre-coated (ALOC) bolt,
replace with a new one.
FORK
ITEM Q'TY DIA TRQ REMARKS
Top bridge pinch bolt 4 8 20
Bottom bridge pinch bolt 4 8 32
Brake hose clamper bolt 2 6 12
Fork bolt 2 27 22
Fork socket bolt 2 8 20 Apply locking agent.
REAR SUSPENSION
ITEM Q'TY DIA TRQ REMARKS
Shock link nut (frame side) 1 10 44 Self lock nut
Shock link nut (shock arm side) 1 10 44 Self lock nut
Shock arm nut (swingarm side) 1 10 44 Self lock nut
Shock absorber upper bolt 1 10 44
Shock absorber lower nut 1 10 44 Self lock nut
Swingarm pivot nut 1 14 88 Self lock nut
Drive chain slider screw 1 5 6.0
FRONT BRAKE
ITEM Q'TY DIA TRQ REMARKS
Brake lever pivot bolt 1 6 1.0
Brake lever pivot nut 1 6 5.9
Front brake light switch screw 1 4 1.2

5-7
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 & Engine
07757-0010000 Valve spring compressor
07984-MA60001 Valve guide reamer, 5.0 mm
07942-MA60000 Valve guide driver, 4.8 mm
07724-0010200 Gear holder
07GMB-KT70101 Clutch center holder
07725-0040001 Flywheel holder
07933-KM10001 Flywheel puller
07746-0050400 Bearing remover head, 15 mm
07746-0050100 Bearing remover shaft
07746-0010200 Attachment, 37 x 40 mm
07746-0010100 Attachment, 32 x 35 mm
07746-0040300 Pilot, 15 mm
07749-0010000 Driver
07748-0010001 Oil seal remover
07747-0010100 Fork seal driver weight
Frame & Chassis
07747-0010300 Fork seal driver attachment
07747-0010600 Fork seal driver attachment
07916-KA50100 Lock nut wrench
07746-0050500 Bearing remover head, 17 mm
07746-0040400 Pilot, 17 mm
07953-MJ10000 Ball race remover set
07746-0010300 Attachment 42 x 47 mm
07914-SA50001 Snap ring pliers

5-8
XR190CT-H ADDENDUM

CABLE & HARNESS ROUTING

COMBINATION
SWITCH WIRE

RIGHT HEADLIGHT LEFT


HANDLEBAR WIRE HANDLEBAR
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
· LEFT HANDLEBAR SWITCH
MAIN WIRE WIRE CONNECTOR
HARNESS

MAIN WIRE
HARNESS

INSIDE BOOT CONNECTORS:


· RIGHT HANDLEBAR SWITCH 6P
· LEFT FRONT TURN SIGNAL LIGHT
WIRE CONNECTOR
· RIGHT FRONT TURN SIGNAL LIGHT 5 – 10 mm
WIRE CONNECTOR
· FRONT TURN SIGNAL LIGHT
GROUND WIRE CONNECTOR

5-9
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
XR190CT-H ADDENDUM

INSIDE BOOT CONNECTORS: BATTERY


· REAR BRAKE LIGHT SWITCH 2P NEGATIVE (–)
· ALTERNATOR 3P NEUTRAL
CABLE
· ALTERNATOR 2P SWITCH
· NEUTRAL SWITCH WIRE CONNECTOR WIRE

To be butted.

O2 SENSOR
2P CONNECTOR
ALTERNATOR
WIRE

EOT SENSOR
2P CONNECTOR DLC
ECM 33P
CONNECTOR

STARTER
MOTOR
CABLE

BATTERY
NEGATIVE (–)
CABLE

45° ± 5°
ALTERNATOR
WIRE
BATTERY
NEGATIVE (–)
CABLE
NEUTRAL
SWITCH WIRE

5-11
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
XR190CT-H ADDENDUM

MAIN WIRE
HARNESS

INJECTOR 2P
CONNECTOR

MAIN WIRE
HARNESS IACV 4P
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
· RIGHT REAR TURN SIGNAL LIGHT WIRE CONNECTOR
· REAR TURN SIGNAL LIGHT GROUND WIRE CONNECTOR

5-13
XR190CT-H ADDENDUM

MAINTENANCE SCHEDULE (LA type)


• Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
• I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
• The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may
require more technical information and tools. Consult a dealer.
• Refer to “Basic" Service Manual for each maintenance instruction except the instructions described in this
manual.

