BMW F 650 GS Repair Manual
  1. Manuals
  2. Brands
  3. BMW Manuals
  4. Motorcycle
  5. F 650 GS DAKAR -
  6. Repair manual
BMW F 650 GS Repair Manual

BMW F 650 GS Repair Manual

Hide thumbs Also See for F 650 GS:
Table of Contents

Advertisement

Quick Links

See also: Repair Manual , Rider's Manual
Repair Manual
F 650 GS
BMW AG Motorcycle Division
After Sales

Advertisement

Table of Contents
loading

Related Manuals for BMW F 650 GS

Summary of Contents for BMW F 650 GS

  • Page 1 Repair Manual F 650 GS BMW AG Motorcycle Division After Sales...
  • Page 2 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.

  • Page 3: Key To Symbols

    Usage Each chapter starts with the list of contents. The list of contents is followed by the Technical Data table. Chapter 00 “Maintenance and general instructions” details the handover checklist and lists all tightening torques and operating fluids. Key to symbols In this Workshop Manual for the F 650 GS model, the following symbols are used;...
  • Page 4 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...

  • Page 5: Pre-Delivery Check

    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 – Engine idle speed –...

  • Page 6: Service Data

    BMW AG Motorcycle Division Service data F 650 GS 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 Telescopic fork – for each post 0.60 (1.06/0.63) Litres (Imp.
  • Page 7 F 650 GS Instructions for pre-delivery check BMW AG Sparte Motorrad After Sales UX-VS-2 Hufelandstr. 6 D-80937 München Edition: 11/99...

  • Page 9: Table Of Contents

    Removing right and centre covers ..................5 Filling and charging the battery ....................6 Checking that delivery is complete ..................7 Reading the fault code memory with the BMW MoDiTeC ........7 Checking tyre pressures ......................7 Adding fuel to tank ........................7 Final inspection and function check .................7...

  • Page 11: General View Of Crated Motorcycle

    E000250 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.

  • Page 12: Inspecting Motorcycle For Damage

    Inspecting motorcycle for damage • Check for defects. • Use the “express handling service” to notify 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.

  • Page 13: Filling And Charging The Battery

    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. •...

  • Page 14: Filling And Charging The Battery

    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.

  • Page 15: Checking That Delivery Is Complete

    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. •...

  • Page 16: Final Cleaning

    Final cleaning Handing over the motorcycle • Clean the motorcycle. This is the ideal opportunity to familiarise the cus- tomer with the motorcycle in order to ensure the customer’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:...
  • Page 17 Contents << Back Group / Chapter 00 Maintenance and general instructions ..........00.1 11 Motor ....................... 11.1 12 Engine electrics ..................12.1 13 Fuel preparation and control ..............13.1 16 Fuel tank and lines................. 16.1 17 Radiator ....................17.1 18 Exhaust system ..................18.1 21 Clutch......................
  • Page 18 >> Continuation Group / Chapter 32 Steering....................32.1 33 Rear wheel drive ..................33.1 34 Brakes ..................... 34.1 36 Wheels and tyres..................36.1 46 Frame ...................... 46.1 51 Equipment....................51.1 61 General electrical equipment ............... 61.1 62 Instruments..................... 62.1 63 Lights....................... 63.1 <<...
  • Page 19 00 Maintenance and general instructions Contents Page Table of operating fluids ......................5 Tightening torques ........................6 Key to maintenance intervals ....................15 Reading the fault code memory with the MoDiTeC ..........16 (Inspections I, II, III and IV) .........................16 Changing the engine oil and oil filter element ............16 (Inspections I, II, III and IV) .........................16 Preparatory work...
  • Page 20 Contents Page Adjusting valve clearances .......................22 Installing cylinder head cover ......................23 Installing fan shroud ..........................23 Installing intake air silencer ........................23 Installing the intake air duct .......................23 Replacing spark plugs ......................24 (Inspection III) ............................24 Emptying drain hose from intake air silencer .............24 (Inspections II and III) .........................24 Replacing air cleaner element...
  • Page 21 Contents Page Replacing primary sealing boot, front brake master cylinder ......31 (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ..........31 Replacing primary sealing boot, rear brake master cylinder ......32 (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ..........32 Inspecting front and rear wheel bearings, replacing if necessary ....33 (Inspection III) ............................33...
  • Page 22 00.4...

  • Page 23: Table Of Operating Fluids

    83 19 9 407 855 500 ml spray housings Crack testing agent for aluminium Developer MR 70 81 22 9 407 495 500 ml spray housings Installation aid BMW chilling spray Chilling components before assembly 83 19 9 407 762 300 ml spray 00.5...

  • Page 24: Tightening Torques

    Tightening torques Model F 650 GS Connection 11 Engine Freewheel housing and freewheel 35 (clean thread + Loctite 648) Engine block Double drive gear on crankshaft 180 (clean thread + Loctite 243) Driver 140 (clean thread + Loctite 243) Pressure plate Magnet hub 180 (clean thread + Loctite 243) Signal transmitter...
  • Page 25 Model F 650 GS Connection Cylinder head Collar nuts for cylinder head Collar screws for cylinder head Machine screws (chaincase) Camshaft mount Chain sprockets to camshafts 60 threads oiled Chain guide to camshaft mount 10 (clean thread + Loctite 243) Cylinder head cover Machine screw (hole for locating pin) Cylinder head to frame...
  • Page 26 Model F 650 GS Connection 13 Fuel preparation and control Air intake connection to cylinder head Fuel filter to frame Injector holder to throttle valve Connecting flange, air filter box to battery carrier Intake air silencer to retainer Oil tank to intake air silencer Throttle-valve potentiometer to throttle flap stub Throttle lifter to throttle flap stub 5 (clean thread + Loctite 243)
  • Page 27 Model F 650 GS Connection 18 Exhaust system Oxygen sensor to exhaust Exhaust manifold to cylinder head Silencer to exhaust manifold (Torca clamp) Silencer to rear frame Guard to silencer 21 Clutch Driver 140 (clean thread + Loctite 243) Pressure plate Engine block cover, left 23 Transmission Selector lever to selector shaft...

  • Page 28: 32 Steering

    Model F 650 GS Connection 31 Front forks Fork stabiliser to fork leg Clamp screws for fork bridges, top/bottom Plate for bottom fork bridge to fork bridge Oil drain plug Damper retaining screw Knurled nut/bearing preload Locknut at upper fork bridge 32 Steering Handlebar to fork bridge Handlebar weight to handlebar...

  • Page 29: 34 Brakes

    Model F 650 GS Connection 34 Brakes Bleed screw in front/rear brake calliper Brake calliper to fork slider tube Brake disc and sensor ring to front wheel 9 (clean thread + Loctite 243) Brake disc to rear wheel 9 (clean thread + Loctite 243) Brake fluid reservoir for rear brake to rear frame Brake pedal to frame Brake lines/hoses...

