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Repair Manual F 650 GS/GS Dakar BMW Motorrad After Sales...
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A new issue of this Repair manual will be published if amendments or additions (supplements) are needed. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.
Chapter 00 “Maintenance and general instructions” lists all tightening torques and the operating fluids. Key to symbols In this Repair Manual for the F 650 GS/GS Dakar, the following symbols are used; their meanings are ex- plained in the tables.
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Licence plate no. Order No. Mechanic’s signature Read the fault code memory with the BMW MoDiTeC Change the engine oil while at regular operating temperature; replace the oil filter element if motorcycle is used only for short journeys or at outside temperatures below 0°C (32°F): every...
Check that the delivery is complete: – Toolkit – Documentation – Motorcycle keys – Optional extras Read the fault code memory with the BMW MoDiTeC Check tyre pressures Fill fuel tank Final inspection as functional check: – Oil inspection – Clutch, gearshift –...
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BMW Motorcycle Service data F 650 GS/F 650 GS Dakar Item Rated value Unit of measurement/ specification Oil capacities Engine (with filter) 2.3 (4.05/2.43) Litres (Imp. pints/US quarts) Specification: see current Service Information Litres (Imp. pints/US quarts) Telescopic fork – for each post [Dakar version only] 0.55 (0.97/0.58)
Model F 650 GS / GS Dakar Connection 11 Engine Cylinder head cover Machine screw (hole for locating pin) Cylinder head to frame Cylinder head to frame, adjusting sleeve zero play, max. 5 Cylinder head to frame, locknut Model F 650 GS / GS Dakar...
Model F 650 GS / GS Dakar Connection 16 Fuel tank and lines Fuel tank to rear frame (M 8 stud) Fuel filler cap to fuel tank Roll-over valve to fuel tank Bracket, activated charcoal filter to fuel tank Fuel pump to fuel tank...
Model F 650 GS / GS Dakar Connection 21 Clutch Driver (clean thread + Loctite 243) Pressure plate Engine block cover, left Model F 650 GS / GS Dakar Connection 23 Transmission Selector lever to selector shaft Model F 650 GS / GS Dakar...
Model F 650 GS / GS Dakar Connection 32 Steering Handlebars to fork bridge (apply Optimoly TA to thread) Handlebar weight to handlebars Clutch fitting to handlebars, M 6 Clutch switch to handlebar fitting Pivot pin for brake lever Locknut for pivot pin, clutch lever...
Model F 650 GS / GS Dakar Connection 34 Brakes Brake lines/hoses Brake hose to brake caliper Brake hose to brake lever fitting Brake hose/brake line interfaces Brake line to master brake cylinder, rear wheel ABS sensor front/rear ABS pressure modulator to holder...
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Model F 650 GS / GS Dakar Connection 46 Frame Seat lock to rear frame Number-plate carrier to rear section of rear mudguard (clean thread + Loctite 243) Mudguards/wheel guards Front mudguard, rear section to front section Front mudguard to fork bridge...
Model F 650 GS / GS Dakar Connection 51 Equipment Ignition/steering lock to fork bridge Model F 650 GS / GS Dakar Connection 61 General electrical equipment ABS sensor cable to sliding tube ABS sensor to brake caliper mount, rear...
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Removing right and centre covers ..................19 Filling and charging the battery ....................20 Checking that delivery is complete ..................21 Reading the fault code memory with the BMW MoDiTeC ........21 Checking tyre pressures ......................21 Adding fuel to tank ........................21 Final inspection and function check ................21...
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E000251 General view of crated motorcycle • Notify the supplier (e.g. freight company) without delay. Checking the shipping crate for Unpacking the motorcycle damage • • When the motorcycle arrives, check the crate im- Lever off the cover. • mediately for damage and if necessary examine Take out the separate pack of items.
• • Use the “express handling service” to notify Install quick-release axle (2) with spacer (3). BMW AG Sparte Motorrad, UX-VS-1 Fax: 00 49 89 382-33220 • Rectify the fault. • If parts are needed, order them by using the electronic parts list.
Installing windscreen • Wheel the motorcycle clear of the wooden pallet. E000311 • [Dakar] After turning the handlebars to full left/ right lock, align the hand protectors (4) with the E000260 windscreen and the handlebar fittings. • [Dakar] Tighten fasteners (5). •...
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Installing front mudguard, mirrors and handlebar weights E000271 • Install front mudguard. Caution: Insert four washers (arrow) between front mudguard and lower fork bridge. E000310 • Install handlebar weights (1). • Tighten clamp screw (2) on handlebar fitting. • Install each mirror and secure by tightening nut (3).
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E000280 Filling and charging the battery Removing right and centre covers Note: Do not remove the windscreen after the side panels have been removed, as otherwise the headlight beam setting will have to be checked. • Remove the lid of the stowage compartment. •...
E000290 Filling and charging the battery Caution: Warning: Connect the positive battery terminal first, then the Battery acid is highly caustic. negative terminal. Protect your eyes, face, hands, clothing and the • paintwork. Apply acid-proof grease to the battery terminal posts.
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7.5A, 15A, 20A • Documentation • Motorcycle keys, 3 Reading the fault code memory with the BMW MoDiTeC E000300 • Oil check: if oil is not visible in the sight glass, check whether the oil tank (2) contains oil. •...
Final cleaning Handing over the motorcycle • Clean the motorcycle. This is the ideal opportunity to familiarise the custo- mer with the motorcycle in order to ensure the cu- stomer’s satisfaction and safety. Note: • Do not use a steam or high-pressure water jet. The The following points must be demonstrated and high steam or water pressure could damage seals, explained to the customer:...
00 Maintenance Contents Page Key to maintenance intervals ....................27 Reading the fault code memory with the MoDiTeC ..........28 (Inspections I, II, III and IV) .........................28 Changing the engine oil and oil filter element ............28 (Inspections I, II, III and IV) .........................28 Preparatory work ...........................28 Draining engine oil...
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Contents Page Replacing spark plugs ......................36 (Inspection III) ............................36 Emptying drain hose from intake air silencer .............36 (Inspections II and III) .........................36 Replacing air cleaner element ....................36 (Inspection III) ............................36 Replacing fuel filter ........................37 (Inspection III, every 20,000 km/12,000 miles) ...................37 Checking clutch play, adjusting if necessary ..............38 (Inspections I, II and III) ........................38...
Contents Page Changing brake fluid (rear brake) ...................43 Replacing primary sealing boot front brake master cylinder ......44 (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ...........44 Replacing primary sealing boot, rear brake master cylinder ......45 (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ...........45 Checking chain, chainwheel and chain sprocket, replacing if necessary ..46 (Inspections II and III) .........................46...
BMW Running-in Check after the first 1,000 km — BMW Service at 10,000 km (6,000 miles)...II (600 miles). — BMW Inspection at 20,000 km (12,000 miles) .. III — BMW Annual Service........IV BMW Service After the first 10,000 km (6,000 miles) and each ad- ditional 20,000 km (12,000 miles) (at 40,000 km ...
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Reading the fault code Changing the engine oil and 00 13 624 00 11 215 memory with the MoDiTeC oil filter element (Inspections I, II, III and IV) (Inspections I, II, III and IV) Note: If an engine failure occurs, the oil tank and feed line must be cleaned with the material used for this pur- pose in the workshop, and then blown through with compressed air.
(1). • Remove the cable for the neutral-indicator switch from its guide. • Engage the oil drain guide, BMW No. 11 7 511, on the pins (arrows) on the engine block. • Position a drip tray beneath the engine. •...
Checking coolant, topping up if nec- essary Note: Mix the coolant to a ratio of 50 % antifreeze, (Inspections I, II and III) 50 % water. • Check coolant level in the expansion tank, top up Note: coolant if necessary. Check coolant level only when the engine is cold.
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E170030 E170090 • • Disconnect the coolant hose (arrow) at the frame Slacken bleed screw (2) in cylinder head. • on the left and drain the radiator. Connect a hose to the bleed screw. • Fill the radiator until coolant escapes at the bleed screw;...
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[Dakar] Changing oil in tele- 00 11 279 scopic forks (Inspection III) – Install stand, BMW No. 00 1 610, and place the motorcycle on the stand. – Relieve load on front wheel. E310160 • Position a drip tray beneath the telescopic forks.