FREQUENCY (NOTE 1) REFER


ANNUAL REGULAR
ITEMS NOTE X1,000 km 1 6 12 18 24 30 36 CHECK REPLACE TO
X1,000 mi 0.6 4 8 12 16 20 24 PAGE
* FUEL LINE I I I I I I I
* THROTTLE OPERATION I I I I I I I
* AIR CLEANER NOTE2 R R 2-7
CRANKCASE BREATHER NOTE3 C C C C C C
SPARK PLUG I R I R I R 4-22
* VALVE CLEARANCE I I I I I I 2-14
ENGINE OIL R R R R R R R R 2-13
** ENGINE OIL STRAINER
C C C 2-13
SCREEN
** ENGINE OIL CENTRIFUGAL
C C C 2-21
FILTER
* ENGINE IDLE SPEED I I I I I I I I
DRIVE CHAIN NOTE4 Every 1000 Km (600 mi) I, L
DRIVE CHAIN SLIDER I I I I I I
BRAKE FLUID NOTE5 I I I I I I I 2 years
BRAKE SHOES/PADS WEAR I I I I I I I
BRAKE SYSTEM I I I I I I I I
BRAKE LIGHT SWITCH I I I I I I I
HEADLIGHT AIM I I I I I I I 4-33
CLUTCH SYSTEM I I I I I I I I
SIDESTAND I I I I I I I
* SUSPENSION I I I I I I I
* NUTS, BOLTS, FASTENERS NOTE4 I I I I I
** WHEELS/TIRES NOTE4 I I I I I I I
** STEERING HEAD BEARINGS I I I I
• * 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. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Service more frequently when riding OFF-ROAD.
5. Replacement requires mechanical skill.

5-14
XR190CT-H ADDENDUM

MAINTENANCE SCHEDULE (U type)


• Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
• I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
• The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may
require more technical information and tools. Consult a dealer.
• Refer to “Basic" Service Manual for each maintenance instruction except the instructions described in this
manual.

FREQUENCY (NOTE 1) REFER


ANNUAL REGULAR
ITEMS NOTE X1,000 km 1 6 12 18 24 30 36 CHECK REPLACE TO
X1,000 mi 0.6 4 8 12 16 20 24 PAGE
* FUEL LINE I I I I I I I
* THROTTLE OPERATION I I I I I I I
* AIR CLEANER NOTE2 R R 2-7
CRANKCASE BREATHER NOTE3 C C C C C C
SPARK PLUG I R I R I R 4-22
* VALVE CLEARANCE I I I I I I 2-14
ENGINE OIL R R R R R R R R 2-13
** ENGINE OIL STRAINER
C C C 2-13
SCREEN
** ENGINE OIL CENTRIFUGAL
C C C 2-21
FILTER
* ENGINE IDLE SPEED I I I I I I I I
DRIVE CHAIN NOTE4 Every 1000 Km (600 mi) I, L
DRIVE CHAIN SLIDER I I I I I I
BRAKE FLUID NOTE5 I I I I I I I 2 years
BRAKE SHOES/PADS WEAR I I I I I I I
BRAKE SYSTEM I I I I I I I
BRAKE LIGHT SWITCH I I I I I I I
HEADLIGHT AIM I I I I I I I 4-33
CLUTCH SYSTEM I I I I I I I
SIDESTAND I I I I I I I
* SUSPENSION I I I I I I I
* NUTS, BOLTS, FASTENERS NOTE4 I I I I
** WHEELS/TIRES NOTE4 I I I I I I I
** STEERING HEAD BEARINGS I I I I
• * 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. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Service more frequently when riding OFF-ROAD.
5. Replacement requires mechanical skill.