  • Page 30: Frame

    Model F 650 GS Connection 46 Frame Body Fairing sections/covers Fairing support bracket to frame Grip to rear frame End trimmer to rear frame Tail to rear frame Seat lock to rear frame Number-plate carrier to rear section of rear mudguard 3 Mudguards/wheel guards Front mudguard, rear section to front section Front mudguard to fork bridge...

  • Page 31: 51 Equipment

    Model F 650 GS Connection 51 Equipment Ignition/steering lock to fork bridge 61 General electrical equipment ABS sensor cable to sliding tube ABS sensor to brake calliper mount, rear Clutch switch to handlebar fitting Brake light switch to handlebar fitting Brake light switch, footbrake, to frame Wiring harness with electronic equipment box to frame 7 Lid of electronic equipment box to frame...
  • Page 32 00.14...

  • Page 33: Key To Maintenance Intervals

    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 18,000 miles ...

  • Page 34: Reading The Fault Code Memory With The Moditec

    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.

  • Page 35: Replacing Oil Filter Element

    • Remove the cable for the neutral indicating 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. •...

  • Page 36: Checking Coolant, Topping Up If Necessary

    Checking coolant, topping up if nec- essary Note: Mix the coolant in a mix 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.
  • Page 37 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;...

  • Page 38: Changing Oil In Telescopic Forks

    Install the sealing caps. Oil content of each fixed fork tube ....0.60 l (1.06 Imp. pints/0.62 US quarts) Operating fluids: Telescopic fork....BMW telescopic fork oil E310010 Tightening torques: • Pull the fork legs up and tighten the clamp Oil drain plug..........

  • Page 39: Checking And Adjusting Valve Clearances

    Remove spark plug. • • Pull the intake air silencer with intake air pipe and Use pliers, BMW No. 17 5 500, to release hose battery carrier to the rear to remove. clip (5) and disconnect cylinder-head breather • Cover/seal the throttle flap stub.

  • Page 40: Checking Valve Clearance

    00 11 602 11 7 503 E000040 11 7 502 • Secure thruster, BMW No. 11 7 503, on the shaft by tightening the screw (arrow). 11 7 501 • Position thruster, BMW No. 11 7 503, on the edge of the bucket tappet.

  • Page 41: Installing Cylinder Head Cover

    • Before installing new shim, check thickness with Installing the intake air duct a micrometer. • Position the shim in the bucket tappet. • Carefully release the clamp on the shaft, then re- move the shaft and the hold-down assembly. Caution: Check that the shim is correctly seated in the bucket tappet.

  • Page 42: Replacing Spark Plugs

    Replacing spark plugs Replacing air cleaner 00 12 620 00 13 630 element (Inspection III) • Pull spark plug connector off spark plug. (Inspection III) • Remove the spark plug with the a/f 18 socket – Remove right cover. • wrench.

  • Page 43: Replacing Fuel Filter

    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 ........

  • Page 44: Checking Clutch Play, Adjusting If Necessary

    Strike 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 •...

  • Page 45: Checking Brake Pads And Discs For Wear, Replacing If Necessary

    Checking brake pads and discs for Replacing brake pads wear, replacing if necessary (Inspections II and III) Caution: Do not operate the brake when dismantled. Checking brake pads for wear Do not permit the brake pads to wear past the spec- ified minimum thickness.

  • Page 46: Brake Pads, Rear Brake

    Checking the brake fluid level and 00 34 633 Brake pads, rear brake • Press the brake calliper against the brake disc in topping up if necessary order to force the pistons back. (Inspection II) Note: The volume of the brake fluid (MIN/MAX) is sufficient for lining thicknesses from new to the wear limit.

  • Page 47: Brake Fluid Level (Rear Brake)

    Brake fluid level (rear brake) Checking operation of brake system and freedom from leaks, repairing/ replacing if necessary Checking brake fluid level (rear brake) (Inspection III) • Check all brake lines for damage and correct routing. • Wipe down all threaded unions on the brake lines and check them.

  • Page 48: Changing Brake Fluid

    Changing brake fluid 00 34 606 Brake fluid grade .........DOT 4 (Inspection IV) Tightening torques: Caution: Bleed screw ........... 7 Nm Refer to notes on the hazards involved in handling brake fluid. Changing brake fluid (rear brake) Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint.

  • Page 49: Replacing Primary Sealing Boot, Front Brake Master Cylinder

    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. Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint.

  • Page 50: Replacing Primary Sealing Boot, Rear Brake Master Cylinder

    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. Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint.

  • Page 51: Inspecting Front And Rear Wheel Bearings, Replacing If Necessary

    Inspecting front and rear wheel Checking chain tension, 27 71 005 bearings, replacing if necessary adjusting if necessary (Inspections I, II, III and IV) (Inspection III) Checking chain tension 27 71 005 Note: – Place the unloaded motorcycle on its main (cen- Check play when bearings are cold.

  • Page 52: Adjusting Chain Tension

    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 –...

  • Page 53: Cleaning And Greasing The Battery Terminals, If Necessary

    Cleaning and greasing the Checking and adjusting 61 21 520 32 00 454 battery terminals, if necessary steering head bearing play, replacing if necessary (Inspections III and IV) (Inspections II and III) Note: Disconnecting the battery clears all entries (such as Checking steering head bearing play errors, adaptations) from the BMS control unit mem- •...

  • Page 54: Checking And Adjusting Steering Head Bearing Play

    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.

  • Page 55: Greasing The Side And Main Stands And The Brake Pedal Lever

    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 •...

  • Page 56: Brake Pedal

    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 t frame – Main and side stands – Exhaust mountings –...

  • Page 57: Final Inspection With Road Safety And Functional Check

    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: It must comply with legal regulations concerning minimum tyre tread depth.
  • Page 58 00.40...
  • Page 59 11 Motor Contents Page Technical Data ..........................5 Sectional 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 ...........................16 Removing camshafts ........................18 Removing cylinder head ......................18...
  • Page 60 Contents Page Disassembling and assembling cylinder head ..............29 Removing valves ..........................29 Bore for bucket tappet ........................29 Checking valve guide for wear ......................30 Removing valve guide ........................30 Installing valve guide .........................31 Checking valve seat for wear ......................31 Installing valve stem seal ........................32 Checking valve for wear ........................32 Installing valves ..........................33 Removing cylinder...
  • Page 61 Contents Page Removing and installing main bearings ................43 Removal ............................43 Installation ............................44 Assembling engine ........................45 Installing crankshaft and balancing shaft ................45 Shimming crankshaft .........................45 Installing double drive gear .......................46 Installing oil pump gears ......................47 Installing clutch ..........................48 Installing clutch cage .........................48 Installing driver ..........................48 Installing pressure plate ........................49 Installing countershaft for starter motor...
  • Page 62 11.4...

