TABLE OF CONTENTS
4
16.4.32 Checking shift mechanism......................... 137
16.4.33 Preassembling shift shaft .......................... 137
16.4.34 Disassembling the main shaft .................... 138
16.4.35 Dismantling countershaft........................... 138
16.4.36 Checking the transmission ......................... 139
16.4.37 Assembling the main shaft......................... 140
16.4.38 Assembling countershaft ........................... 141
16.4.39 Checking the starter drive .......................... 142
16.4.40 Checking freewheel ................................... 142
16.4.41 Removing freewheel .................................. 143
16.4.42 Installing freewheel................................... 143
16.5
Engine assembly........................................... 144
16.5.1
Installing transmission shafts..................... 144
16.5.2
Installing crankshaft and balancer shaft...... 145
16.5.3
Installing left engine case.......................... 146
16.5.4
Installing oil pumps .................................. 146
16.5.5
Installing locking lever .............................. 147
16.5.6
Installing shift drum locating ..................... 147
16.5.7
Installing shift shaft .................................. 147
16.5.8
Installing starter drive ............................... 147
16.5.9
Installing primary gear............................... 148
16.5.10 Installing clutch basket ............................. 148
16.5.11 Installing crankshaft position sensor ........... 149
16.5.12 Installing timing chain and timing chain
sprocket................................................... 150
16.5.13 Installing timing chain rails ....................... 150
16.5.14 Installing rotor.......................................... 150
16.5.15 Adjusting crankshaft position sensor
distance................................................... 151
16.5.16 Setting engine to top dead center............... 151
16.5.17 Installing piston........................................ 151
16.5.18 Installing cylinder head ............................. 153
16.5.19 Installing camshafts.................................. 153
16.5.20 Installing timing chain tensioner ................ 154
16.5.21 Checking valve clearance........................... 154
16.5.22 Adjusting valve clearance .......................... 155
16.5.23 Installing spark plug.................................. 156
16.5.24 Installing spacer and spring ....................... 156
16.5.25 Installing clutch cover ............................... 156
16.5.26 Mounting water pump cover ....................... 156
16.5.27 Installing thermostat ................................. 157
16.5.28 Installing the oil filter................................ 157
16.5.29 Installing gear position sensor .................... 157
16.5.30 Installing the spacer.................................. 158
16.5.31 Installing oil screens ................................. 158
16.5.32 Installing alternator cover .......................... 159
16.5.33 Installing the starter motor......................... 159
16.5.34 Installing valve cover................................. 160
16.5.35 Removing the engine from the engine
assembly stand......................................... 160
17 CLUTCH.................................................................. 161
17.1
Checking/rectifying the fluid level of the
hydraulic clutch............................................ 161
17.2
Changing the hydraulic clutch fluid ................ 161
18 WATER PUMP, COOLING SYSTEM ............................ 162
18.1
Draining the coolant...................................... 162
18.2
Filling/bleeding the cooling system ................. 162
18.3
Checking the antifreeze and coolant level ........ 163
18.4
Checking the coolant level ............................. 164
19 LUBRICATION SYSTEM............................................ 165
19.1
Oil circuit..................................................... 165
19.2
Checking the engine oil level.......................... 165
19.3
Checking the engine oil pressure .................... 166
19.4
Changing the engine oil and filter, cleaning
the oil screens .............................................. 167
19.5
Draining the engine oil .................................. 167
19.6
Removing the oil filter ................................... 168
19.7
Installing the oil filter.................................... 168
19.8
Cleaning the oil screens................................. 169
19.9
Filling up with engine oil ............................... 170
19.10 Adding engine oil.......................................... 170
20 IGNITION SYSTEM................................................... 171
20.1
Alternator - checking the stator winding .......... 171
20.2
Checking the spark plug connector ................. 171
20.3
Ignition coil
–
checking the secondary
winding........................................................ 172
21 TECHNICAL DATA.................................................... 173
21.1
Engine ......................................................... 173
21.2
Engine tolerance, wear limits ......................... 173
21.3
Engine tightening torques .............................. 175
21.4
Capacities .................................................... 176
21.4.1
Engine oil ................................................ 176
21.4.2
Coolant .................................................... 176
21.4.3
Fuel ........................................................ 176
21.5
Chassis ........................................................ 176
21.6
Electrical system........................................... 177
21.7
Tires ............................................................ 177
21.8
Fork............................................................. 178
21.9
Shock absorber ............................................. 178
21.10 Chassis tightening torques ............................. 179
22 CLEANING/PROTECTIVE TREATMENT....................... 181
22.1
Cleaning the motorcycle ................................ 181
22.2
Checks and maintenance steps for winter
operation...................................................... 182
23 STORAGE................................................................ 183
23.1
Storage ........................................................ 183
23.2
Preparing for use after storage........................ 183
24 SERVICE SCHEDULE ............................................... 184
24.1
Service schedule........................................... 184
25 WIRING DIAGRAM ................................................... 186
25.1
Page 01 of 10 .............................................. 186
25.2
Page 02 of 10 .............................................. 188
25.3
Page 03 of 10 .............................................. 190
25.4
Page 04 of 10 .............................................. 192
25.5
Page 05 of 10 .............................................. 194
25.6
Page 06 of 10 .............................................. 196
25.7
Page 07 of 10 .............................................. 198
25.8
Page 08 of 10 .............................................. 200
25.9
Page 09 of 10 .............................................. 202
25.10 Page 10 of 10 .............................................. 204
26 SUBSTANCES ......................................................... 206
27 AUXILIARY SUBSTANCES ........................................ 208
28 SPECIAL TOOLS ...................................................... 210
29 STANDARDS ........................................................... 223
INDEX ............................................................................ 224
Summary of Contents for 2013 690 SMC R EU
Page 1: ...REPAIR MANUAL 2013 690 SMC R EU 690 SMC R AUS UK Art no 3206153en ...
Page 2: ......
Page 33: ...7 HANDLEBAR CONTROLS 31 Tighten counter nut 1 ...
Page 187: ...185 ...