Pull the intake air silencer with intake air pipe and Remove spark plug. • battery carrier to the rear to remove. Use pliers, BMW No. 17 5 500, to release hose • Cover/seal the throttle valve stub. clip (5) and disconnect cylinder-head breather hose (7).
Remove the screw at the oil feed stub pipe and timing-chain sprockets are at the top. insert locating screw, BMW No. 11 6 570, to lock the crankshaft at TDC. •...
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• Installation is the reverse of the removal proce- dure: pay particular attention to the following. • When installing the inlet camshaft, press the chain rail back against the chain tensioner if necessary. Note: TDC position: marks on the timing-chain sprockets are parallel with the cylinder head, the bores in the timing-chain sprockets are at the top.
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Replacing spark plugs Replacing air cleaner ele- 00 12 620 00 13 630 ment (Inspection III) • Pull spark plug connector off spark plug. (Inspection III) • Remove the spark plug with the a/f 18 socket – Remove right cover ( 46.5).
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Note the installed positions of fuel feed line (7) and fuel return line (3). • Close hose clamps with pliers, BMW No. 13 1 500. Tightening torques: Fuel filter to frame .......... 9 Nm Oil tank to intake air silencer ......9 Nm Air filter box to frame ........
Tap the spokes and listen for differences in the pitch of the sound. • If spokes are loose, tighten them with spoke nip- ple wrench, BMW No. 36 3 800. Vertical runout......max. 2 mm (0.08 in) Lateral runout......max. 2 mm (0.08 in) E000240 •...
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Checking brake pads and discs for Replacing brake pads wear, replacing if necessary (Inspections II and III) Important: Do not operate the brake when dismantled. Do not permit the brake pads to wear past the spec- Checking brake pads for wear ified minimum thickness.
Checking the brake discs 00 34 633 Brake pads, rear brake • Press the brake caliper against the brake disc in • order to force the piston back. Carefully check the brake discs for cracks, dam- age, deformation and scoring. E340021 E000080 •...
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Checking the brake fluid level and Brake fluid level (rear brake) topping up if necessary (Inspections II and III) Checking brake fluid level (rear brake) Note: The volume of the brake fluid (MIN/MAX) is sufficient for brake-pad thicknesses from new to the wear lim- it.
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Manual. If the BMWMoDiTeC is not used there is a danger of • Using resetting tool, BMW No. 34 1 500, and residual air remaining in the control circuits of the strips of metal sheet (1) (approx. 9 mm/0.35 in ABS system.
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Changing brake fluid (rear brake) • Installation is the reverse of the removal proce- dure: pay particular attention to the following. • • Press the brake caliper against the brake disc in Before reassembling, carefully wipe the rim of order to force the piston back. the reservoir, the rubber gaiter and the cover to remove all traces of brake fluid.
Replacing primary sealing boot front brake master cylinder (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) – Place the motorcycle on its main (centre) stand. Important: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint.
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Replacing primary sealing boot, rear brake master cylinder (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) – Place the motorcycle on its main (centre) stand. Important: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint.
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Checking chain, chainwheel and Checking chain tension, 27 71 005 chain sprocket, replacing if neces- adjusting if necessary sary (Inspections I, II, III and IV) Checking chain tension (Inspections II and III) 27 71 005 – Remove the sprocket cover. •...
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Adjusting chain tension Checking battery acid level, 27 71 005 61 20 029 adding distilled water if necessary (Inspections II, III and IV) Warning: Battery acid is highly caustic! Protect your eyes, face, hands, clothing and the paintwork! Checking battery acid level 61 20 029 –...
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Cleaning and greasing the Checking and adjusting 61 21 520 32 00 454 battery terminals, if necessary steering head bearing play, renewing if necessary (Inspection IV) – Remove left, right and centre covers ( 46.5). (Inspections II and III) Checking steering head bearing play Important: •...
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E000220 • Slacken round nut (6) with pin-wrench adapter, BMW No. 31 6 521, then tighten to 25 Nm. • Turn forks back and forth twice from lock to lock, and leave the forks at the full left lock position.
Greasing the side and main stands and the brake pedal lever (Inspections II and III) Side stand E000230 Note: Use the punch marks (arrow) to align the handlebars as shown. E460010 Warning: Begin by tightening the front securing screws (as •...
Brake pedal Checking security of threaded fasteners (Inspections I, II, III and IV) • Check the security of the following threaded fas- teners: – Engine mounting bolts and nuts – Threaded fasteners of frame – Main and side stands – Exhaust mountings –...
Final inspection with road safety and functional check (Inspections I, II, III and IV) Road safety check • Check wheels and tyres. • Check tyre pressures and correct if necessary. Tyre tread depth (recommended minimum value) Warning: Thread depth must comply with legal regulations concerning minimum tyre tread depth.
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11 Motor Contents Page Technical Data ..........................5 Cutaway view of engine ......................11 Engine oil circuit .........................12 Valve gear ............................13 Valves, components ........................14 Oil pumps, components ......................15 Removing and installing cylinder head, engine installed ........16 Preparatory work ...........................
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Contents Page Disassembling and assembling cylinder head ..............27 Removing valves ..........................27 Bore for bucket tappet ........................27 Checking valve guide for wear ......................28 Removing valve guide ........................28 Installing valve guide .........................29 Checking valve seat for wear ......................29 Installing valve stem seal ........................30 Checking valve for wear ........................30 Installing valves ..........................31 Removing cylinder...
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Contents Page Removing and installing grooved ball bearings of balancing shaft ......41 Removing and installing main bearings ................41 Removal ............................41 Installation ............................42 Assembling engine ........................43 Installing crankshaft and balancing shaft ................43 Shimming crankshaft .........................43 Installing double drive gear .......................44 Installing oil pump gears ......................45 Installing clutch ..........................46...
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Technical Data F 650 GS / GS Dakar Engine, general Type Single-cylinder four-stroke, double overhead camshafts driven by roller chain, 4 valves operat- ed by bucket tappets, balancing shaft, liquid- cooled cylinder and cylinder head, integral water pump, 5-speed gearbox and dry sump lubrica- tion.
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Technical Data F 650 GS / GS Dakar Connecting rod Wear limit, connecting rod Radial clearance Big-end bore mm (in) 0.08 (0.003) Small-end bore mm (in) 0.05 (0.002) Big end bearing endplay Installed dimension mm (in) 0.30...0.65 (0.012...0.026) Wear limit mm (in) 0.80 (0.031)
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Technical Data F 650 GS / GS Dakar Valve seat angle Inlet ° 45 Exhaust ° 45 Included valve angle Inlet ° 15 Exhaust ° 18 Valve seat width Inlet mm (in) 1.05...1.35 (0.041...0.053) Wear limit mm (in) 1.60 (0.063) Exhaust mm (in) 1.25...1.55 (0.049...0.061)
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Technical Data F 650 GS / GS Dakar Piston Piston dia. “A” Installed dimension mm (in) 99.975...99.985 (3.9361...3.9365) Wear limit mm (in) 99.940 (3.9347) Installed clearance mm (in) 0.015...0.040 (0.0006...0.0016) Wear limit mm (in) 0.090 (0.0035) Piston dia. “B” Installed dimension mm (in) 99.985...99.995 (3.9365...3.9369)
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Technical Data F 650 GS / GS Dakar Piston pin Piston pin dia. Wear limit mm (in) 21.98 (0.865) Piston-pin play in piston-pin bore mm (in) 0.015...0.029 (0.0006...0.0011) Wear limit mm (in) 0.050 (0.0020) in bore (piston) mm (in) 0.012...0.021 (0.0005...0.0008) Wear limit mm (in) 0.050 (0.0020)
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Removing and installing cyl- 11 12 116 inder head, engine installed Note: If an engine failure occurs, the oil tank and oil lines must be cleaned with the material used for this pur- pose in the workshop, and then blown through with compressed air.
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Remove fastener for oil lines (2) from the cylinder Turn crankshaft to top dead centre position with head. an Allen key. • Use pliers, BMW No. 17 5 500, to open the clamp securing the breather hose at the cylinder head cover. Note: •...
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E110480 • Remove screws securing cylinder head to E110420 frame (arrow). • Use pin wrench, BMW No. 11 6 661, to slacken • Remove chain guide (1). the locknut. • Remove upper section of camshaft carrier (2). •...