  • Page 63: Technical Data

    Technical Data F 650 GS 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.
  • Page 64 Technical Data F 650 GS Crank gear Crankshaft - main bearing play On installation mm (in) 0.030...0.070 (0.0012...0.0028) Wear limit mm (in) 0.10 (0.004) Wear limit, main bearing bore diameter mm (in) 46.08 (1.814) Wear limit Main bearing journal diameter mm (in) 47.97 (1.888) Bearing play...
  • Page 65 Technical Data F 650 GS Valve seat angle Inlet ° Exhaust ° Included valve angle Inlet ° Exhaust ° 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) Wear limit mm (in) 2.2 (0.09) Valve guide...
  • Page 66 Technical Data F 650 GS Piston rings 1st groove Rectangular-section ring Ring thickness mm (in) 1.2 (0.05) Ring thickness wear limit mm (in) 1.15 (0.045) End gap mm (in) 0.2...0.4 (0.008...0.016) End-gap wear limit mm (in) 1.0 (0.04) Groove-height wear limit mm (in) 1.30 (0.051) Ring float...
  • Page 67 Technical Data F 650 GS Housing depth (primary) mm (in) 14 (0.6) Housing depth (secondary) mm (in) 19 (0.7) Wear limit, installed clearance (radial) mm (in) 0.25 (0.010) Wear limit, installed clearance (axial) mm (in) 0.25 (0.010) 11.9...
  • Page 68 11.10...

  • Page 69: Sectional View Of Engine

    Sectional view of engine E110550 11.11...

  • Page 70: Engine Oil Circuit

    F119109 Engine oil circuit 1 Delivery pump 2 Oil tank 3 Check valve 4 Oil filter 5 Control valve 6 Low-pressure line (gearbox) 7 Low-pressure line (clutch) 8 High-pressure line (crankshaft) 9 High-pressure line (big end bearing) 10 High-pressure line (camshafts) 11 Chain tensioner 12 Spray nozzle (for piston) 13 Oil sump...

  • Page 71: Valve Gear

    Valve gear E110440 11.13...

  • Page 72: Valves, Components

    Valves, components E110450 11.14...

  • Page 73: Oil Pumps, Components

    Oil pumps, components E110460 11.15...

  • Page 74: Preparatory Work

    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.
  • Page 75 Remove fastener for oil lines (2) from the cylinder Turn crankshaft to top dead centre position with head. an Allen key. • User pliers, BMW No. 17 5 500, to open the clamp securing the breather hose at the valve cover. Note: •...

  • Page 76: Removing Camshafts

    Raise the rear frame.............See Group 46 E110480 • Remove screws securing cylinder head to frame (arrow). • Use pin wrench, BMW No. 11 6 661, to slacken the locknut. E110470 • Disconnect the oil feed line (arrow) from the en- Note: gine.
  • Page 77 • 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.

  • Page 78: Removing Cylinder, Engine Installed

    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).

  • Page 79: Removing Engine

    • Disconnect plug of side-stand switch (6). • Unscrew connector for idle indicator (7). • Disconnect the plug of ignition trigger (8). • Disconnect plug of oil pressure sensor in oil filter housing. • Disconnect positive lead from starter motor. •...

  • Page 80: Removing Engine

    (arrow). • Continue lowering the engine; the engine tilts to- • Secure adapter, BMW No. 11 0 591, to the plate ward the rear. • for the engine lifter. Continue lowering the engine until the fastening •...

  • Page 81: Lowering Engine

    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.

  • Page 82: Lowering The Engine

    Remove the brake pedal. • Remove the gear shift pedal. Lowering the engine 11 00 050 • Secure adapter, BMW No. 11 0 591, to the plate for the engine lifter. • Place engine lifter, BMW No. 00 1 540, under engine. E110030 •...
  • Page 83 Tightening torques: Water pump drain screw ......10 Nm Intake air silencer to frame ......9 Nm Engine guard to frame........9 Nm Engine oil drain plug........40 Nm Rear quick-release axle......100 Nm Drive chain tensioning screws ...... 10 Nm Exhaust manifold to cylinder head....

  • Page 84: Disassembling Engine

    Turn crankshaft to top dead centre position with an Allen key. • Remove screw (5) and lock the crankshaft with locating screw, BMW No. 11 6 570. Caution: If there is any mechanical damage, the oil tank and the oil lines must be cleaned.

  • Page 85: Checking Camshaft For Wear

    “B”. 00 2 590 F110040 • Measure bearing play with Plastigage type PG-1, BMW No. 00 2 590. • Tighten camshaft carrier to specified torque. E110090 Tightening torque: Camshaft carrier........... 10 Nm Distance “B”...

  • Page 86: Checking Timing Chain For Wear

    Checking timing chain for wear • Remove front chain rail (1). • Release the coolant line hose clips with pliers, BMW No. 17 5 500. • Allow the timing chain to slide into its cavity. • Remove the starter motor.

  • Page 87: Disassembling And Assembling Cylinder Head

    BMW No. 11 0 523. • Secure adapter plate, BMW No. 11 0 521, sup- port, 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. E110120 •...

  • Page 88: Checking Valve Guide For Wear

    BMW No. 00 1 900, to check the temperature. imum play at right angles to the camshaft axis. • Use drift, BMW No. 11 0 571, to drive out the Play: valve guide toward the combustion chamber. Max. play........0.4 mm (0.016 in) Intl.

  • Page 89: Installing Valve Guide

    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.

  • Page 90: Installing Valve Stem Seal

    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). 11.32...

  • Page 91: Installing Valves

    Secure adapter plate, BMW No. 11 0 521, sup- E110140 port, 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- •...

  • Page 92: Removing Piston

    11 25 050 cylinder • 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.

  • Page 93: Determining Piston Ring Gaps

    ......max. 0.050 mm (0.0019 in) • Remove the central plug and install handle, Assembling pistons 11 25 671 BMW No. 12 5 500. Note: The “Top” must face towards the piston crown. Install the piston rings with their gaps offset by 120 °.
  • Page 94 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 •...

  • Page 95: Disassembling And Assembling Freewheel

    E110240 Disassembling and 12 11 077 assembling 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. E110300 •...

  • Page 96: Removing Clutch

    Turn engine round in assembly fixture. • Remove left retaining for engine housing cover • 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. •...

  • Page 97: Removing Oil Pump

    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 idler gear. 10 Markings • Remove the retaining rings of the oil-pump 11 Needle roller gears (2) and disengage the oil-pump gears.

  • Page 98: Removing Double Drive Gear

    Removing double drive gear E110320 • Swivel assembly fixture so that clutch side is up- E110290 permost. • Remove knurled nuts (4). Note: Retaining screw (arrow) must be installed. Caution: Do not tilt engine housing: this can cause damage • Remove hex nut (1).

  • Page 99: Checking Crankshaft For Wear

    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 • Installation is the reverse of the removal proce- gear.

  • Page 100: Removing And Installing Gearbox Compensating Shaft Bearings

    Using bearing puller plate, BMW No. 11 6 561, 11 6 561 spindle, BMW No. 11 6 562, and spreader 11 6 564 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).

  • Page 101: Removing And Installing Grooved Ball Bearings Of Gearbox Compensating Shaft

    Using bearing puller plate, BMW No. 11 6 561, spindle, BMW No. 11 6 562, and spreader 00 5 500 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).

