BMW F 650 GS 2003 Maintenance Instruction

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Repair manual (307 pages)

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Maintenance Instructions

F 650 GS

F 650 GS Dakar

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Rider's Manual

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Page 1 Maintenance Instructions F 650 GS F 650 GS Dakar BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad...
Page 2 Please note Warning: This symbol indicates pre- cautions and measures which are essential in protecting the rider or other persons from severe or fatal injury. Attention: Specific instructions and safety precautions intended to pre- vent damage to the motorcycle. Disregarding them may render the warranty invalid.
Page 3 Important: and will gladly advise and assist BMW refuses to accept liability you. for damage or consequential damage due to repairs or serv- Best wishes, ice work carried out by other...
Page 4: Important Safety Information
BMW cannot assess every sin- gle product of outside origin in order to decide whether it can be used on or with a BMW vehi- cle without constituting a safety hazard. For your own safety, use only...
Page 5: Maintenance Work
Maintenance work is divided up into Service, Inspection and Annual Inspection. BMW Inspection 1,000 km (600 miles) BMW running-in check after the first 1,000 km (600 miles). BMW Service After the first 10,000 km (6,000 miles) and every further 20,000 km (12,000 miles) (30,000 km…, 50,000 km …,...
Page 6 Confirmations of maintenance work BMW Service Pre-delivery check 10,000 km (6,000 miles) Carried out in accordance with manufacturer’s instructions Carried out in accordance with manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection, BMW Inspection,...
Page 7: Confirmation Of Maintenance Work
Confirmation of maintenance work BMW Service BMW Service 30,000 km 50,000 km (18,000 miles) (30,000 miles) Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature...
Page 8 Confirmation of maintenance work BMW Service BMW Service 70,000 km 90,000 km (42,000 miles) (54,000 miles) Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature...
Page 9 Confirmation of maintenance work BMW Service BMW Service 110,000 km 130,000 km (66,000 miles) (78,000 miles) Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature...
Page 10: Annual Inspection
Confirmation of maintenance work Annual Inspection Annual Inspection Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Brake fluid changed: Brake fluid changed: Coolant changed: Coolant changed: Date, stamp, signature Date, stamp, signature Annual Inspection Annual Inspection Carried out in accordance with Carried out in accordance with...
Page 11 Confirmation of maintenance work Annual Inspection Annual Inspection Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Brake fluid changed: Brake fluid changed: Coolant changed: Coolant changed: Date, stamp, signature Date, stamp, signature Annual Inspection Annual Inspection Carried out in accordance with Carried out in accordance with...
Page 12 Confirmation of maintenance work Annual Inspection Annual Inspection Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Brake fluid changed: Brake fluid changed: Coolant changed: Coolant changed: Date, stamp, signature Date, stamp, signature Annual Inspection Annual Inspection Carried out in accordance with Carried out in accordance with...
Page 13: Confirmation Of Service
Confirmation of service Record of all work carried out in workshop Work performed km/miles Date The list is intended as a record of maintenance, warranty and repair work, the installation of optional accessories and, if appropriate, special campaign work.
Page 14 Confirmation of service Record of all work carried out in workshop Work performed km/miles Date The list is intended as a record of maintenance, warranty and repair work, the installation of optional accessories and, if appropriate, special campaign work.
Page 15 Confirmation of service Odometer replaced Odometer replaced Odometer reading is not total Odometer reading is not total distance covered. distance covered. Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature Odometer replaced Odometer replaced Odometer reading is not total Odometer reading is not total distance covered.
Page 16: General Instructions
General instructions Your motorcycle is equipped with a digital electronic engine management system and a high-power ignition system. If you intend to perform the maintenance and general care Warning: work described in the following When the engine is running or section yourself, you must pos- the ignition is switched on, do sess the necessary knowledge...
