Honda XR190CT 2017 Shop Manual Download Page 1

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Shop Manual

XR190L

This book is Specific Shop Manual.

Refer to “Basic Shop Manual” for basic and

common maintenance instructions.

1. General Information

2. Fuel & Engine

3. Frame & Chassis

4. Electrical System

Addendum

5. XR190CT

XR190L-H (2017)

XR190CT-H (2017)

Summary of Contents for XR190CT 2017

Page 1: ...book is Specific Shop Manual Refer to Basic Shop Manual for basic and common maintenance instructions 1 General Information 2 Fuel Engine 3 Frame Chassis 4 Electrical System Addendum 5 XR190CT XR190L...

Page 2: ...IFICATIONS 5 5 TORQUE VALUE 5 7 SPECIAL TOOL LIST 5 8 CABLE HARNESS ROUTING 5 9 MAINTENANCE SCHEDULE LA type 5 14 MAINTENANCE SCHEDULE U type 5 15 BODY PANELS 5 16 RIGHT SIDESTAND 5 18 FRONT WHEEL 5 1...

Page 3: ...te 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 replac...

Page 4: ...u 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...

Page 5: ...190CT H ADDENDUM 5 4 MODEL IDENTIFICATION Model name XR190CT H Code Type Destination LA Latin America U Australia New zealand South Africa VEHICLE IDENTIFICATION NUMBER COLOR LABEL ENGINE SERIAL NUMBE...

Page 6: ...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 incli...

Page 7: ...th 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 Char...

Page 8: ...5 18 Sidestand pivot nut 1 10 39 Self lock nut 5 18 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 ITEM Q TY DIA TRQ REMARK...

Page 9: ...200 Gear holder 07GMB KT70101 Clutch center holder 07725 0040001 Flywheel holder 07933 KM10001 Flywheel puller Frame Chassis 07746 0050400 Bearing remover head 15 mm 07746 0050100 Bearing remover shaf...

Page 10: ...RE CONNECTOR FRONT TURN SIGNAL LIGHT GROUND WIRE CONNECTOR INSIDE BOOT CONNECTORS LEFT HANDLEBAR 9P LEFT HANDLEBAR SWITCH WIRE CONNECTOR TURN SIGNAL LIGHT WIRE MAIN WIRE HARNESS MAIN WIRE HARNESS MAIN...

Page 11: ...XR190CT H ADDENDUM 5 10 2 4 mm THROTTLE CABLE A THROTTLE CABLE B WHITE IDENT MARK AREA 15 mm WHITE IDENT MARK SPEEDOMETER CABLE...

Page 12: ...33P CONNECTOR EOT SENSOR 2P CONNECTOR INSIDE BOOT CONNECTORS REAR BRAKE LIGHT SWITCH 2P ALTERNATOR 3P ALTERNATOR 2P NEUTRAL SWITCH WIRE CONNECTOR To be butted O2 SENSOR 2P CONNECTOR STARTER MOTOR CAB...

Page 13: ...XR190CT H ADDENDUM 5 12 NEUTRAL SWITCH WIRE NEUTRAL SWITCH WIRE NEUTRAL SWITCH WIRE DRIVE SPROCKET COVER DRIVE SPROCKET COVER DRIVE SPROCKET COVER BANK ANGLE SENSOR 3P CONNECTOR IGNITION COIL WIRE...

Page 14: ...IRE HARNESS TURN SIGNAL LIGHT WIRE IACV 4P CONNECTOR INJECTOR 2P CONNECTOR INSIDE BOOT CONNECTORS LICENSE LIGHT 2P BRAKE TALE LIGHT 3P LEFT REAR TURN SIGNAL LIGHT WIRE CONNECTOR RIGHT REAR TURN SIGNAL...

Page 15: ...rain or at full throttle 4 Service more frequently when riding OFF ROAD 5 Replacement requires mechanical skill Refer to Basic Service Manual for each maintenance instruction except the instructions d...

Page 16: ...n rain or at full throttle 4 Service more frequently when riding OFF ROAD 5 Replacement requires mechanical skill Refer to Basic Service Manual for each maintenance instruction except the instructions...

Page 17: ...XR190CT H ADDENDUM 5 16 BODY PANELS DRIVE CHAIN COVER U type only MUD GUARD ENGINE GUARD...

Page 18: ...XR190CT H ADDENDUM 5 17 REAR CARRIER REAR CARRIER BASE Rear center cowl 3 5...

Page 19: ...H ADDENDUM 5 18 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 s...

Page 20: ...XR190CT H ADDENDUM 5 19 FRONT WHEEL 59 N m Wheel inspection...

Page 21: ...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 t...

Page 22: ...XR190CT H ADDENDUM 5 21 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...

Page 23: ...010100 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 t...

Page 24: ...XR190CT H ADDENDUM 5 23 STEERING STEM TOP BRIDGE 20 N m 103 N m Speedometer 4 34 Handlebar 3 18...

Page 25: ...XR190CT H ADDENDUM 5 24 REAR SUSPENSION 44 N m 44 N m Left side cover 3 7 44 N m 88 N m 44 N m Rear wheel 3 21 Drive chain case 3 7...

Page 26: ...XR190CT H ADDENDUM 5 25 8 9 mm 6 0 N m 0 7 mm 3 8 4 2 mm 6 8 7 2 mm 0 5 mm 4 5 mm 0 7 mm 44 N m 44 N m Press the bearings with the marked side facing out...

Page 27: ...CT H ADDENDUM 5 26 FRONT BRAKE BRAKE MASTER CYLINDER 1 0 N m Silicone grease Silicone grease 5 9 N m 1 2 N m Brake fluid 3 24 Remove the snap ring Snap ring pliers 07914 SA50001 Master cylinder inspec...

Page 28: ...XR190CT H ADDENDUM 5 27 ELECTRICAL STARTER STARTER MOTOR SPEEDOMETER VS SENSOR Starter motor 4 25 Electric starter inspection...

Page 29: ...MEMO...

Page 30: ...G W Lg Y Gr Bu Y Y R G W Lg Y Y G W Y R G G G R W Y W G Y W G Bl Bl R Bl O G W G Bl P B R Lg R G R G R Lg R Y G Bl Bl R Bl G Y Bl G Y Bu G Bl Bl R G W Bl W Y R Y Bl O Bl G G G Bu Y P Bu Gr Bu P Bl P...

Page 31: ...Honda Motor Co Ltd 2016 Published by Honda Motor Co Ltd Printed in Japan Book 62K79B0Z A 2016 11...

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