  • Page 102: Installation

    The bearing bushing must not project beyond the oil pockets. The end gap of the bearing bushing must always face the balancing shaft. • Coat bearing bushings with Optimoly TA and drive in with drift, BMW No. 11 0 551, working from the inside. 11.44...

  • Page 103: Assembling Engine

    • 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 joint line = dimension “B”. E110330 •...

  • Page 104: Installing Double Drive Gear

    • Lock the crankshaft in the TDC position with lo- • Fit left engine housing and screw down. cating screw, BMW No. 11 6 570. Note: Note the two fasteners in the oil filter housing. • Cut off protruding gasket.

  • Page 105: Installing Oil Pump Gears

    Installing oil pump gears 11 41 000 E110350 • Install idler 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).

  • Page 106: Installing Clutch

    Insert driver (7) and coat internal splines with Optimoly MP 3. • • Fit locking washer (8); it must engage securely. Insert locating ring, BMW No. 21 4 600. • • Clean threads of compensating shaft and hexa- Tighten hex nut and bend wings of locking gon nut (9), coat threads with Loctite 243 and in- washer (8).

  • Page 107: Installing Pressure Plate

    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 .........
  • Page 108 3 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 bolt together.

  • Page 109: Installing Piston

    Press the piston pin in with drift, 11 6 581 BMW No. 11 6 581. E110390 • Position sleeve, BMW No. 11 6 583, with instal- lation arbor, BMW No. 11 6 581, against piston. Caution: Support side of piston. •...

  • Page 110: Installing Cylinder

    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). •...
  • Page 111 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 ....
  • Page 112 E110420 Installing camshaft and adjust- 11 31 529 ing valves • Oil outside of bucket tappets and reinstall on original valves. • Measure thickness of shims with micrometer and note down dimension. • Place lower part of camshaft carrier (1) on cylin- der head.
  • Page 113 • Connect the oil lines to the cylinder head. • Take out locating pin, BMW No. 11 6 570, and insert screw plug with sealing ring. • Install the spark plug.

  • Page 114: Installing Engine

    Installing engine 11 00 050 Bleeding engine oil circuit • Remove oil filter. • Installation is the reverse of the removal proce- dure: pay particular attention to the following. • Working from the right, manoeuvre the engine on the lifter into position below the motorcycle. •...
  • Page 115 12 Engine electrics Contents Page Technical Data ..........................3 Ignition magneto ...........................5 Ignition magneto, components .....................6 Removing ignition magnet .......................7 Removing right engine housing cover ...................7 Removing/installing ignition trigger ..................8 Removing/installing stator ......................8 Installing magnetic ignition trigger ..................8 Installing magnet wheel ........................8 Removing/installing or dismantling starter motor .............9...
  • Page 116 12.2...

  • Page 117: Technical Data

    Technical Data F 650 GS Ignition system Type Fully transistorised ignition integrated in BMS. -300 Inductive sensor Ignition Ignition system BMS (mapped characteristic control) Speed governing rpm 7500 Ignition coil Primary coil 500 ±50 Starter motor Type Permanent magnet motor with wedge-block free- wheel, driving crankshaft via countershaft.
  • Page 118 12.4...

  • Page 119: Ignition Magneto

    Ignition magneto E120050 12.5...

  • Page 120: Ignition Magneto, Components

    Ignition magneto, components E120040 1 Ignition trigger 2 Freewheel housing 3 Lock ring 4 Freewheel gear 5 Starter countershaft 6 Freewheel 7 Magnet rotor 8 Stator winding 12.6...

  • Page 121: Removing Ignition Magnet

    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. E110180 • Remove central plug and install handle, BMW No.

  • Page 122: Removing/Installing Ignition Trigger

    Removing/installing ignition • 12 11 060 Installation is the reverse of the removal proce- dure: pay particular attention to the following. trigger • Coat the rubber grommet of the stator with 3 Bond 1209 before inserting it into the cover. •...

  • Page 123: Removing/Installing Or Dismantling Starter Motor

    Removing/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 bolt together. Removing/installing starter 12 41 020 •...
  • Page 124 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 (0.02 in) deeper...

  • Page 125: Replacing Spark Plug

    Replacing spark plug • 12 12 011 Disengage the clamp securing the breather hose and disconnect the hose from the intake air si- lencer. • See Group 00 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 flap stub.
  • Page 126 12.12...

  • Page 127: Fuel Preparation And Control

    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/installing air temperature sensor ...............5 Replacing air filter element ....................6 See Group 00 ............................6 Removing and installing intake air silencer ..............6 Removing and installing intake air pipe ................6...
  • Page 128 13.2...

  • Page 129: Technical Data

    Technical Data F 650 GS Fuel grade Super (premium), unleaded. 95 octane (RON) Mixture preparation Manifold injection Fuel pressure bar (psi) 3.5±0.2 (49.8±2.8) Throttle stub pipe intl. dia. mm (in) 46 (1.8) Air filter Paper filter Intake stub pipe mm (in) 43 (1.7) 13.3...
  • Page 130 13.4...

  • Page 131: Removing And Installing Bms Control Unit

    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.

  • Page 132: Replacing Air Filter Element

    Replacing air filter element 00 13 630 See Group 00 Removing and installing 13 72 130 intake air silencer – Remove left, right and centre covers. – Remove the intake air pipe. • Disengage the rubber strap holding the battery. E130090 •...

  • Page 133: Removing And Installing Throttle Valve Actuator

    Disconnect the plug of fuel injector (1). – Remove intake air silencer. • 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 flap stub.

  • Page 134: Replacing Throttle-Valve Potentiometer

    Disconnect the plugs for fuel injector (2), throttle- dure. valve potentiometer (4) and throttle-valve actuator (3). • Use a hose clamp, BMW No. 13 3 010, to close Note: off fuel line (5). • It is not necessary to adjust the throttle-valve poten- Slacken the hose clip securing the fuel line and tiometer after installation (self-teaching system).

  • Page 135: Removing And Installing Intake Pipe

    Connecting flange .......... 5 Nm • Fasteners, cover/ Connect a test pressure gauge, trim panel for turn indicator ......3 Nm BMW No. 16 1 500, between fuel feed line and tank outlet. • Start engine and allow to idle. Fuel pressure: Specification ....

  • Page 136: Removing And Installing Fuel Hoses

    Remove left, right and centre covers. • 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.

  • Page 137: Fuel Tank And Lines

    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 ........................8 See Group 00 ............................8 Removing and installing fuel pump...
  • Page 138 16.2...

  • Page 139: Technical Data

    Technical Data F 650 GS Fuel tank Type Plastic tank with cover Tank capacity l (Imp.gal/ 17.3 (3.8/4.6) US gal) (including 4 l (0.88/1.06) reserve) Type of fuel Super (premium), unleaded. 95 octane (RON) Fuel pump Type Peripheral-gear pump Operating voltage V 7 - 15 Fuel pressure bar (psi) 3.5 (49.8)
  • Page 140 16.4...

  • Page 141: Removing And Installing Fuel Tank

    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. •...
  • Page 142 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.