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• When looping the timing chain over the camshaft sprockets, make sure that the sprockets are at the TDC position. • Before installing the cylinder head cover, remove all traces of the gasket and clean the sealing face with degreasing agent. Also clean the groove and the seating faces for the gasket.
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E110520 • Oil the piston rings and press the sliding piston ring sleeve, BMW No. 11 6 510, over the piston rings from above so that the piston projects from E110500 the sliding sleeve by about 2 mm (0.08 in).
Note: When locating pin, BMW No. 11 0 661, is inserted and the floating bearing stud is pulled out 22.5 cm E110050 (8.86 in), the rear swinging fork remains in place in the frame, but the engine is free.
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Lay the engine on its left side, as viewed in the forward direction of travel. • Secure engine adapter, BMW No. 11 0 640, to the right side of the engine without a spacer. • Position the assembly stand beside the lifting platform.
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Turn crankshaft to top dead centre position with an Allen key. • Remove screws (5) and lock the crankshaft with locating screw, BMW No. 11 6 570. Important: If there is any mechanical damage, the oil tank and the oil lines must be cleaned.
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“B”. 00 2 590 F110040 • Measure bearing play with Plastigage type PG-1, BMW No. 00 2 590. • Tighten camshaft mount to specified torque. E110090 Tightening torque: Camshaft mount........... 10 Nm Distance “B”...
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11 12 116 Removing cylinder head Checking timing chain for wear • Remove front chain rail (1). • Release the coolant line hose clips with pliers, BMW No. 17 5 500. • Secure timing chain with cable tie. • Remove starter ( 12.9).
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If the wear limit, distance “B”, is exceeded, first 11 34 020 Removing valves • inspect the tensioner rail and the two guide rails Use suction cup, BMW No. 11 3 251, to pull out for score-marks and renew them if necessary. the bucket-type tappets. •...
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BMW No. 00 1 900, to check the temperature. imum tilt clearance across the camshaft axis. • Use drift, BMW No. 11 0 571, to drive out the Tilt clearance: valve guide toward the combustion chamber. Max. tilt clearance ....... 0.4 mm (0.016 in) Intl.
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F110151 • Heat the cylinder head to 100 °C (212 °F). • Using driving-in tool, BMW No. 11 0 571, drive F110160 valve guide (1) into the cylinder head until valve guide projection is as specified. • Check valve seat width “A” and contact pattern Projection: for wear.
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E110120 For wear limits, see Technical Data. • • Install bottom valve spring retainer (1). Check grooves for valve collets. • Use a drift, BMW No. 11 6 650, to insert valve stem seal (2). 11.30...
Secure adapter plate, BMW No. 11 0 521, E110140 support, BMW No. 11 5 691, spindle, BMW No. 11 5 692, nut, BMW No. 11 5 693, • and thrust plate, BMW No. 11 0 522. Check cylinder face and sealing faces for dam- •...
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11 25 050 inder • Remove piston pin circlips. • Press out piston pin with drift, BMW No. 11 6 581. Note: Mark exhaust-valve side on piston crown. Disassembling piston 11 25 671 • Remove piston rings with piston ring pliers.
• Release the central locking screw, insert and Assembling pistons 11 25 671 tighten handle, BMW No. 12 5 500. Note: The “Top” must face towards the piston crown. Install the piston rings with their gaps offset by 120 °.
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Heat hub to 80 °C (176 °F). Note: Use temperature measuring device, BMW No. 00 1 900, to check the temperature. • Using puller, BMW No. 12 5 510, pull off magnet rotor. Removing countershaft for 11 26 500 starter E110220 •...
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Disassembling and assem- 12 11 077 Assembling freewheel bling freewheel Disassembling freewheel 1. Machine screw 2. Magnet rotor 3. Freewheel 4. Lock ring 5. Freewheel housing 6. Freewheel gear Warning: Securing screws (1) are secured with Loctite 648 and considerable torque is required to release them. •...
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Turn engine round in assembly fixture. • Remove fastener for left engine block scover and • remove cover. Using locating ring, BMW No. 21 4 600, prevent clutch cage (4) and driver (3) from moving and Removing pressure plate unscrew hex nut. •...
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Removing and installing oil 11 41 000 Installing oil pump pump Removing oil pump F110370 7. Inner rotor E110270 8. Outer rotor 9. Cover • Remove circlip (1) from angled gear. 10.Markings • Remove the retaining rings of the oil-pump 11.Needle roller gears (2) and disengage the oil-pump gears.
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Removing double drive gear E110320 • Swivel assembly fixture so that clutch side is E110290 uppermost. • Remove knurled nuts (4). Note: Retaining screw (arrow) must be installed. Important: Do not tilt engine housing: this can cause damage • Remove hex nut (1). to bearing shell.
Press off compensating gear with pressure pad, BMW No. 11 6 502, and pressure pad, BMW No. 11 0 561. BMW No. 11 6 503, to pull off the crankshaft gear. • Installation is the reverse of the removal proce- dure: pay particular attention to the following.
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• Using bearing puller plate, BMW No. 11 6 561, E230040 spindle, BMW No. 11 6 562, and spreader sleeve, BMW No. 11 6 564, pull off the ball bear- ing. • Note: Installation is the reverse of the removal proce- To protect the gasket surfaces of the engine block, dure: pay particular attention to the following.
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Using bearing puller plate, BMW No. 11 6 561, 00 5 500 spindle, BMW No. 11 6 562, and spreader sleeve, BMW No. 11 6 563, pull off the ball bear- ing. • Heat the right of the engine block to 80 - 100 °C (176 - 212 °F).
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The end gap of the bearing bushing must always face the balancing shaft. Before driving in, fit both bearing halves with O-ring on mandrel. • Coat bearing bushings with Optimoly TA and drive in with drift, BMW No. 11 0 551, working from the inside. 11.42...
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• Secure right side of engine housing in engine bracket with magnet side facing downwards. F111041 • Using depth gauge, BMW No. 00 2 550, meas- ure distance from crankshaft web to housing mating face = dimension “B”. E110330 •...
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• Lock the crankshaft in the TDC position with lo- • Fit left engine housing and install fasteners. cating screw, BMW No. 11 6 570. Note: Note the two fasteners in the oil filter housing. • Cut off protruding gasket.
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Installing oil pump gears 11 41 000 E110350 • Install angled gear (1) with washer and circlip. • Install washers (4) of oil pump gears and slide needle rollers (5) into position. • Install oil pump gears (3) and install the circlips (2).
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Insert driver (7) and coat internal splines with Optimoly MP 3. • • Fit retaining washer (8); it must engage securely. Insert locating ring, BMW No. 21 4 600. • • Clean threads of countershaft and hexagon Tighten hex nut and bend tabs of retaining nut (9), coat threads with Loctite 243 and washer (8).
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Always replace selector shaft seal in clutch cover. • Install selector shaft sealing ring in clutch cover with sliding sleeve, BMW No. 21 4 620, and drift, BMW No. 21 4 630. Tightening torque: Pressure plate to driver ........ 10 Nm Engine cover, left .........
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Three Bond 1209 and install in cover of engine block. • Fit gasket. • Screw assembly handle, BMW No. 12 5 500, into the central hole in the right engine cover. • Fit right engine housing cover and install secur- ing screws.
Press the piston pin in with drift, BMW No. 11 6 581. 11 6 581 E110390 • Position sleeve, BMW No. 11 6 583, with instal- lation arbor, BMW No. 11 6 581, against piston. Important: Support side of piston. •...
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E110400 • Oil the piston rings and press the sliding piston ring sleeve, BMW No. 11 6 510, over the piston rings from above so that the piston projects from the sliding sleeve by about 2 mm (0.08 in). •...
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E110151 • Initially tighten the collar nuts of the cylinder head to 20 Nm (1-4) and then tighten to 60 Nm (5-8). Tightening torques: • Tighten the fasteners of the cylinder head to cyl- Machine screws (chaincase) ......10 Nm inder in the sequence as shown (9-14) to speci- Collar screws for cylinder head ....
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E110420 Installing camshaft and adjust- 11 31 529 ing valves • Oil outside of bucket tappets and install at the correct valves. • Measure thickness of shim plates with microme- ter and note down thickness. • Place lower part of camshaft mount (1) on cylin- der head.