5-15
XR190CT-H ADDENDUM

BODY PANELS
DRIVE CHAIN COVER (U type only)

MUD GUARD

ENGINE GUARD

5-16
XR190CT-H ADDENDUM
REAR CARRIER

REAR CARRIER BASE

• Rear center cowl 3-5

5-17
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
XR190CT-H ADDENDUM
FRONT WHEEL

59 N·m

• Wheel inspection

5-19
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
• Drive in a new bearing squarely with its marked side facing outside until it is fully seated.
Driver: 07749-0010000
Attachment, 32 x 35 mm: 07746-0010100
Pilot, 15 mm: 07746-0040300
• Install the distance collar.
• Drive in a new bearing squarely with its marked side facing outside until it is seated on the distance collar.
Driver: 07749-0010000
Attachment, 32 x 35 mm: 07746-0010100
Pilot, 15 mm: 07746-0040300
• Wheel disassembly and inspection

5-20
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
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
• Pour the specified amount of recommended fork fluid into the fork pipe.
RECOMMENDED FORK FLUID: CN10# or equivalent
FORK FLUID CAPACITY: 390 cm3
• Compress the fork leg fully and measure the fluid level from the top of the fork pipe.
FORK FLUID LEVEL: 140 mm
• Pull the fork pipe up and install the fork spring with its tightly wound coil side facing down.

• Fork disassembly and inspection

5-22
XR190CT-H ADDENDUM
STEERING STEM
TOP BRIDGE

20 N·m
103 N·m

• Speedometer 4-34
• Handlebar 3-18

5-23
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
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
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
XR190CT-H ADDENDUM
ELECTRICAL STARTER
STARTER MOTOR