  • Page 143: Installing Fuel Tank

    (2) are correctly routed. Warning: Do not use screw-type hose clamps on the fuel hos- es, because they could damage the hoses and re- sult in a fire hazard. • Close hose clamps with pliers, BMW No. 13 1 500. 16.7...

  • Page 144: Removing And Installing Roll-Over Valve

    Tightening torques: Close off fuel supply line (5) and the fuel return Roll-over valve to fuel tank ......3 Nm line (4) with hose clips, BMW No. 13 3 010. • Open the hose clips (arrows) and disconnect the Replacing fuel filter 16 12 008 fuel lines from the fuel-pump unit.
  • Page 145 Installation is the reverse of the removal proce- E160060 dure. • Release ring (1) using wrench, BMW No. 16 1 021 Note: • Remove fuel-pump unit (3) with gasket (2). The reserve fuel capacity of the fuel tank can be ad- •...

  • Page 146: Removing And Installing Fuel-Evaporation Control Valve

    Removing and installing Removing and installing 16 13 001 fuel-evaporation 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. • Remove the BMS control unit from the holder.
  • Page 147 17 Radiator Contents Page Technical Data ..........................3 Coolant circuit ..........................5 Thermostat, components ......................6 Removing and installing coolant pump ................7 Removing coolant pump ......................7 Installing coolant pump ........................8 Adding coolant ..........................8 Removing and installing coolant-temperature sensor ............9 Checking cooling system for leaks ..................10 Removing and installing coolant hoses .................10...
  • Page 148 17.2...

  • Page 149: Technical Data

    Technical Data F 650 GS Cooling system Cooling system capacity Total capacity l (Imp.pints/ US quarts) 1.3 (2.29/1.37) Coolant circuit l (Imp.pints/ US quarts) 1.20 (2.113/1.268) Coolant expansion tank l (Imp.pints/ US quarts) 0.10 (0.176/0.106) Coolant Use only nitrite-free long-term antifreeze and corrosion inhibitor.
  • Page 150 17.4...

  • Page 151: Coolant Circuit

    Coolant circuit E170010 17.5...

  • Page 152: Thermostat, Components

    Thermostat, components E170020 1 Coolant-temperature sensor 2 Thermostat housing 3 Thermostat 4 Cover 5 O-ring 6 Spring clip 17.6...

  • Page 153: Removing Coolant Pump

    Drain off all the coolant. – Place motorcycle on its centre stand. • • Remove the gear shift pedal. Using hose clip pliers, BMW No. 17 5 500, re- – Remove the starter motor. move hose clips (13). • ............See Group 12 Remove water pump cover (2) with seal (3).

  • Page 154: Installing Coolant Pump

    • Drive inner sealing ring onto its seat with drift, expel the air. • BMW No. 11 6 540. Tighten bleed screw (1). • Drive in outer sealing ring flush with the friction face, using the appropriate adapter.

  • Page 155: Removing And Installing Coolant-Temperature Sensor

    Removing and installing Antifreeze Use only nitrite-free long-term antifreeze and corro- coolant-temperature sensor sion inhibitor. – Drain coolant. Concentration ............See Group 00 • Antifreeze ............50% Place motorcycle on its centre stand. Water ...............50% • Run the engine for a short time, then switch it off. •...

  • Page 156: Removing And Installing Coolant Hoses

    • Connect pump, BMW No. 17 0 500, with adapt- Disconnect the coolant hose from the radiator er and neck, BMW No. 17 5 520, to filler neck. and the expansion tank. • Pressure-test the system; the pressure must re- main unchanged for at least 5 minutes.

  • Page 157: Removing And Installing Thermostat

    • 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.
  • Page 158 17.12...

  • Page 159: Exhaust System

    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...
  • Page 160 18.2...
  • Page 161 Technical Data F 650 GS Exhaust system Emission control 3-way catalytic converter Silencer (muffler) Reflection/absorption-type silencer 18.3...
  • Page 162 18.4...
  • Page 163 E180030 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 18 11 301 right-hand silencer • Remove number plate. • Remove the fastener (arrow) securing the silenc- er to the rear frame.
  • Page 164 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.
  • Page 165 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. E180020 E630010 • Tighten clamp (1) for the silencer, making sure that the clamp is correctly positioned (arrow). •...
  • Page 166 18.8...
  • Page 167 21 Clutch Contents Page Technical Data ..........................3 Clutch, components ........................5 Removing and installing clutch ....................6 Removing clutch ..........................6 Removing pressure plate ........................6 Disassembling and reassembling pressure plate .................6 Removing clutch plates, driver and clutch cage ..................7 Installing clutch cage ...........................8 Installing driver ............................8 Installing pressure plate ........................8 Removing and installing releaser shaft ....................9...
  • Page 168 21.2...
  • Page 169 Technical Data F 650 GS Clutch Type Pull-action multi-plate clutch in oilbath Clutch plate diameter mm (in) 144 (5.7) Manual effort required N 85 (at 40 mm/1.6 in from pivot point) Operation mechanical Wear limits: Distortion of lined plates mm (in) 0.25 (0.010) Distortion of steel plates mm (in)
  • Page 170 21.4...
  • Page 171 Clutch, components E210010 21.5...

  • Page 172: Removing Pressure Plate

    Disconnect the oil line from the cylinder head. Disassembling and reassembling pressure plate E170060 E210030 • Using hose clip pliers, BMW No. 17 5 500, re- move hose clips (1). • • Remove left engine housing cover. Remove circlip (7) with circlip pliers.

  • Page 173: Removing Clutch Plates, Driver And Clutch Cage

    Remove driver (7). • Remove clutch cage (5) incl. serrated washer (6). • Remove needle cages (3, 4). 21 4 600 E110260 • Using locating ring, BMW No. 21 4 600, secure clutch cage (5) and driver (7) in position. 21.7...

  • Page 174: Installing Clutch Cage

    • install nut. Height of complete compressed plate cluster. • Insert locating ring, BMW No. 21 4 600. • Tighten hex nut and tilt up retaining plate (8). Height of lined plate cluster ........min. 27.5 mm (1.08 in)

  • Page 175: Removing And Installing Releaser Shaft

    Pressure plate to driver ........ 10 Nm • Remove keeper (6) for release shaft (7). • Withdraw release 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...

  • Page 176: Installing Clutch

    Insert release shaft. • Cover the splines on the release 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 • Lower the engine.
  • Page 177 23 Gearbox Contents Page Technical Data ..........................3 Gearbox shafts, components ....................5 Gear shift pedal, components ....................6 Removing/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...
  • Page 178 23.2...
  • Page 179 Technical Data F 650 Transmission Type Integral 5-speed gearbox with claw shift Gear steps Primary: 37/72=1:1.946 Gearbox ratios: 1st gear 12/33 = 1:2.750 2nd gear 16/28 = 1:1.750 3rd gear 16/21 = 1:1.313 4th gear 22/23 = 1:1.045 5th gear 24/21 = 1:0.875 Engine ratio: 1st gear...
  • Page 180 23.4...

  • Page 181: Gearbox Shafts, Components

    Gearbox shafts, components E230050 23.5...