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• Connect the oil lines to the cylinder head. • Remove locating pin, BMW No. 11 6 570, and insert screw plug with sealing ring. • Install the spark plug.
• Tighten locknut (3) using special wrench, Important: BMW No. 11 6 661. Never start the engine after it has been dismantled • Tighten fastener (4). and re-assembled until the engine oil circuit has been bled.
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Bleeding engine oil circuit • Remove oil filter. E110560 • Remove check valve (1). • Remove spark plug. • Turn engine over with the starter motor until oil emerges at the filter chamber. • Install check valve. • Install oil filter. •...
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12 Engine electrics Contents Page Technical Data ..........................3 Ignition magneto ...........................5 Ignition magneto, components .....................6 Removing ignition magneto ....................7 Removing right engine housing cover ...................7 Removing and installing ignition trigger ................8 Removing and installing stator ....................8 Installing magnetic ignition trigger ..................8 Installing magnet rotor ........................8...
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12 5 500 Note: Use temperature measuring device, BMW No. 00 1 900, to check the temperature. • Using puller, BMW No. 12 5 510, pull off magnet rotor. E110180 • Remove the central locking screw, insert and tighten handle, BMW No. 12 5 500.
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Removing and installing igni- • 12 11 060 Installation is the reverse of the removal proce- dure: pay particular attention to the following. tion trigger • Coat the rubber grommet of the stator with Three Bond 1209 before inserting it into the cover.
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Removing and installing or • Fit gasket. 12 41 020 • Screw assembly handle, BMW No. 12 5 500, dismantling starter motor into the central hole in the right engine cover. • Fit right engine housing cover and install secur- Removing and installing ing screws.
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Remove front cover (5). E120070 • Remove armature (3) from housing (1). • Using puller, BMW No. 00 8 400, pull the ball bearing (4) off the armature shaft. Note: Note: Make sure that the mark on the housing (arrow) is The insulation should be 0.5 mm (0.0197 in) deeper...
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Replacing spark plug • 12 12 011 Disengage the clamp securing the breather hose and disconnect the hose from the intake air si- 00.36) lencer. • Press the oil tank slightly to the left and carefully disconnect the intake air silencer from the throt- Replacing ignition lead 12 12 085 tle valve stub.
13 Fuel preparation and control Contents Page Technical Data ..........................3 Removing and installing BMS control unit ..............5 Removing and installing intake air pipe ................5 Removing and installing air temperature sensor ...............5 Replacing air filter element ( 00.36) ................6 Removing and installing intake air silencer ..............6 Removing and installing intake air pipe .................6...
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Removing and installing • 13 61 010 Installation is the reverse of the removal proce- dure: pay particular attention to the following. BMS control unit – Remove seat. • Unhook the retaining strap and remove the con- trol unit. • Pull the red locking grip forward and at the same time pull the connector up and off the control unit.
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Replacing air filter element 00 13 630 00.36) Removing and installing 13 72 130 intake air silencer – Remove left, right and centre covers ( 46.5). – Remove intake air pipe ( 13.5). • Disengage the rubber strap holding the battery. E130090 •...
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13.6). • Disconnect the plug of fuel injector (1). • Use a hose clamp, BMW No. 13 3 010, to close off fuel line (3). • Slacken the hose clip securing the fuel line and disconnect the line from the throttle valve stub.
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Disconnect the plugs for fuel injector (2), throttle- valve potentiometer (4) and throttle-valve actuator (3). • Note: Use a hose clamp, BMW No. 13 3 010, to close It is not necessary to adjust the throttle-valve poten- off fuel line (5). • tiometer after installation (self-teaching system).
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Connecting flange .......... 5 Nm Fasteners, cover/ • trim panel for turn indicator ......3 Nm Connect a test pressure gauge, BMW No. 16 1 500, between fuel feed line and tank outlet. • Start engine and allow to run in neutral. Fuel pressure: Specification ....
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Remove left, right and centre covers ( 46.5). • Comply with safety precautions when handling or Use a hose clamp, BMW No. 13 3 010, to close working with fuel; note that the fuel lines are pressu- off the fuel feed line. rised.
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16 Fuel tank and lines Contents Page Technical Data ..........................3 Removing and installing fuel tank ..................5 Removing fuel tank .........................5 Installing fuel tank ...........................7 Removing and installing fuel filler cap ................7 Removing and installing roll-over valve ................8 Replacing fuel filter ( 00.37) ....................8 Removing and installing fuel pump...
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Technical Data F 650 GS /GS Dakar Fuel tank Type Plastic tank with cover Tank capacity l (Imp. gal/US gal) 17.3 (3.8/4.6) (including 4 l (0.88/1.06) reserve) Type of fuel Super (premium), unleaded. 95 octane (RON) Fuel pump Type Peripheral-gear pump...
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E160020 • Close off fuel supply line (1) and the fuel return line (2) with hose clips, BMW No. 13 3 010. • Open the hose clips (arrows) and disconnect the fuel lines from the fuel-pump unit. •...
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E160010 • • Remove lower fasteners (1) securing rear frame Remove upper fasteners (2) securing the rear to main frame. frame to the main frame and carefully remove the rear frame complete with the tank. • Remove the fastener securing the rear section of the rear mudguard to the rear frame.
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(2) are correctly routed. Warning: Do not use screw-type hose clamps on the fuel hos- es, because they could damage the hoses and result in a fire hazard. • Close hose clamps with pliers, BMW No. 13 1 500. 16.7...
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• Roll-over valve to fuel tank ......3 Nm Close off fuel supply line (5) and the fuel return line (4) with hose clips, BMW No. 13 3 010. • Open the hose clips (arrows) and disconnect the fuel lines from the fuel-pump unit.
E160061 • Release ring (1) using wrench, BMW No. 16 1 021. • Remove fuel-pump unit (3) with gasket (2). • Installation is the reverse of the removal proce- dure: pay particular attention to the following.
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Removing and installing fuel-evapo- Removing and installing 16 13 001 ration control valve activated charcoal filter [USA version] [USA version] – Place motorcycle on its centre stand. – Place motorcycle on its centre stand. – Remove seat. – Remove seat. •...
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Technical Data F 650 GS / GS Dakar Cooling system Cooling system capacity Total capacity l (Imp. pints/ 1.3 (2.29/1.37) US quarts) Coolant circuit l (Imp. pints/ 1.20 (2.11/1.27) US quarts) Coolant expansion tank l (Imp. pints/ 0.10 (0.18/0.11) US quarts)
Pack the space between the sealing rings with Shell Retinax EP2. • Drive inner sealing ring onto its seat with drift, BMW No. 11 6 540. • Drive in outer sealing ring flush with the friction face, using the appropriate adapter.
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Removing and installing coolant-tem- Antifreeze Use only nitrite-free long-term antifreeze and corro- perature sensor sion inhibitor. – Drain coolant ( 00.30). • Concentration Place motorcycle on its centre stand. Antifreeze ............50% Water ...............50% • Run the engine for a short time, then switch it off. •...
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Connect pump, BMW No. 17 0 500, with adapt- and pull it to one side. • er and neck, BMW No. 17 5 520, to filler neck. Disconnect the coolant hose from the radiator • Pressure-test the system; the pressure must re- and the expansion tank.
• Disconnect the coolant hose (arrow) at the frame on the left and drain the radiator. • Use pliers, BMW No. 17 5 500, to open the clamp securing the coolant hose to the water pump housing (1). • Remove the radiator fasteners.
18 Exhaust system Contents Page Technical Data ..........................3 Removing and installing exhaust system ................5 Removing and installing right-hand silencer ...............5 Removing and installing left-hand silencer ................5 Removing and installing exhaust manifold and oxygen sensor ........6 Removing exhaust manifold and oxygen sensor ..................6 Installing exhaust manifold and oxygen sensor ..................6 Replacing guard for silencer ....................7...
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E180032 Removing and installing • 18 00 020 Installation is the reverse of the removal proce- dure: pay particular attention to the following. exhaust system Removing and installing right- 18 11 301 hand silencer • Remove number plate. • Remove the fastener (arrow) securing the silenc- er to the rear frame.
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Lightly coat the threads of the oxygen sensor with Optimoly TA. • Tighten the oxygen sensor at the hexagon with socket wrench insert, BMW No. 11 7 020. • Position a new gasket (4) on the manifold. • Introduce the exhaust manifold into the left-hand silencer and into the cylinder head.