Page 17 Remember: the safety and reli- ability of your motorcycle are the most important considera- tions. BMW refuses to accept liability You should therefore not for damage or consequential attempt any complex repair or damage due to repairs or serv- maintenance tasks.
Page 18 Tampering with the electronic Genuine BMW parts engine management system For reasons of safety, use only represents an increased safe- genuine BMW parts and acces- ty risk for the rider. sories. Genuine BMW parts are identi- cal with those fitted to your...
Page 19 Toolkit • Vehicle toolkit under the seat Contents 1 wallet 1 screwdriver, reversible blade 1 cross-head screwdriver, 1 Allen key small w/f* 8 mm (0.31 in) 4 open-ended spanners, 4 Torx screwdrivers T25, T30, w/f* 8 x 10 mm (0.39 in), T40, T45 14 x 19 mm (0.75 in), 4 fuses 4 A, 7.5 A,10 A, 15 A...
Page 20: Troubleshooting Chart
Troubleshooting chart Fault: Engine does not start or is very difficult to start Possible cause Remedy Page Wrong ignition Operation Rider’s Manual key position Chapter 1 Kill switch is off Operation Rider’s Manual Chapter 3 Power supply Blown fuse interrupted Gear engaged, clutch Select neutral or Rider’s Manual...
Page 21 – not described on pages More detailed technical infor- 14 ...62 – attended to by a spe- mation is available in the follow- cialist workshop, preferably an ing publications: authorised BMW motorcycle – Repair Manual dealer. – Electrical circuit diagrams...
Page 22: Removing The Front Wheel
• Place the motorcycle on its sary). main stand (Dakar: use auxil- Do not scratch the rim when iary stand, BMW special tool forcing back the brake pads or number 00 1 610, or some removing the calipers (apply other, suitable auxiliary stand) masking tape if necessary).
Page 23 Removing the front wheel Warning: • Remove securing screw 2, Make sure that the motorcy- using w/f 10 open-ended cle is standing firmly and can- spanner ( not topple forward or to either side. Attention: If a spacer 3 is installed to com- Attention: pensate component tolerances, Remove ABS sensor...
Page 24 Removing the front wheel Note: Warning: Check the brake pads Make sure that the motorcy- 33) (have them replaced if cle is standing firmly and can- necessary). not topple forward or to either side. Attention: When setting down the front •...
Page 25: Installing The Front Wheel
Installing the front wheel Note: Note the installed position of • Clean and grease spacer the ABS sensor ring or the di- bushing 1 and spacer 4 and rection-of-rotation arrow on the insert them into the wheel tyre. hub. As viewed in forward direction of travel: Attention: –...
Page 26 Always have the security of the brake lever firmly several fasteners checked by a special- times to check that the front ist workshop, preferably an au- brake is operating correctly. thorised BMW motorcycle deal- Optional extra...
Page 27: Removing The Rear Wheel
• Place the motorcycle on its disc and pads when removing main stand (Dakar: use auxil- the wheel. iary stand, BMW special tool Do not damage the ABS sensor number 00 1 610, or some cable , ABS sensor ring...
Page 28 Removing the rear wheel • Hold the brake caliper and roll the wheel out toward the rear • Remove axle nut 3 using w/f Attention: 24 mm (0.94 in) socket and Sprocket 6 sits loosely in the spark-plug wrench as exten- wheel.
Page 29: Installing The Rear Wheel
Installing the rear wheel • Roll the rear wheel between the rear swinging arm forks and carefully position the Attention: brake disc in the brake cali- When tensioning the chain, per. note correct wheel alignment • Lift chain 5 onto sprocket 6 (marks on swinging fork arms).
Page 30 Installing the rear wheel Warning: Screws 1 of rear wheel cover • Make sure that the same are secured with Loctite. number of notches has been Before reinstalling, clean the reached at marking point 5 on screw threads and coat them the left and right swinging fork with Loctite No.