  • Page 182: Gear Shift Pedal, Components

    Gear shift pedal, components F239030 23.6...

  • Page 183: Removing/Installing Gearbox

    E230010 Removing/installing gearbox • 23 00 100 Swing the selector forks (5) out and remove them. • Inspect contact surfaces of selector forks and guide pins for signs of wear. Caution: Removing selector drum If there is any mechanical damage, the oil tank must 23 00 651 be cleaned.

  • Page 184: Removing, Disassembling And Reassembling Gearbox Shafts

    • 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.

  • Page 185: Checking Mainshaft For Wear

    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...

  • Page 186: Disassembling And Reassembling Compensating Shaft

    Renew gears only together with the corresponding meshing gears. Edges of ring grooves must not be blunt. 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.

  • Page 187: Checking Countershaft For Wear

    • 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.

  • Page 188: Replacing Gearbox Compensating Shaft Bearings

    • 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).

  • Page 189: Installing Selector Shaft

    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.
  • Page 190 • 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.
  • Page 191 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 arm installed...
  • Page 192 27.2...

  • Page 193: Technical Data

    Technical Data F 650 GS 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) 1000 (39.4) Roller diameter mm (in) 10.16 (0.400) 27.3...
  • Page 194 27.4...

  • Page 195: Removing And Installing Chain

    E270020 Removing and installing 27 71 000 Tightening torques: chain, chainwheel and chain Swinging arm pivot shaft ......100 Nm sprocket Strut to swinging arm ........41 Nm Rear quick-release axle......100 Nm Chain tensioning screws ......10 Nm Wheel cover bracket to swinging arm..... 9 Nm Caution: Always replace the chain, chainwheel and chain 27 72 009 Removing and installing chain guide...

  • Page 196: Removing Chainwheel

    • Remove screws (3) and remove the chainwheel. Remove the locking washer (4). • Use puller, BMW No. 00 8 400, to pull the chain- wheel off the mainshaft. • Tightening torques: Installation is the reverse of the removal proce- Chainwheel to carrier ........

  • Page 197: Removing And Installing Chain Guide Rail With Swinging Arm Installed

    Removing and installing chain 27 72 009 guide rail with swinging arm 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 arm.
  • Page 198 27.8...
  • Page 199 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 handlebar ..................9 Removing and installing clutch cable ................10...
  • Page 200 32.2...
  • Page 201 Technical Data F 650 GS Steering Type One-part tubular handlebar with cross-tie Steering lock angle ° 40 Steering tube diameter mm (in) 22 (0.87) Width across handlebars (handlebar only, without grips) mm (in) 770 (30.3) 32.3...
  • Page 202 32.4...
  • Page 203 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. E320060 –...

  • Page 204: Removing And Installing Clutch

    Removing and installing clutch 61 31 295 switch – Place motorcycle on its centre stand. – Remove seat. – Remove left, right and centre covers. • Release clutch switch on handlebar fitting. • Cut through the cable ties securing the cables at the handlebar and the multi-function switch.
  • Page 205 E320050 Removing and installing right handlebar fitting – Place motorcycle on its centre stand. – Remove seat. – Remove left, right and centre covers. • Cut the cable tie at the handlebar. Caution: Refer to notes on the hazards involved in handling brake fluid.
  • Page 206 • 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. •...
  • Page 207 E320110 Removing and installing 32 71 008 Caution: handlebar Note the position of the clamping blocks. Wide hole spacing (arrow) to the front. – Remove left handlebar fitting. – Remove right handlebar fitting. • Remove impact pad (1). • Loosen clamping screws (2). •...
  • Page 208 E320140 Removing and installing 32 72 330 clutch cable E320160 • Make sure that slots in adjusting screw, locknut and lever fitting (arrow) are in line. E320150 • Pull back cable shroud (2). • Pull the cable forward through the slot and disen- •...
  • Page 209 Caution: 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”...
  • Page 210 E320170 Removing and installing • 32 72 305 Remove cover (4). • Remove fastener for throttle cable (1) from in- throttle cable strument cluster housing. • Disengage throttle-cable adapter (3) and disen- – Remove seat. gage nipple (4). • – Remove left cover.
  • Page 211 Checking and adjusting Checking and adjusting 32 00 454 32 00 454 steering head bearing play, steering head bearing play, renewing if necessary renewing if necessary (Inspections II and III) (Inspections II and III) Checking steering head bear- Adjusting steering head bear- 32 00 454 32 00 454 ing play...
  • Page 212 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.
  • Page 213 Removing and installing left and right handlebar levers Removing and installing left 32 72 070 handlebar lever E000200 • After installing the cable, adjust clutch clearance by setting distance “B” by turning adjusting screw (4) on the clutch handlebar fitting. •...
  • Page 214 32.16...
  • Page 215 33 Rear wheel drive Contents Page Technical Data ..........................3 Removing and installing suspension strut ..............5 Removing and installing rear swinging fork ..............6 Removing and installing needle roller races in rear swinging fork ......7 Removing needle roller races ......................7 Installing needle roller races ........................8 Removing and installing struts .....................8 Removing and installing needle roller bearing in tension strut...
  • Page 216 33.2...

  • Page 217: Technical Data

    Technical Data F 650 GS Rear suspension Suspension strut Central suspension strut pivoted to lever system. Spring base and rebound damping continuously adjustable. Suspension travel mm (in) 165 (6.50) at wheel mm (in) 47.5 (1.87) at suspension strut Swinging arm Type Twin box swinging arm.
  • Page 218 33.4...

  • Page 219: Removing And Installing Suspension Strut

    Removing and installing sus- 33 53 000 pension strut – Remove exhaust manifold.............See Group 18 • Secure front wheel in position. E330070 Caution: Do not raise the rear frame all the way, as it is seated against the lock of the seat (arrow). E330100 •...

  • Page 220: Removing And Installing Rear Swinging Fork

    Removing and installing 33 17 350 rear swinging fork – Removing ABS sensor – Remove rear wheel.............See Group 36 E330080 • Remove the fastener securing the spring strut to frame (1). • Pull the spring strut with adjusting knob to the rear and remove.

  • Page 221: Removing And Installing Needle Roller Races In Rear Swinging Fork

    ABS sensor to holder ........9 Nm F330100 Caution: Protect mating faces (arrow) of the swinging arm from scratches by covering with masking tape or similar. • Drive needle roller races out of rear swinging arm with drift, BMW No. 33 6 661. 33.7...

  • Page 222: Installing Needle Roller Races

    Strut 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 arm.

  • Page 223: Removing And Installing Needle Roller Bearing In Tension Strut

    • 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).

  • Page 224: Removing And Installing Angled Lever

    To facilitate removal, 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.