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Replacing guard for silencer • Uniformly tighten the fasteners securing the 18 12 212 manifold to the cylinder head. – Remove the lid of the glove compartment. E180021 E630010 • Tighten clamp (1) for the silencer, making sure • that the clamp is correctly positioned (arrow). Remove the fastener (arrow) securing the turn in- •...
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(10), coat threads with Loctite 243 and in- stall nut. Height of lined plate cluster • Insert locating ring, BMW No. 21 4 600..........min. 27.5 mm (1.08 in) • Tighten hex nut and bend tabs of retaining Height of complete plate cluster washer (9).
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Pressure plate to driver ........ 10 Nm • Remove keeper (6) for releaser shaft (7). • Withdraw releaser shaft from cover. 21 4 610 E210050 • Using puller, BMW No. 21 4 610, pull out both needle roller bearings and the sealing ring to- gether. 21.9...
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Insert releaser shaft. • Cover the splines on the releaser shaft with slide- on sleeve, BMW No. 21 4 620. • Using drift, BMW No. 21 4 630, drive in sealing ring. Installing clutch 21 21 000 • Align splines on water pump driven gear with driving gear on balancing shaft.
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23 Gearbox Contents Page Technical Data ..........................3 Gearbox shafts, components ....................5 Gear shift pedal, components ....................6 Removing and installing gearbox ..................7 Removing selector shaft with pawl and index lever ............7 Removing selector forks ......................7 Removing selector drum ......................7 Removing, disassembling and reassembling gearbox shafts ......8 Removing gearbox shafts ......................8...
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E230010 Removing and installing Removing selector drum 23 00 100 23 00 651 gearbox • Withdraw selector drum (4). Important: If there is any mechanical damage, the oil tank must be cleaned. – Remove engine ( 11.21). – Disassemble engine ( 11.24).
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• Do not alter the stop on the special pliers, Position retaining ring (7) approx. 3 mm (0.12 in) BMW No. 23 4 500, in order to avoid opening up the below the groove. After installing retaining circlip too much.
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Checking mainshaft for wear F230050 Wear limits: “A” Shaft diameter, magneto side ..........24.98 mm (0.983 in) “B” Shaft diameter, clutch side ..........16.98 mm (0.669 in) Runout ........0.02 mm (0.0008 in) 23.9...
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Renew gears only together with the corresponding meshing gears. Edges of ring grooves must not be rounded. Always renew circlips and install them only with spe- cial pliers, BMW No. 23 4 500. • Assembly is the reverse of the disassembly pro- cedure.
• Using bearing puller plate, BMW No. 11 6 561, spindle, BMW No. 11 6 562, and spreader sleeve, BMW No. 11 6 564, pull off the ball bear- ing. • Drive out the mainshaft sealing ring from the in- side.
• Using bearing puller plate, BMW No. 11 6 561, spindle, BMW No. 11 6 562, and spreader sleeve, BMW No. 11 6 565, pull off the ball bear- ing. • Heat the right of the engine block to 80 - 100 °C (176 - 212 °F).
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Installing selector shaft Installing selector forks 23 00 640 23 00 658 F230100 F230120 • • Install index lever (2) with index spring (1) in Insert selector fork (9) in shift gear of counter- housing. shaft. • Insert selector rod and swivel together with the selector fork in the direction of the crankshaft.
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• Cover the splines on the selector shaft with slide- on sleeve, BMW No. 21 4 620. • Using drift, BMW No. 21 4 630, drive in sealing ring. • Drive in the mainshaft sealing ring with drift, BMW No. 23 4 550, and sliding sleeve, BMW No.
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27 Drive chain Contents Page Technical Data ..........................3 Removing and installing chain, chainwheel and chain sprocket .......5 Removing and installing chain ....................5 Removing and installing chain guide rail ....................5 Removing and installing chain takeup roller ..................5 Removing chainwheel ........................6 Removing chain sprocket ......................6 Removing and installing chain guide rail with swinging fork installed...
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Technical Data F 650 GS / GS Dakar Chain drive Number of teeth on chain sprocket Number of teeth on chainwheel Secondary ratio 1:2.937 Secondary drive O-ring chain 5/8" x 1/4" Chain links Chain length mm (in) 1,000 (39.4) Roller diameter mm (in) 10.16 (0.40)
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E270020 Removing and installing 27 71 000 Tightening torques: chain, chainwheel and chain Swinging-fork pivot shaft......100 Nm sprocket Strut to swinging fork ........41 Nm Rear quick-release axle......100 Nm Chain tensioning screws ......10 Nm Wheel cover bracket to swinging fork..... 9 Nm Important: Always renew the chain, chainwheel and chain 27 72 009 Removing and installing chain guide rail...
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Remove screws (3) and remove the chainwheel. Unscrew central nut (5). • Remove the locking washer (4). • Use puller, BMW No. 00 8 400, to pull the Tightening torques: sprocket off the mainshaft. • Chainwheel to carrier ........21 Nm Installation is the reverse of the removal proce- dure: pay particular attention to the following.
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Removing and installing chain 27 72 009 guide rail with swinging fork installed • Remove the sprocket cover. • Remove the rear quick-release axle. • Remove the chain from the chainwheel and chain sprocket. • Remove the fasteners securing the chain guide rail to the swinging fork.
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Technical Data F 650 GS F 650 GS Dakar Front forks Front wheel caster mm (in) 113 (4.449) 123 (4.842) Steering lock angle ° 40 Front suspension travel mm (in) 170 (6.69) 210 (8.268) (normal-load position, 85 kg (187 lbs) load) Length of suspension spring in fork mm (in) 515.1 (20.279)
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[Dakar] Changing oil in tele- 00 11 279 scopic forks – Install stand, BMW No. 00 1 610, and place the motorcycle on the stand. – Relieve load on front wheel. E310160 • Position a drip tray beneath the telescopic forks.
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[GS] Release ABS sensor cable from clip (4). Remove round nut with upper taper roller bear- • Remove brake hose with ABS sensor cable from ing, using socket, BMW No. 31 6 521. • clip (3) on sliding tube. Remove front forks.
(arrow). • Align the mark on pin-wrench adapter, BMW No. 31 6 521, with the right-hand end of the marked arc. Note: 40 mm (1.575 in) around the circumference of the locking plate corresponds to an angle of rotation of 60°.
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• [GS] Fit caps to fork legs. • [Dakar] Lightly oil threads of screw plugs. Note: Check O-rings of screw plugs for damage and renew if necessary. Warning: Screw plugs are spring-loaded. • [Dakar] Install and tighten screw plugs on left and right.
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E310081 Disassembling telescopic fork • 31 42 503 [GS] Remove sealing caps (1). Removing fixed tube • Remove clamp (6). Warning: • Remove fork stabiliser (5). Note that plugs (3) at left and right are spring-load- • Slacken clamping screws (4) at lower fork ed.
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F310100 Disassembling fixed tube • Clamp slider tube in vice with protective jaws. • Remove spacer and spring with washer from fixed tube. • Remove dust cap (1). • Lever out circlip (2) with screwdriver. Note: Catch escaping oil in a suitable container. •...
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[GS] ..........215 mm (8.46 in) [Dakar] ........218 mm (8.58 in) 31 4 620 F310060 • Place two straight-edges, BMW No. 31 4 620, across the upper and lower ends of the fixed tubes. Important: Replace distorted fork bridges.
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Checking parallel alignment of fixed tubes Checking fixed tube runout F310080 F310070 • Place both ends of fixed tube in V-blocks. Note: The fork bridge must slide smoothly over the fixed tubes. Warning: Do not attempt to straighten bent fixed tubes. •...
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F310091 Assembling telescopic fork 31 42 503 Assembling fixed tube • Fit damper tube (6) with piston ring (5) and spring (4) into fixed tube. • Fit guide piece (3) onto damper tube (6). Note: Lightly oil slide bushes with fork oil before assembly. •...
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Note: • Drive dust sleeve (6) into the slider tube with the Lightly oil slide bushes with fork oil before assembly. convex side of drift, BMW No. 31 3 650. • Tighten shock absorber retaining screw (1) in the •...