Page 31 Installing the rear wheel Attention: Always have the security of the fasteners checked by a special- ist workshop, preferably an au- thorised BMW motorcycle deal- Warning: When assembly work has Tightening torque: been completed, depress the Axle nut 3 ....100 Nm...
Page 32: Checking The Chain
Have the chain, sprocket and • Grip the chain at the rearmost pinion replaced by a specialist point of sprocket 1 and pull workshop, preferably an the chain to the rear, away authorised BMW motorcycle from the sprocket dealer.
Page 33: Adjusting The Chain
Adjusting the chain Adjusting the chain • Place the motorcycle on its main stand [Dakar: side stand] – Make sure the ground is Attention: level and firm. When tensioning the chain, • Slacken axle nut 2 using w/f note correct wheel alignment 24 mm (0.94 in) socket and (notches in swinging fork arms).
Page 34 • Make sure that the same BMW motorcycle dealer. number of notches has been reached at marking point 1 on the left and right swinging fork...
Page 35: Checking Brake Pads
– If the wear indicating mark is having work on the brake sys- no longer clearly visible: tem performed by a specialist have the brake pads replaced workshop, preferably an by a specialist workshop, authorised BMW motorcycle preferably an authorised dealer. BMW motorcycle dealer.
Page 36: Rear Brake
– If the wear indicating mark is having work on the brake sys- no longer clearly visible: tem performed by a specialist have the brake pads replaced workshop, preferably an by a specialist workshop, authorised BMW motorcycle preferably an authorised dealer. BMW motorcycle dealer.
Page 37: Adding Coolant
Adding coolant Attention: Use only nitrite-free antifreeze and corrosion inhibitor. Check coolant level only when the engine is cold. Top up the fluid in the expan- • Place the motorcycle on its sion tank only if the loss of cool- main stand [Dakar: side stand] ant is minor.
Page 38 It is advisable to have the • Remove cap 1 from filler neck coolant changed by a specialist • Top up coolant to MIN mark workshop, preferably your • Place motorcycle on main authorised BMW motorcycle (centre) stand or hold it upright dealer.
Page 39: Notes On Changing Bulbs
Notes on changing bulbs Attention: Your motorcycle has one bulb for the low-beam /high-beam headlight, one for the parking light, one for the brake light and Your motorcycle is equipped one for the rear light, plus four with a digital electronic engine bulbs for the turn indicators.
Page 40: Changing Bulbs
Changing bulbs • Place the motorcycle on its Flashing turn indicators main stand [Dakar: side stand] – Make sure the ground is level and firm. Attention: • Remove securing screw 1 Switch off the ignition before • Remove turn indicator glass 3 changing a bulb.
Page 41 Changing bulbs Tail light/brake light Note: The rear light is also the number-plate light. • Place the motorcycle on its main stand [Dakar: side stand] – Make sure the ground is Attention: level and firm. Switch off the ignition before •...
Page 42 Changing bulbs • Place the motorcycle on its Parking light main stand [Dakar: side stand] – Make sure the ground is level and firm. Attention: • Pull off multi-pin plug 2 Switch off the ignition before • Pull the rubber sleeve 1 to the changing a bulb.
Page 43 Changing bulbs High-beam/low-beam • Pull off multi-pin plug 2 headlight • Pull rubber sleeve 1 to the rear to remove • Turn retainer 4 counter-clock- Attention: wise to disengage Switch off the ignition before • Remove bulb 3 changing a bulb. •...
Page 44: Changing Fuses
It is advisable to have the elec- number of spare fuses in the trical system checked by a spe- toolkit ( 17). cialist workshop, preferably an Use only fuses of the specified authorised BMW motorcycle rating and type. dealer, if fuses blow frequently.
Page 45 Fuses Equipment connected to fuses 1 Engine electronics ..15 A 2 Instrument panel, on-board socket, diagnosis plug, 6 Brake light, flashing turn OA plug ...... 10 A indicators, 3 Horn, instrument panel, headlight flasher ..7.5 A instrument lighting ..7.5 A 4 Low-beam headlight ..