  • Page 225: Installing Needle Roller Bearings And Needle Roller Races

    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 •...
  • Page 226 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 •...
  • Page 227 34 Brakes Contents Page Technical Data ..........................3 Removing and installing front brake calliper ..............5 Removing and installing front brake pads ................5 See Group 00 ............................5 Removing and installing front brake pistons ...............6 Removing and installing front brake disc ...............7 Checking brake disc for wear ....................7 See Group 00 ............................7...
  • Page 228 Contents Page Checking play at piston thrust rod, adjusting if necessary ........12 Checking play at piston thrust rod .....................12 Adjusting play at piston thrust rod .....................13 Removing and installing front ABS sensor ..............13 Removing front ABS sensor ring ..................14 Removing and installing rear ABS sensor ..............14 Removing and installing rear ABS sensor ring ............15...
  • Page 229 Technical Data F 650 GS Brakes Brake fluid DOT 4 Brake actuation Hydraulic Front wheel Front brake 2-piston floating calliper 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) Permissible lateral runout mm (in) 0.25 (0.010)
  • Page 230 34.4...
  • Page 231 Removing and installing Removing and installing front 34 11 021 34 11 008 front brake calliper brake pads See Group 00 Caution: Refer to notes on the hazards involved in handling brake fluid. • Press the brake calliper against the brake disc in order to force the pistons back.
  • Page 232 Caution: when installing. 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 pistons (5), using a Install the brake pads.
  • Page 233 • Remove brake disc. BMW No. 36 3 600. • Using dial gauge, BMW No. 00 2 510, measure lateral runout. Caution: The inscription on the brake disc must face towards Lateral runout “A” ....max. 0.25 mm (0.010 in) the outside.
  • Page 234 Removing and installing • 34 21 222 Installation is the reverse of the removal proce- dure. rear brake calliper Caution: Note: Refer to notes on the hazards involved in handling Remove sealing rings for brake line. brake fluid. • Remove wheel cover together with chain cover. •...
  • Page 235 Caution: stalling. Do not insert your fingers between the pistons; risk • of injury. Using piston compressor, BMW No. 34 1 500, if necessary press the piston fully back. • • Carefully press out brake piston (3), using a Install the brake pads.
  • Page 236 00 2 510 E340100 E340110 • Note: Attach dial gauge holder, BMW No. 00 2 500, to Retaining screws (1) are secured with Loctite 243 the rear swinging arm. • and should be heated if necessary before removal. Using dial gauge, BMW No. 00 2 510, measure lateral runout.
  • Page 237 Removing and installing front brake Removing and installing 32 72 119 master cylinder handbrake lever – Place the motorcycle on its main (centre) stand. See Group 32 Replacing primary sealing boot, Caution: rear brake master cylinder Refer to notes on the hazards involved in handling brake fluid.
  • Page 238 Caution: Caution: Top up brake fluid and bleed brake system. Check operation of brake-light switch (6). Operate brake several times until brake pads rest on disc. Play at piston thrust rod ......0.5...1.5 mm (0.02...0.06 in) Play at piston thrust rod ......

  • Page 239: Removing And Installing Front Abs Sensor

    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. 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).

  • Page 240: Removing And Installing Rear Abs Sensor

    Removing front ABS sensor Removing and installing 34 51 610 34 52 111 ring rear ABS sensor – Place motorcycle on its centre stand. Caution: – Remove seat. • Do not operate the brake with the wheel removed. Remove wheel cover together with chain cover. –...
  • Page 241 Check the speed/ABS sensor gap and adjust if necessary.............See Group 34 Caution: All work on the ABS control unit must be carried out by an authorised BMW workshop. Tightening torque: ABS sensor to holder ........9 Nm – Remove the rear frame.
  • Page 242 Caution: Top up brake fluid and bleed brake system. Operate brake several times until brake pads rest on disc. Tightening torque: Brake line to ABS control unit ...... 18 Nm Brake line at interface to brake hose ........... 18 Nm Expansion tank to radiator......
  • Page 243 Removing and installing front 34 32 401 brake hoses Caution: – Place the motorcycle on its main (centre) stand. Top up brake fluid and bleed brake system. – Remove seat. Operate brake several times until brake pads are – Remove left cover. correctly seated.
  • Page 244 Caution: Top up brake fluid and bleed brake system. Operate brake several times until brake pads are correctly seated. Tightening torque: Brake line to ABS control unit ...... 18 Nm Brake line at interface to brake hose .... 18 Nm Brake line to brake master cylinder ....
  • Page 245 Checking/adjusting front Checking/adjusting rear 34 52 544 34 52 544 ABS sensor gap speed/ABS sensor gap Caution: Caution: Always check the ABS sensor gap after replace- Always check the speed/ABS sensor gap after re- ment of ABS sensor, sensor ring, wheel bearing, placement of ABS sensor, sensor ring, brake-calli- front wheel, front forks, spacer, quick-release axle per bracket, spacer sleeve, rear wheel or wheel...
  • Page 246 34.20...
  • Page 247 36 Wheels and tyres Contents Page Technical Data ..........................3 Removing/installing front wheel ..................5 Removing front wheel ........................5 Installing the front wheel ......................5 Removing/installing front wheel bearing ................6 Removing left-hand wheel bearing ......................6 Removing right-hand wheel bearing ....................6 Installing wheel bearings ........................7 Removing/installing rear wheel ....................7 Removing/installing rear wheel bearings...
  • Page 248 36.2...
  • Page 249 Technical Data F 650 GS Wheels and tyres Rim size Front 2.50"x19" Rear 3.00"x17" Vertical runout mm (in) 2.0 (0.08) Lateral runout mm (in) 2.0 (0.08) Maximum permissible imbalance g (oz.) 5 (0.18) Tyre size Front 100/90-19 Rear 130/80-17 Tyre pressures (tyres cold) Solo Front bar (psi)
  • Page 250 36.4...
  • Page 251 Removing/installing front Installing the front wheel 36 30 300 36 30 300 wheel Removing front wheel 36 30 300 Caution: • 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.

  • Page 252: Wheel Bearing

    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 253 • 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.
  • Page 254 100 °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...
  • Page 255 • 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 256: Removing/Installing Wheel Spokes

    – Remove/install front wheel............See above • 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 257: Outer Right Spokes

    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. • Turn spoke (3) outwards............

  • Page 258: Removing/Installing Rear Wheel Spokes

    • 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............See below Outer left and right spokes •...

  • Page 259: Checking And Centering Front And Rear Wheel Rims

    F360150 Checking and centering 36 32 528 Note: front and rear wheel rims Apply the dial gauge, BMW No. 00 2 510, only to the machined inner surface of the wheel rim. – Remove the wheels. • Measure lateral and vertical runout with dial...