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....0.62 l (1.09 Imp. pints/0.65 US quarts) Screw plugs/screws are spring-loaded. [Dakar] ..0.56 l (0.98 Imp. pints/0.59 US quarts) • [GS] Press plugs down and insert retaining rings Oil grades ......BMW telescopic-fork oil to secure. • [Dakar] Lightly oil threads of screw plugs. Tightening torques: Oil drain plug..........
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E310081 Assembling telescopic fork • Install fork stabiliser (5), noting positions of the screws (length). Hand-tighten the screws. • Screw in the quick-release axle all the way, but do not tighten. • Place lower fork bridge in position. Hand-tighten clamping screws (4). •...
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(2), using a suitable mandrel. head mandrel, BMW No. 46 5 607, puller, BMW No. 31 4 820, two spacers, BMW No. 31 6 510, and lever, BMW No. 46 5 605, and make sure the bearing race is correctly seated. 31.18...
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E310140 • Use universal puller, BMW No. 00 7 500, jaws, BMW No. 31 3 672, and thrust piece, BMW No. 31 3 671, to pull the bearing off the steering tube. • Place new dust cap in position. •...
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32 Steering Contents Page Technical Data ..........................3 Removing and installing left and right handlebar fittings ........5 Removing and installing left handlebar fitting ..............5 Removing and installing clutch switch ...................6 Removing and installing right handlebar fitting ..............7 Removing and installing handlebars .................9 Removing and installing clutch cable ................10...
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E320040 Removing and installing left and right handlebar fittings Note: To avoid damage, use a protective apron for the tank, BMW No. 16 1 600. Removing and installing left handlebar fitting – Place motorcycle on its centre stand. – Remove seat.
Removing and installing clutch 61 31 295 switch – Place motorcycle on its centre stand. – Remove seat. – Remove left, right and centre covers ( 46.5). • Release clutch switch on handlebar fitting. • Cut through the cable ties securing the cables at the handlebar and the multi-function switch.
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E320050 Removing and installing right handle- bar fitting – Place motorcycle on its centre stand. – Remove seat. – Remove left, right and centre covers ( 46.5). – [Dakar] Remove hand protectors ( 46.8). • Cut the cable tie at the handlebar. Important: Refer to notes on the hazards involved in handling brake fluid.
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• Disconnect the expansion tank and pull it to one side. • Remove the fasteners securing the oil tank and allow the oil tank to dangle to one side on the hoses. • Remove the starter relay from the holder. •...
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E320110 Removing and installing han- 32 71 008 Important: dlebars Note the position of the clamping blocks. Wide hole – Remove left handlebar fitting ( 32.5). spacing (arrow) to the front. – Remove right handlebar fitting ( 32.7). • Remove impact pad (1). •...
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E320140 Removing and installing 32 72 330 clutch cable E320160 • Make sure that slots in adjusting screw, locknut E320150 and lever fitting (arrow) are in line. • Pull back cable shroud (2). • • Disengage clutch cable (5) from release lever. Pull the cable forward through the slot and disen- •...
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Important: Make sure that the clutch cable is not kinked when installed. E000200 • After installing the cable, adjust clutch clearance by setting distance “B” by turning adjusting screw (2) on the clutch handlebar fitting. • Lock adjusting screw (2) with knurled nut (3). Distance “B”...
E320170 Removing and installing • 32 72 305 Remove cover (4). • Remove fastener for throttle cable (1) from in- throttle cable strument cluster housing. • – Remove seat. Disengage throttle-cable adapter (3) and disen- – Remove left cover ( 46.5).
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Checking and adjusting Adjusting steering head bear- 32 00 454 32 00 454 steering head bearing play, ing play renewing if necessary (Inspections II and III) Important: Cover or mask off the instrument cluster and trim to Checking steering head bear- 32 00 454 prevent scratches.
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E000220 E000230 • Slacken round nut (1) with pin-wrench adapter, BMW No. 31 6 521, then tighten to 25 Nm. Note: • Turn forks back and forth twice from lock to lock, Use the punch marks (arrow) to align the handlebars and leave the forks at the full left lock position.
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Removing and installing left and right handlebar levers Removing and installing left 32 72 070 and right handlebar levers E000200 • After installing the cable, adjust clutch clearance by setting distance “B” by turning adjusting screw (4) on the clutch handlebar fitting. •...
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Technical Data F 650 GS F 650 GS Dakar Rear suspension Suspension strut Central suspension strut pivoted to lever system. Spring base and rebound damping continuously adjustable. Suspension travel at wheel mm (in) 165 (6.50) 210 (8.268) at suspension strut mm (in) 47.5 (1.87)
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Removing and installing sus- • 33 53 000 Remove brake fluid reservoir from rear frame. • Remove lower fasteners securing rear frame to pension strut main frame. • – Remove exhaust manifold ( 18.6). Slightly pretension the strap. • • Secure front wheel in position.
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Removing and installing rear 33 17 350 swinging fork – Remove ABS sensor ( 34.15). – Remove rear wheel ( 36.7). E330080 • Remove the fastener securing the spring strut to frame (1). • Pull the spring strut with adjusting knob to the rear and remove.
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ABS sensor to holder ........9 Nm F330100 Important: Protect mating faces (arrow) of the swinging fork from scratches by covering with masking tape or similar. • Drive needle roller races out of rear swinging fork with drift, BMW No. 33 6 661. 33.7...
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Link to angled lever ........71 Nm F330120 • Press in the outer needle roller races with drift, BMW No. 33 6 651, and spacing sleeve, BMW No. 33 6 652. • Fit bearing bushes and sealing rings into swing- ing fork.
Page 238
• Press in sealing rings (3) with drift, • Drive out needle roller bearing (2) with drift, BMW No. 33 6 671, and spacing ring, BMW No. 33 6 620. BMW No. 33 6 672. • Fit bearing bushing (1).
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To simplify driving out, heat the angled lever to 100 °C (212 °F). Use temperature measuring device, BMW No. 00 1 900, to check heat rise. • Drive out needle roller bearings (8, 9) with drift, BMW No. 33 6 620.
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Drive in needle roller races (5) with drift, • Heat bearing seats to 100 °C (212 °F). BMW No. 33 6 611, and spacing sleeve, BMW No. 33 6 613, working from both sides. Press-in depth “C”......4.5 mm (0.18 in) 33 6 631 F330210 •...
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33 6 611 33 6 614 F330170 F330260 • Press in sealing rings (6) with drift, BMW No. 33 6 611, and spacing ring, BMW No. 33 6 614. • Install bearing bushings (4, 11, 10). 33 6 631 33 6 632 F330250 •...
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34 Brakes Contents Page Technical Data ..........................3 Removing and installing front brake caliper ..............5 Removing and installing front brake pads ( 00.39) ............5 Removing and installing front brake pistons ...............6 Removing and installing front brake disc ................7 Checking brake disc for wear ( 00.40) ................7 Checking front brake disc for lateral runout...
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Contents Page Removing and installing rear ABS sensor ..............15 Removing and installing rear ABS sensor ring ............16 Removing and installing ABS control unit ..............16 Removing and installing front brake lines/hoses (with ABS) ......17 Removing and installing brake lines ..................17 Removing and installing front brake hoses ................18 Removing and installing rear brake lines/hoses (with ABS) .......19...
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Technical Data F 650 GS / GS Dakar Brakes Brake fluid DOT 4 Brake actuation hydraulic Front wheel Front brake 2-piston floating caliper with rigidly mounted disc Brake disc dia. mm (in) 300 (11.81) Brake disc thickness mm (in) 5 (0.20) Minimum thickness mm (in) 4.5 (0.18)
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Removing and installing • 34 11 021 Installation is the reverse of the removal proce- dure. front brake caliper Note: Important: Replace sealing rings for brake line. Refer to notes on the hazards involved in handling brake fluid. • Press the brake caliper against the brake disc in Important: order to force the piston back.
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Keep the brake pistons parallel with their bores Do not insert your fingers between the pistons; when installing. risk of injury. • Using piston compressor BMW No. 34 1 500, if • Carefully press out brake pistons (5), using a necessary press the pistons fully back. •...