Page 46: Side Panel
Side panel Removing right side panel • Remove the four securing screws 2 holding the turn indicator • Remove 2 retaining screws 1 • Slacken securing screw 3 Removing and installing • Pull right side panel out of side panel locator 4 at bottom and lift it •...
Page 47 Side panel Removing and installing left side panel Note: The procedure for removing and installing the left side panel is analogous to that for the right Removing and installing side panel. centre panel Remove the oil filler plug before • Remove the remaining two removing the left side panel.
Page 48: Jump Starting
Jump starting Jump starting Battery adapter points Do not use proprietary start- BMW calls an easily accessible assist sprays to start the battery positive terminal 1 and a engine. defined earthing point 2 the bat- Use only jump leads fitted with tery adapter points.
Page 49 Jump starting • On the BMW, battery adapter points 1 and 2 are the connec- tion points for jump starting • Remove protective cap 3 from the positive terminal • Connect one end of a jump lead to positive terminal 1 of...
Page 50: Battery Safety Instructions
Battery safety instructions Warning: Always wear protective gog- gles and protective gloves when performing work asso- ciated with the battery. If anyone comes into contact with battery acid or is exposed to toxic fumes from the battery, have them exam- ined by a physician without delay.
Page 51 – The battery can be recharged • Check battery acid level with the BMW battery trickle • Store the battery in a cool, dry charger room – Charge the battery prior to lay-ups and before restoring to use –...
Page 52: Removing The Battery
Removing the battery • Place the motorcycle on its main stand [Dakar: side stand] – Make sure the ground is level and firm. • Remove the seat Warning: • Remove the side panel Do not damage cables and 44-45) hoses when removing. •...
Page 53: Installing The Battery
Installing the battery Warning: Before connecting the bat- tery, make sure the ignition is Attention: switched off. Make sure that breather hose 4 To avoid short-circuits: for the battery is routed free of • Connect positive battery kinks and is not clogged. lead (+) 2 first •...
Page 54: Checking Battery Acid Level
Battery • Check the acid level at the MIN/MAX marks UPPER mark LOWER mark • Top up with distilled water only as far as the MAX (UPPER) mark Checking battery acid level Attention: – Check the level of acid in the Do not set the battery on the battery every three months or motorcycle when you are top-...
Page 55: Changing Air Filter
Changing air filter • Place the motorcycle on its • Pull air filter element 5 out of main stand [Dakar: side stand] the air filter housing – Make sure the ground is • Place the new filter element in level and firm. position inside the air filter •...
Page 56: Spark Plugs
Spark plugs Warning: When the engine is running or the ignition is switched on, do not touch electrically live components, terminals or wiring. – Risk of fatal accident • Work on the electrical sys- tem only when the circuit has been interrupted (igni- tion and lights switched off).
Page 57 Spark plugs Changing secondary Attention: spark plug The direct ignition coils have • Turn direct ignition coil 1 as different colour codes: take far as it will go clockwise care not to mix them up. Direct (arrow) ignition coil of the •...
Page 58 Spark plugs • Remove the direct ignition coil of the secondary spark Changing plug primary spark plug • Turn direct ignition coil 1 as far as it will go counter-clock- wise (arrow) Attention: • Pry direct ignition coil 1 up In order to prevent foreign mat- and off, using w/f 15 open- ter from entering the combus-...
Page 59 Cleaning/care Attention: Do not use aggressive or pene- trating cleaning agents or sol- vents, as they would cause damage to rubber and plastic Note: parts. Correct and regular cleaning is Do not use a steam jet or high- an important factor in maintain- pressure cleaning equipment.
Page 60: Washing The Motorcycle
Cleaning/care • Thoroughly dry all wet sur- Washing the motorcycle faces • Do not use solvents or clean- ing products on the instru- Warning: ment cluster, switches or After cleaning and before windscreen starting a journey, always test • Do not scratch the wind- the brakes.