  • Page 260: Centering Lateral Runout

    Centering lateral runout Centering vertical runout F360170 F360160 Caution: Caution: Never attempt to eliminate all the lateral runout by Spokes which protrude from the spoke nipples must adjusting only one or two spokes. be shortened. • Correct vertical runout “H” by tightening the Note: spokes at left and right (arrow).
  • Page 261 [Rear wheel] Remove chainwheel carrier com- plete with chainwheel from the rear-wheel hub. • Level the balancing unit, BMW No. 36 3 600, by means of bubble gauge (2) in the baseplate. • Pass the balancing shaft, BMW No. 36 3 617, through the wheel bearings.
  • Page 262 36.16...
  • Page 263 46 Frame Contents Page Removing and installing covers ....................5 Removing and installing left/right cover ....................5 Removing and installing centre cover ....................5 Removing and installing cockpit fairing ................6 Removing and installing fairing bracket ....................6 Raising rear frame ...........................7 Removing and installing front mudguard ................8 Removing and installing rear frame ..................8...
  • Page 264 46.2...
  • Page 265 Technical data F 650 Frame Frame Bridge frame with frame trussing Type plate location Top section of main frame, at right Location of VIN On right of steering head Max. height (windscreen) mm (in) 1265 (49.803) Maximum width (across mirrors) mm (in) 890 (35.04) Maximum length mm (in) 2101 (82.72)
  • Page 266 46.4...

  • Page 267: Removing And Installing Covers

    E460040 Removing and installing covers Removing and installing centre cover – Remove left and right covers. • – Remove the seat. Remove securing screws (2) from centre cover. • Remove centre cover (5). • Removing and installing left/right cover Installation is the reverse of the removal proce- •...

  • Page 268: Removing And Installing Cockpit Fairing

    E460050 Removing and installing cockpit fairing • Installation is the reverse of the removal proce- dure: pay particular attention to the following. – Remove left and right covers............See above Warning: After installing the windscreen, check and if neces- Note: sary adjust the headlight setting.

  • Page 269: Raising Rear Frame

    Raising rear frame – Remove exhaust manifold.............See Group 18 • Secure front wheel in position. E460060 • Disconnect plug of instrument panel (1). • Cut through cable clip. • Push cable holder through toward inside. • Turn the handlebars to the left. E330100 •...
  • Page 270 Removing and installing front 46 61 000 mudguard – Place the motorcycle on its centre stand. E330070 Caution: E460041 Do not raise the rear frame all the way, as it would contact the lock of the seat (arrow). • Remove fasteners securing front mudguard (1). •...
  • Page 271 • • Close off fuel supply line (1) and the fuel return Unclip ABS sensor plug (arrow) from the control- line (2) with hose clips, BMW No. 13 3 010. unit holder. • • Open the hose clips (arrows) and disconnect the [US] Disconnect hose from fuel evaporation con- fuel lines from the fuel-pump unit.
  • Page 272 46.10...
  • Page 273 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...
  • Page 274 51.2...
  • Page 275 Technical Data F 650 GS 51.3...
  • Page 276 51.4...
  • Page 277 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 –...
  • Page 278 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.
  • Page 279 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.
  • Page 280 51.8...
  • Page 281 61 General electrical equipment Contents Page Technical Data ..........................3 Wiring harness ..........................5 View from left ............................5 View from right ..........................6 Component positions in electronic equipment box ..........7 Relay positions in electronic equipment box ..............7 Connectors, electronic equipment box .................7 Removing and installing battery ...................8 Removing and installing battery carrier...
  • Page 282 61.2...

  • Page 283: Technical Data

    Technical Data F 650 General electrical equipment Circuit voltage V 12 Battery A/h 12 61.3...
  • Page 284 61.4...

  • Page 285: Wiring Harness

    Wiring harness View from left E619011 61.5...

  • Page 286: View From Right

    View from right E619020 61.6...

  • Page 287: Component Positions In Electronic Equipment Box

    Component positions in electronic equipment box E619012 Relay positions in electronic Connectors, electronic equipment box equipment box 5 Ignition light switch 1 Relief relay 6 Brake light switch 2 BMS relay 7 Multi-function switch, right 3 Diode relay 8 Multi-function switch, left 4 Flasher unit 9 Clutch switch 10 ABS switch...
  • Page 288 Removing and installing bat- 61 21 010 tery Note: Disconnecting the battery clears all entries (such as errors, adaptations) from the BMS control unit mem- Warning: ory. Battery acid is highly caustic. The loss of the adaptations may sometimes lead to Protect your eyes, face, hands, clothing and the engine performance being temporarily impaired paintwork.

  • Page 289: Replacing Fuses

    Removing and installing bat- Fuses 61 21 100 tery carrier – Place motorcycle on its centre stand. – Remove seat. – Remove left, right and centre covers. – Remove the battery............See above – Remove the intake air pipe.............See Group 13 –...

  • Page 290: Removing And Installing Coolant-Temperature Sensor

    Tightening torques: Intake air silencer to retainer ......9 Nm Intake air silencer to oil tank ......9 Nm Connecting flange .......... 5 Nm Fasteners, cover/ trim panel for turn indicator ......3 Nm Lid of electronic equipment box ..... 4 Nm Electronic equipment box to frame....
  • Page 291 • 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. • Remove the lid of the electronic equipment box. • Cut through the cable tie holding the wiring har- ness at the electronic equipment box.
  • Page 292 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 idle-indicator switch and coat with Loctite 243. – Remove front mudguard.............See Group 46 Tightening torques: Idle-indictor switch...
  • Page 293 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...
  • Page 294 62.2...

  • Page 295: Technical Data

    Technical Data F 650 GS Instruments Speedometer and revolution counter lighting W5/1.2 - 12V 1.2W Telltale and warning lights Flashing turn indicator W5/1.2 - 12V 1.2W Idle W5/1.2 - 12V 1.2W Oil pressure W5/1.2 - 12V 1.2W Water temperature W5/1.2 - 12V 1.2W High (main) beam headlight W5/1.2 - 12V 1.2W W5/1.2 - 12V 1.2W...
  • Page 296 62.4...

  • Page 297: Telltale/Warning Lights

    E620050 Telltale/warning lights 1 Water temperature 2 Oil pressure 3 Idle 4 High (main) beam headlight 5 Fuel gauge 6 ABS 7 Flashing turn indicator 8 Speedometer lighting 9 Revolution counter lighting 62.5...

  • Page 298: Replacing Telltale/Warning Lights

    Removing and installing Replacing telltale/warning lights 62 11 200 instrument panel – Remove instrument panel. – Place motorcycle on its centre stand. – Remove left and right covers. Note: Note washers and rubber ring. • Remove the windshield. • Remove the instrument cover. •...

  • Page 299: Removing And Installing Wiring Harness

    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.
  • Page 300 62.8...
  • Page 301 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 angle ............7 Vertical adjustment .........................7...
  • Page 302 63.2...
  • Page 303 Technical Data F 650 Lights Headlight Halogen headlight and manual beam throw ad- justment Bulbs High beam/low beam H4 halogen, 12V 60/55W, asymmetric Parking light 12V 5W Type T8/4 Brake light/rear light 12V 21/5W Type P25-2 Flashing turn indicator 12V 10W Type P25-1 63.3...
  • Page 304 63.4...
  • Page 305 E630020 Removing and installing Removing and installing 63 12 090 63 21 380 headlight rear light • – Place motorcycle on its centre stand. Remove the lid of the stowage compartment. • – Remove left and right covers. Remove the number plate holder complete with the rear light from the frame.

  • Page 306: Replacing Bulb

    • 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.

  • Page 307: Flashing Turn Indicator

    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 •...

Table of Contents