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• Remove retaining screws (1) from brake disc. BMW No. 36 3 600. • • [ABS] Remove sensor ring (2). Using dial gauge, BMW No. 00 2 510, measure • Remove brake disc. lateral runout. • Remove separators (3). Lateral runout “A” ....max. 0.25 mm (0.010 in)
Page 249
Removing and installing rear • 34 21 222 Installation is the reverse of the removal proce- dure. brake caliper Note: Important: Replace sealing rings for brake line. Refer to notes on the hazards involved in handling brake fluid. • Remove wheel cover together with chain cover. Important: •...
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Do not insert your fingers between the pistons; risk • of injury. Using piston compressor BMW No. 34 1 500, if necessary press the pistons fully back. • Carefully press out brake piston (3), using a compressed air gun at the brake line connection.
Page 251
E340110 Note: • Retaining screws (1) are secured with Loctite 243 Attach dial gauge holder, BMW No. 00 2 500, to and should be heated if necessary before removal. the rear swinging fork. • Using dial gauge, BMW No. 00 2 510, measure •...
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Removing and installing front brake Removing and installing 32 72 119 master cylinder handbrake lever ( 32.15) – Place the motorcycle on its main (centre) stand. Replacing primary sealing boot, rear brake master cylinder ( 00.45) Important: Refer to notes on the hazards involved in handling brake fluid.
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Removing and installing rear 34 31 001 brake master cylinder Important: Top up brake fluid and bleed brake system. – Place the motorcycle on its main (centre) stand. Operate brake several times until brake pads are bedded. Important: Refer to notes on the hazards involved in handling brake fluid.
Page 254
Removing and installing Checking play at piston thrust rod, 35 21 000 footbrake lever adjusting if necessary Checking play at piston thrust rod E340040 • E340270 Remove footrest plate (1). • Disengage piston thrust rod (4). • • Remove hexagon fit bolt (2). With no load applied to the brake pedal, i.e.
Removing and installing Adjusting play at piston thrust rod 34 52 044 front ABS sensor – Place the motorcycle on its main (centre) stand. – Remove seat. – Remove left cover ( 46.5). E340260 • Insert feeler gauge (1) 0.2 mm (0.008 in) thick be- tween the lug of the brake pedal and the stop on the frame (arrow).
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Removing and installing Removing and installing rear 34 51 610 34 52 111 front ABS sensor ring ABS sensor – Place motorcycle on its centre stand. – Remove seat. • Important: Remove wheel cover together with chain cover. Do not operate the brake with the wheel removed. –...
Page 257
34.21). Important: All work on the ABS control unit must be carried out Tightening torques: by an authorised BMW workshop. ABS sensor to holder ........9 Nm Wheel cover bracket to swinging fork..... 9 Nm – Remove rear frame ( 46.14).
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Removing and installing front brake Important: lines/hoses (with ABS) Top up brake fluid and bleed brake system. Operate brake several times until brake pads are bedded. Important: If the vehicle is equipped with ABS, the brake sys- tem has to be bled using the BMWMoDiTeC, and the Control Units, Toolbox ABS, routine;...
Page 259
Important: Refer to notes on the hazards involved in handling brake fluid. • Drain the brake system. • Disconnect brake hose from brake caliper. E340180 • Disconnect brake line to brake caliper (4) and brake line to brake master cylinder (3) at inter- face.
Page 260
Removing and installing rear brake lines/hoses (with ABS) Important: If the vehicle is equipped with ABS, the brake sys- tem has to be bled using the BMWMoDiTeC, and the Control Units, Toolbox ABS, routine; this proce- dure is supplementary to that described in the Re- pair Manual.
Page 261
Checking/adjusting front 34 52 544 Important: ABS sensor gap Top up brake fluid and bleed brake system. Operate brake several times until brake pads are bedded. Important: Check the ABS sensor gap if the ABS sensor, sen- sor ring, wheel bearing, front wheel, telescopic fork, spacer, quick-release axle, or brake disc has been Tightening torques: replaced.
Page 262
Checking and adjusting gap 34 52 544 of speed/rear ABS sensor Important: Check the speed/ABS sensor gap if the ABS sen- sor, sensor ring, brake-caliper holder, spacer sleeve, rear wheel, or wheel bearing has been re- placed. – Take the weight off the rear wheel. •...
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36 Wheels and tyres Contents Page Technical Data ..........................3 Removing and installing front wheel .................5 Removing front wheel ........................5 Installing the front wheel ......................5 Removing and installing front wheel bearing ..............6 Removing left-hand wheel bearing ......................6 Removing right-hand wheel bearing ....................6 Installing wheel bearings ........................7 Removing and installing rear wheel ...................7...
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Technical Data F 650 GS F 650 GS Dakar Wheels and tyres Rim size Front 2.50"x19" 1.60"x21" Rear 3.00"x17" Vertical runout mm (in) 2.0 (0.079) Lateral runout mm (in) 2.0 (0.079) Maximum permissible imbalance g (oz.) 5 (0.20) Tyre size...
Removing and installing Installing the front wheel 36 30 300 36 30 300 front wheel Removing front wheel 36 30 300 Important: – Place motorcycle on its centre stand. When installing, avoid damage to ABS sensor, sen- – Take load off front wheel/lift clear of ground. sor ring, brake disc and brake pads.
Remove wheel bearing (4) with counter-support, wheel bearing BMW No. 00 8 572, internal puller, – Remove front wheel. BMW No. 00 8 571, and support ring, BMW No. 36 6 651. • Remove spacer sleeve (3). 00 8 572 Removing right-hand wheel bearing •...
Page 269
• Install the spacer bushing. • Drive in the right-hand wheel bearing with drift, BMW No. 36 6 600, until seated, making sure that the load is supported only on the left-hand wheel bearing. Note: The left-hand bearing must be seated on the stop in the wheel hub.
100 °C (212 °F). BMW No. 00 8 571. • Use temperature measuring device, Remove spacer sleeve (6). BMW No. 00 1 900, to check heat rise. 00 8 571 00 8 572 36 6 651 XF?????? F360050...
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• Drive in the right-hand wheel bearing with drift, BMW No. 36 6 600, making sure that the load is supported only on the left-hand wheel bearing. Note: The left-hand bearing must be seated on the stop in the wheel hub.
Page 272
– Remove and install front wheel ( 36.5). • Remove tyre. Note: Use nipple tensioner, BMW No. 36 3 800. Outer left spokes • Release spoke nipple (1). • Pull spoke (2) out of wheel hub. Inner left spokes •...
Page 273
F360130 • Outer right spokes Installation is the reverse of the removal proce- • Release spoke nipple (1). dure: pay particular attention to the following. • Release spoke nipple (2). – After installing, centre the wheel rim ( 36.13). • Turn spoke (3) outwards.
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Pull spoke (8) out of wheel hub. • Installation is the reverse of the removal proce- Note: dure: pay particular attention to the following. Use nipple tensioner, BMW No. 36 3 800. – After installing, centre the wheel rim ( 36.13). Outer left and right spokes •...
Page 275
36 3 600 F360150 Checking and centering front 36 32 528 Note: and rear wheel rims Apply the dial gauge, BMW No. 00 2 510, only to – Remove the wheels. the machined inner surface of the wheel rim. Checking rims •...
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Centering lateral runout Centering vertical runout F360160 F360160 Important: Important: Never attempt to eliminate all the lateral runout at Spokes which protrude from the spoke nipples must only one or two spokes. be shortened. • Correct vertical runout “H” by tightening the Note: spokes at left and right (arrow).
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[Rear wheel] Remove chainwheel carrier com- plete with chainwheel from the rear-wheel hub. • Level the balancing unit, BMW No. 36 3 600, at bubble gauge (2) in the baseplate. • Pass the balancing shaft, BMW No. 36 3 617, through the wheel bearings.
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46 Frame Contents Page Technical Data ..........................3 Removing and installing fairing ....................5 Removing and installing covers ....................5 Removing and installing left and right covers ..................5 Removing and installing centre cover ....................5 Removing and installing cockpit fairing .................6 Removing and installing fairing bracket ....................7 [Dakar] Removing and installing hand protectors .............8 Removing and installing engine guard...
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Technical Data F 650 GS F 650 GS Dakar Frame Frame Bridge-type frame with bottom truss Type plate location Main frame upper rail, right Frame No. location On right of steering head Max. height (windscreen) mm (in) 1,265 (49.80) 1,412 (55.59) Maximum width (across mirrors) mm (in) 890 (35.039)
E460044 Removing and installing fairing 46 63 Removing and installing centre cover – Remove left and right covers. • Removing and installing covers Remove screws (2) securing the centre cover. 46 63 • Lift off the centre cover (5). • –...