Page 61 Cleaning/care Removing road salt • Wash the motorcycle down Cleaning the windscreen immediately with cold water at • Remove dirt and dead insects the end of the journey. with a soft sponge and plenty of water Note: Do not use warm water – this Note: aggravates the effect of the salt.
Page 62 Repairing damage to the paintwork • Minor damage caused by stones striking the painted surface can be touched up with a BMW touch-up pencil of the correct colour Care of the chain • Regularly apply a spray lubri- Attention: cant to the chain; spray lubri-...
Page 63 BMW motorcy- • Coat bright metal/chrome- cle dealer. plated parts with an acid-free Work needed in conjunction grease (e.g.
Page 64: Restoring To Use
Restoring to use Restoring to use • If necessary, remove protec- tive wax coating • Clean the motorcycle ( • Check/correct tyre pressures • Install a charged battery Rider's Manual, Chapter 2) • Check brakes • Coat the battery terminals Rider's Manual, Chapter 2) with grease suitable for bat- •...
Page 65 Engine F 650 GS F 650 GS [37 kW] [25 kW] Type Liquid-cooled single-cylinder four- stroke engine with 4 valves with bucket tappets, 2 overhead cam- shafts, dry-sump lubrication Displacement 652 cc 652 cc (22.04 fl oz.) (22.04 fl oz.) Maximum rated output in accordance with DIN 70 020 37 kW 25 kW...
Page 66: Power Train
Power train F 650 GS Clutch Multi-plate clutch running in oil bath Primary transmission 37/72 = 1:1.946 Gearbox 5-speed, with claw-action shift, integrated into engine block Gear ratios 1st gear = 2.75 in the gearbox 2nd gear = 1.75 3rd gear = 1.31 4th gear = 1.05 5th gear = 0.88 Transmission from gear-...
Page 67: Frame And Suspension
Frame and suspension F 650 GS Frame Bridge-type frame with bottom rail Location of type plate On top rail of main frame, right Location of vehicle identification number (VIN) On right of steering head Front brake Hydraulically actuated single-disc brake with 2-piston floating caliper Rear brake Hydraulic disc brake with 1-piston floating caliper...
Page 68 Frame and suspension F 650 GS Suspension Front Telescopic fork with stabiliser Total suspension travel 170 mm (6.69 in) Dakar version 210 mm (8.27 in) Fixed tube diameter 41 mm (1.61 in) Rear Central suspension strut pivoted to lever system. Spring base point and rebound-phase damping continuously adjustable.
Page 69 F 650 Dakar Wheels and tyres Spoked wheel Note: You can obtain detailed information on approved tyre sizes and makes from your authorised BMW motor- cycle dealer or by visiting www.bmw-motorrad.com on the Internet Front wheel Size and designation 2.50“ x 19“ MT 1.6"...
Page 70: Fuel And Lubricants
Temperatures above or below the limits quoted for the individ- ual SAE classifications are permitted for brief periods only. All engine oils supplied by BMW are subject to regular BMW quality assurance checks. BMW does not approve the use of any upper-cylinder lubricants or similar oil additives.
Page 71 Fuel and lubricants F 650 GS Telescopic fork oil Approved grades BMW telescopic fork oil Refill after disassembly 0.61 l (1.07 Imp. pint) Dakar version 0.56 l (1.06 Imp. pints) Oil change 0.60 l (1.06 Imp. pint) Dakar version 0.55 l (1.06 Imp. pints)
Page 72 Fuel and lubricants F 650 GS Brake fluid DOT 4 We recommend BMW brake fluids Attention: Use only new brake fluid to DOT 4 specification. Coolant Brand-name long-life antifreeze and corrosion inhibitor Attention: Use only nitrite-free antifreeze and corrosion inhibitor.
