BMW F 650 GS 2002 Manuals

Manuals and User Guides for BMW F 650 GS 2002. We have 1 BMW F 650 GS 2002 manual available for free PDF download: Repair Manual

BMW F 650 GS 2002 Repair Manual (335 pages)

Brand: BMW | Category: Motorcycle | Size: 51 MB

Manual Structure
3
Key to Symbols
3
Maintenance Schedule
4
Pre-Delivery Check
5
Service Data
6
Contents
7
Tightening Torques
11
Engine Electrics
12
Fuel Tank and Lines
13
Clutch
14
Steering
15
Frame
16
Equipment
18
Table of Operating Fluids
19
General View of Crated Motorcycle
23
Unpacking the Motorcycle
23
Inspecting Motorcycle for Damage
24
Installing the Front Wheel
24
Installing Remaining Items on Motorcycle
24
Installing Windscreen
25
Installing Front Mudguard, Mirrors and Handlebar Weights
26
Filling and Charging the Battery
27
Removing Right and Centre Covers
27
Filling and Charging the Battery
28
Checking that Delivery Is Complete
29
Reading the Fault Code Memory with the BMW Moditec
29
Checking Tyre Pressures
29
Final Inspection and Function Check
29
Clutch
29
Final Cleaning
30
Handing over the Motorcycle
30
Maintenance
31
Motor
33
Key to Maintenance Intervals
35
Reading the Fault Code Memory with the Moditec
36
Changing the Engine Oil and Oil Filter Element
36
Replacing Oil Filter Element
37
Filling with Engine Oil
37
Operating Fluids
37
Engine Oil Capacity
37
Checking Coolant, Topping up if Necessary
38
Changing Coolant
38
Changing Oil in Telescopic Forks
40
Checking and Adjusting Valve Clearances
41
Removing the Intake Air Silencer Together with the Intake Air Pipe
41
Exposing the Radiator
41
Exposing Cylinder Head
41
Adjusting Valve Clearances
42
Installing Cylinder Head Cover
43
Replacing Spark Plugs
44
Replacing Air Cleaner Element
44
Emptying Drain Hose from Intake Air Silencer
44
Replacing Fuel Filter
45
Checking Clutch Play, Adjusting if Necessary
46
Checking Wheel Spoke Tension, Adjusting if Necessary
46
Gearbox
46
Checking Brake Pads and Discs for Wear, Replacing if Necessary
47
Checking the Brake Discs
48
Checking the Brake Fluid Level and Topping up if Necessary
49
Checking Operation of Brake System; Repairing/Replacing as Necessary
49
Changing Brake Fluid and Bleeding Brake System
50
Replacing Primary Sealing Boot Front Brake Master Cylinder
52
Replacing Primary Sealing Boot, Rear Brake Master Cylinder
53
Checking Chain, Chainwheel and Chain Sprocket, Replacing if Necessary
54
Checking Chain Tension, Adjusting if Necessary
54
Checking Battery Acid Level, Adding Distilled Water if Necessary
55
Cleaning and Greasing the Battery Terminals
56
Checking and Adjusting Steering Head Bearing Play, Renewing
56
Greasing the Side and Main Stands and the Brake Pedal Lever
58
Checking Security of Threaded Fasteners
59
Brake Pedal
59
Final Inspection with Road Safety and Functional Check
60
Motor
61
Engine Technical Data
65
Cutaway View of Engine
71
Engine Oil Circuit View and Parts List
72
Valve Gear View
73
Valves, Components View
74
Oil Pumps, Components View
75
Removing and Installing Cylinder Head, Engine Installed
76
Removing Camshafts
78
Removing Cylinder, Engine Installed
80
Removing Engine
81
Transferring Engine to Assembly Frame
82
Front Forks
82
Disassembling Engine
84
Checking Camshaft for Wear
85
Removing and Installing Timing-Chain Sprockets
85
Checking Centrifugal Decompressor Lever
85
Disassembling and Assembling the Centrifugal Decompressor