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E460050 Removing and installing cockpit • 46 63 Remove the fasteners securing the cockpit fairing (2). fairing • Disconnect multi-pin plug (5). • – Remove left and right covers ( 46.5). Pull the rubber boot to the rear. • Pull the socket of the sidelight out of the head- light housing.
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• Installation is the reverse of the removal proce- 46 63 198 Removing and installing fairing dure: pay particular attention to the following. bracket • [Dakar] Align retainer (11) in fairing bottom – Remove instrument cluster ( 62.6). • section (8). Unclip connector for turn indicator.
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[Dakar] Removing and installing Removing and installing front 46 63 46 61 000 hand protectors mudguard – Place motorcycle on its centre stand. – Place motorcycle on its centre stand. [GS] E000311 E460043 • Release fasteners (2). • Remove hand protector (1). [Dakar] •...
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Removing and installing left/right Removing and installing left/right 46 63 46 63 rear trim panel grip – Remove seat. – Open the stowage compartment. – Remove left/right silencer ( 18.5). • Remove turn-indicator cover. • Disconnect cable and pull through. •...
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Removing and installing base of Removing and installing seat latch 46 63 46 63 stowage compartment and partition – Remove seat. – Remove seat. – Remove number plate panel ( 46.10). – Remove left and right grips ( 46.9). E460160 •...
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Removing and installing rear 46 62 200 mudguard – Remove exhaust manifold ( 18.6). – Remove chain takeup roller ( 27.5). E460150 • Release fasteners (1). E460140 • Release fasteners (2). • Remove mudguard. • Installation is the reverse of the removal proce- dure.
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Raising, removing and installing rear frame Raising rear frame – Remove exhaust manifold ( 18.6). • Secure front wheel in position. E330070 Important: Do not raise the rear frame all the way, as it is seated against the lock of the seat (arrow). •...
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Disconnect the plug for rear light/turn indicator (5). • Close off fuel supply line (1) and the fuel return line (2) with hose clips, BMW No. 13 3 010. • Open the hose clips (arrows) and disconnect the fuel lines from the fuel-pump unit.
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• Close hose clamps with pliers, BMW No. 13 1 500. Tightening torques: Oxygen sensor to exhaust......45 Nm Exhaust manifold to cylinder head....20 Nm Clamp for silencer ........
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• Installation is the reverse of the removal proce- dure: pay particular attention to the following. Note: After installing the rear swinging fork, do not fully tighten the stud in the swinging-fork pivot until the engine is installed. After installing the brake lines, install the rear frame first, before installing the engine.
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E460250 Removing and installing right Removing and installing left 46 71 061 46 71 061 footrest footrest • • Remove 3 screws (4). Remove 3 screws (3). • • Remove footrest (5). Remove footrest (2). • • Remove keeper (8). Disassemble the right footrest in the same way as the left footrest.
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Release fasteners (1, 2). • • Installation is the reverse of the removal proce- Use hook, BMW No. 46 5 721, to disengage dure: pay particular attention to the following. springs (3). Remove plate (6) with the springs. • Remove retaining ring (1).
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Removing and installing main 46 52 000 (centre) stand E460220 Important: Note spring loading. • Use hook, BMW No. 46 5 721, to disengage springs (5). • Remove fasteners (1) on left and right. • Remove the main stand •...
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51 Equipment Contents Page Technical Data ..........................3 Removing and installing ignition switch/steering lock ...........5 Removing and installing lock barrel ..................6 Removing and installing lock for rear stowage compartment ......6 Removing and installing lock barrel for fuel tank filler cap ........6 Replacing mirrors .........................7...
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Removing and installing • 51 25 040 Cut through the 2 cable ties at the left of the frame head. ignition switch/steering lock • Remove the fasteners securing the oil tank and allow the oil tank to dangle to one side on the –...
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Tighten the non-removable screws with socket – Place motorcycle on its centre stand. • wrench insert, BMW No. 51 0 530. Remove the lid of the rear stowage compart- ment. • Clamp the lid in a vise with protective jaws.
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E510030 • Insert key in lock barrel and press down on retainer (1). • Pull out lock barrel with key. • Grease the new lock barrel with Optimoly MP 3. • Insert the lock barrel with the key. • Installation is the reverse of the removal proce- dure.
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61 General electrical equipment Contents Page Technical Data ..........................3 Wiring harness ..........................5 View from left ............................5 View from right ..........................6 [Dakar] General view, left side ....................7 [Dakar] General view, right side ....................8 Component positions in electronic equipment box ..........9 Relay positions in electronic equipment box ..............9 Connectors, electronics box...
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Contents Page [GS] Removing and installing voltage regulator ............15 [Dakar] Removing and installing voltage regulator ..........15 61.2...
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Technical Data F 650 GS / GS Dakar General electrical equipment Circuit voltage V 12 Battery A/h 12 61.3...
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Removing and installing bat- Removing and installing bat- 61 21 010 61 21 100 tery tery carrier – Place motorcycle on its centre stand. Warning: – Remove seat. Battery acid is highly caustic. – Remove left, right and centre covers ( 46.5).
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Replacing fuses Removing and installing 61 13 011 electronic equipment box Motorcycle fuses – Remove seat. • Open the cover of the fuse box. – Remove battery carrier ( 61.10). • • Replace the defective fuse. Disconnect the expansion tank from the radiator, pull it to one side and leave it to dangle from the Fuses hose.
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Removing and installing side Removing and installing 61 31 302 61 31 310 stand switch rear-brake switch for brake light – Place motorcycle on its centre stand. – Remove seat. – Remove engine guard ( 46.8). – Remove right cover ( 46.5).
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Removing and installing • 61 31 300 Remove the fasteners securing the oil tank and allow the oil tank to dangle to one side on the front-brake switch for brake light hoses. • Remove the starter relay from the holder. •...
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Removing and installing • 61 33 000 Installation is the reverse of the removal proce- dure: pay particular attention to the following. horn • Clean the threads of the neutral-indicator switch and coat with Loctite 243. – Remove front mudguard ( 46.8).
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[GS] Removing and installing volt- [Dakar] Removing and installing age regulator voltage regulator – Place motorcycle on its centre stand. – Place motorcycle on its centre stand. – Secure front wheel in position. – Secure front wheel in position. – Remove seat.
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62 Instruments Contents Page Technical Data ..........................3 Telltale/warning lights .......................5 Removing and installing instrument panel ..............6 Replacing telltale/warning lights ..................6 Disassembling and assembling instrument cluster ............6 Removing and installing wiring harness ................7 62.1...
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Removing and installing instru- Replacing telltale/warning lights 62 11 200 ment panel – Place motorcycle on its centre stand. – Remove instrument panel. – Remove left and right covers ( 46.5). Note: Note washers and rubber ring. • Remove the windscreen. •...
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E620030 • Remove the 3 securing screws (1) from the rear of the housing. • Press back the 4 snap locks (arrows) on the plug housing and press out the instrument panel. • Installation is the reverse of the removal proce- dure.
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63 Lights Contents Page Technical Data ..........................3 Removing and installing headlight ..................5 Removing and installing rear light ..................5 Replacing bulb ..........................6 Bulb for low-beam headlight/high-beam headlight ............6 Bulb, parking light ...........................6 Flashing turn indicator ........................7 Rear lights ............................7 Checking and adjusting headlight beam throw ............7 Vertical adjustment .........................7...
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E630020 Removing and installing Removing and installing rear 63 12 090 63 21 380 headlight light • – Place motorcycle on its centre stand. Remove the lid of the stowage compartment. • – Remove left and right covers ( 46.5). Remove the number plate holder complete with the rear light from the frame.
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• Disconnect the plug of the rear light. • Installation is the reverse of the removal proce- dure: pay particular attention to the following. E630070 • Turn retainer (4) counterclockwise to release and remove. E630060 • Remove bulb (5). • Installation is the reverse of the removal proce- Colours of the wires in the housing for tail light/ dure.
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Flashing turn indicator Lateral adjustment 63 99 271 • Remove turn-indicator cover. • Press the bulb to the rear and turn it counter- clockwise to release. • Installation is the reverse of the removal proce- dure. Rear lights 63 99 381 •...