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XR190L
1. General Information
4. Electrical System
5. XR190CT Addendum
A Few Words About Safety ···················· 5-2 BODY PANELS ······································ 5-16
CABLE & HARNESS ROUTING ·············· 5-9 FRONT BRAKE ······································ 5-26
5-1
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.
5-2
XR190CT-H 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:
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.
5-3
XR190CT-H ADDENDUM
MODEL IDENTIFICATION
• Model name: XR190CT-H
Code/Type Destination
LA Latin America
U Australia, New zealand, South Africa
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
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
5-8
XR190CT-H ADDENDUM
COMBINATION
SWITCH WIRE
RIGHT
HANDLEBAR
LEFT
SWITCH WIRE
HANDLEBAR
SWITCH WIRE
TURN
SIGNAL
MAIN WIRE
LIGHT
HARNESS
WIRE
MAIN WIRE
HARNESS
5-9
XR190CT-H ADDENDUM
THROTTLE
CABLE A
2 – 4 mm
THROTTLE
CABLE B
SPEEDOMETER
CABLE
5-10
XR190CT-H ADDENDUM
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
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
5-13
XR190CT-H ADDENDUM
5-14
XR190CT-H ADDENDUM
5-15
XR190CT-H ADDENDUM
BODY PANELS
DRIVE CHAIN COVER (U type only)
MUD GUARD
ENGINE GUARD
5-16
XR190CT-H ADDENDUM
REAR CARRIER
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
5-21
XR190CT-H ADDENDUM
140 mm
22 N·m
20 N·m
LEFT RIGHT
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
88 N·m
44 N·m
44 N·m
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
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
5-26
XR190CT-H ADDENDUM
ELECTRICAL STARTER
STARTER MOTOR
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