• Starter motor 4-25

• Electric starter inspection

SPEEDOMETER
VS SENSOR

5-27
MEMO
XR190CT-H (LA, U)
STARTER
MOTOR

FUSE BOX
SUB1 SUB2
STARTER

R
TURN DC-LOAD ECM
RELAY BANK
SIGNAL SWITCH CUT RELAY ANGLE REAR

IACV1B
IACV2B

IACV1A
IACV2A
BRAKE LIGHT

K-LINE
RELAY IGNITION

SP-SE

IGPLS
NLSW

FI IND
BANK
15A SENSOR

PCM

PCR
VCC
SWITCH

10A

10A

SCS

PCP
SWITCH

PG2
PG1
FFP

THL

IGP
INJ

SG
DLC

TO
PB

O2
LG
TA
-

-
BAT1
IACV

GND
R

OUT
Vcc

A-33
A-32
A-31
A-30
A-29
A-28
A-27
A-26
A-25
A-24
A-23
A-22
A-21
A-20
A-19
A-18
A-17
A-16
A-15
A-14
A-13
A-12

A-10
A-11

A- 9
A- 8
A- 7
A- 6
A- 5
A- 4
A- 3
A- 2
A- 1
4P

VO1
2P R 3P 4P 33P
Bl 4P
BATTERY R
12V 6Ah

Gr/Bu
Bu/W

Bu/W

W/Bu
Bu/Bl

Bu/Bl
R/Bu

R/Bu

R/Bu

Br/W

R/Bu

Br/W

Bu/Y
Br/Bl

Br/Bl

Y/Bu

P/Bu

Bl/W
Lg/Y
G/W

G/W
R/W

Bl/G

Bl/O
Bl/G

G/Bl

G/Bl
W/Y
Bl/R

Bl/R

Bl/R

Bl/R

Bl/R

Bl/R
P/Bl
G/R
G/R

G/R

G/Y
Y/R

Y/R

Y/R
Bu

Bu
Gr
Bl

Bl
Bl

Bl
G
G
R
R

P
Y

Y
2P

Bl 2P
FRONT

G/Y
6P

Bl
BRAKE
LIGHT

R/Bu
R/W
SWITCH G/Y Bl Bl
G/Y G/Y
STARTER ST BAT
Y/R Y/R Y/R
SWITCH Bl/R Bl/R Bl/R

G/R 2P
Bl G/R
Lg/R
DIODE
FUEL METER Y/W
Lg/R
G/Bl

HI-BEAM IND Bu 9P Bl
12V 1.7W G Bl Bl LICENSE LIGHT
Y/W Y/W 12V 5W
FI IND Bl Bu Bu
12V 3.4W W/Bu W/Bu W/Bu G
Y
N IND Bl
12V 3.4W Lg/R Lg/R Lg/R
Y Y RIGHT REAR
TURN IND Lb TURN SIGNAL LIGHT
12V 3.4W O Lb Lb 12V 10W
O O
METER ILLUMI 2 Y G/Bl G/Bl 2P Lb
12V 1.7W G G G G G G
4P R Y Y
METER ILLUMI 1 Y Lb Lb
12V 2.0W G G BRAKE/TAIL LIGHT
G
G 12V 5W/21W
O O
G/Y G/Y G/Y
RIGHT FRONT G G G
TURN SIGNAL Lb Y Y Y
LIGHT G 3P
12V 10W LEFT REAR
TURN SIGNAL LIGHT
12V 10W
HEAD LIGHT
4P Bl G
12V 35W/35W Y Y O
Bl Bl Bu
W W W
G G G
G
G
G

Y/R
Y/R
Y/R
Lb Lb
POSITION Y O O
LIGHT

Gr/Bu
G

Lg/Y
Bl/W

G/W
Y/R
12V 5W
Bu/Y
Lg/R
G/Bl
G/Bl
G/Bl
G/Bl

G/Bl
G/Bl
G/Bl

W/Y

Y
W
G

LEFT FRONT 5P
2P
TURN SIGNAL O 3P 2P
Bl
LIGHT G
12V 10W

Gr/Bu
Bu/Y
W/Y

Lg/Y
G/W
Y/R
W
G

Y
9P Bl
L
TURN O O O
W
SIGNAL Gr Gr Gr
SWITCH R Lb Lb Lb
Bl G/R
LO W W W
DIMMER HL Y Y Y
SWITCH Bu Bu Bu
HI
G G
HO
HORN Lg Lg Lg
Bl/O

G/Bl
Bl/R

Y/W

SWITCH BAT
Bl Bl Bl

Gr/Bu
P/Bu

Lg/Y
G/W
G/W
G/W
G/W

G/W

G/W

G/W
G/Bl
G/Bl
R/W

Bl/R

Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R

P/Bl

Y/R

Y/R
W

Bl

G
G

G
G
Y/Bu

R
Y

Y
G/W
G/Bl

B/R

5P
Lg

CLUTCH Bl
SWITCH G
W
Bu/Y
Lg/R

2P 6P 2P
Bl/O

G/Bl
Bl/R

Y/W

O2 MAP
HORN SENSOR SENSOR TP
W/Y

IAT SENSOR
G

3P
EOT INJECTOR SENSOR
REGULATOR
SENSOR CKP ALTERNATOR /RECTIFIER
FUEL FUEL SENSOR
PUMP LEVEL
VS SENSOR SENSOR IGNITION
COIL
NEUTRAL
SWITCH Bl Black Br Brown
IGNITION STARTER HORN TURN SIGNAL DIMMER Y Yellow O Orange
SWITCH SWITCH SWITCH SWITCH SWITCH Bu Blue Lb Light Blue
BAT1 VO1 BAT ST BAT HO W R L HL LO HI G Green Lg Light Green
R Red P Pink
ON FREE FREE R LO
W White Gr Gray
OFF PUSH PUSH N N
L HI TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
© Honda Motor Co.,Ltd. 2016 Book#: 62K79B0Z
Published by Honda Motor Co.,Ltd. A. 2016.11
Printed in Japan

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