Page 73: Electrical System
Electrical system F 650 GS Spark plugs Approved makes/types NGK DR8 EB Electrode gap 0.6 - 0.7 mm (0.02 - 0.03 in) Wear limit 0.9 mm (0.0354 in) Fuses “Minifuse” flat-socket fuses Ratings 4 A, 7.5 A, 10 A and 15 A Headlights Halogen headlight Bulbs...
Page 74: Dimensions And Weights
Dimensions and weights F 650 GS Overall length 2,185 mm (86.02 in) Dakar version 2,189 mm (86.18 in) Width across mirrors 910 mm (35.82 in) acr. handlebars (with weights) 805 mm (31.69 in) Dakar version 895 mm (35.24 in) across front footrests 568 mm (22.36 in) across rear footrests 664 mm (26.14 in)
Page 75 Dimensions and weights F 650 GS Unladen weight (ready to ride, tank full) 194 kg (428 lbs) Maximum permitted weight 380 kg (838 lbs) Permitted wheel loads Front 124 kg (273 lbs) Rear 256 kg (564 lbs)
Page 76: Performance Data
Performance data F 650 GS F 650 GS [37 kW] [25 kW] Maximum speed acc. to type approval test 170 km/h 145 km/h (105 mph) (90 mph) two-up 162 km/h 135 km/h (100 mph) (84 mph) Power/weight ratio ready for road +rider 7.24 kg/kW 10.72 kg/kW (75 kg/165 lbs)
Page 77 A - D Accessories, genuine BMW Capacity, engine, 68 parts, 16 Castor, 66 Air filter, 53 Chain, 31 Annual Inspection Adjusting, 31 Confirmation of maintenance Checking, 30 work, 8, 9, 10 Cleaning/care Annual Inspection, notes, 3 General instructions, 57, 59...
Page 78 E - P General instructions, 14, 15 Ground clearance, 72 Elasticity, 74 Engine oil Capacity, 68 Consumption, 68 Headlights, 71 Technical data, 68 Viscosity, 68 Idle speed, 63 Engine speed limit, 63 Inspection Engine, type, 63 Notes, 3 Frame, 65 Front brake Jump starting, 46, 47 Checking pads, 33...
Page 79 P - Z Power/weight ratio, 74 Toolkit, 17 Pre-delivery check, 4 Torque, 63 Primary drive ratio, 64 Touching up minor damage, 60 Tread depth, 67 Type plate, 65 Tyres, 67 Rear brake Approved sizes, 67 Checking pads, 34 Technical data, 67 Technical data, 65 Tread depth, 67 Rear wheel...
Page 82 Motorcycle data Model Frame No. Colour No. First registered on Registration No. Dealer data Person to contact for Service work Ms./Mr. Tel. No. Dealer’s address with telephone No. (company stamp)
Page 83: Maintenance Instructions
Maintenance Instructions F 650 GS F 650 GS Dakar BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad...
Page 84 Please note Warning: This symbol indicates pre- cautions and measures which are essential in protecting the rider or other persons from severe or fatal injury. Attention: Specific instructions and safety precautions intended to pre- vent damage to the motorcycle. Disregarding them may render the warranty invalid.
Page 85 Errors and omissions excepted. national-market specification. © 2003 BMW Motorrad No claims will be entertained as Not to be reproduced either a result of such discrepancies. wholly or in part without written...
Page 86 BMW recommends Castrol BMW Motorrad Printed information Order No.: 01 41 7 685 941 10.2003 The Ultimate 1st edition GB / RF Driving Machine...
Page 87 Errors and omissions excepted. national-market specification. © 2003 BMW Motorrad No claims will be entertained as Not to be reproduced either a result of such discrepancies. wholly or in part without written...
Page 88 BMW recommends Castrol BMW Motorrad Printed information Order No.: 01 41 7 685 941 10.2003 The Ultimate 1st edition GB / RF Driving Machine...

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