85
Checking Timing Chain for Wear
86
Disassembling and Assembling Cylinder Head
87
Checking Valve Guide for Wear
88
Removing Valve Guide
88
Installing Valve Guide
89
Checking Valve Seat for Wear
89
Installing Valve Stem Seal
90
Checking Valve for Wear
90
Removing Cylinder
91
Checking Cylinder
91
Installing Valves
91
Removing Piston
92
Determining Clearance of Piston in Cylinder
92
Determining Piston Ring Gaps
93
Assembling Pistons
93
Removing Ignition Magnet
93
Determining Piston Pin Clearance
93
Removing Countershaft for Starter
94
Disassembling/Assembling Freewheel
95
Removing Clutch
96
Removing Pressure Plate
96
Removing Clutch Plates
96
Removing and Installing Oil Pump
97
Removing Double Drive Gear
98
Removing Crankshaft and Balancing Shaft
98
Removing Compensating Gear
99
Removing and Installing Crankshaft Gear
99
Removing and Installing Gear-Box Mainshaft Bearings
100
Removing and Installing Gear-Box Countershaft Bearings
100
Removing and Installing Grooved Ball Bearings of Balancing Shaft
101
Removing and Installing Main Bearings
101
Assembling Engine
103
Installing Crankshaft and Balancing Shaft
103
Installing Double Drive Gear
104
Installing Oil Pump Gears
105
Installing Clutch
106
Installing Clutch Cage
106
Installing Driver
106
Installing Countershaft for Starter Motor
107
Installing Pressure Plate
107
Installing Magnetic Ignition Trigger
108
Installing Piston
109
Installing Cylinder
110
Installing Cylinder Head
110
Installing Camshaft and Adjusting Valves
112
Installing Engine
114
Bleeding Engine Oil Circuit
115
Engine Electrics
116
Engine Electrical Parts Technical Data
118
Ignition Magneto View
120
Ignition Magneto, Components View
121
Removing Ignition Magneto
122
Removing Right Engine Housing Cover
122
Removing and Installing Ignition Trigger
123
Installing Magnet Rotor
123
Removing and Installing or Dismantling Starter Motor
124
Disassembling/Assembling Starter Motor
125
Replacing Spark Plug
126
Replacing Ignition Lead
126
Removing and Installing Coil
126
Fuel Preparation and Control
127
Fuel System Technical Data
129
Removing and Installing BMS Control Unit
131
Removing and Installing Intake Air Pipe
131
Removing and Installing Air Temperature Sensor
131
Replacing Air Filter Element
132
Removing and Installing Intake Air Silencer
132
Removing and Installing Injection Nozzle
133
Removing and Installing Throttle-Valve Actuator
133
Replacing Throttle-Valve Potentiometer
134
Removing and Installing Throttle-Valve Stub Pipe
134
Removing and Installing Intake Pipe
135
Checking Fuel Pressure
135
Removing and Installing Fuel Hoses
136
Removing and Installing Feed and Return Lines
136
Removing and Installing Line to Fuel Injector
136
Fuel Tank and Lines
137
Fuel Tank and Lines Technical Data
139
Removing and Installing Fuel Tank
141
Removing and Installing Fuel Filler Cap
143
Installing Fuel Tank
143
Removing and Installing Roll-Over Valve
144
Removing and Installing Fuel Pump
144
Removing and Installing Fuel Pump
145
Removing and Installing Fuel-Evaporation Control Valve
146
Removing and Installing Activated Charcoal Filter
146
Radiator
147
Radiator Technical Data
149
Coolant Circuit View
151
Thermostat, Components View
152
Removing and Installing Coolant Pump
153
Adding Coolant
154
Removing and Installing Coolant-Temperature Sensor
155
Checking Cooling System for Leaks
156
Removing and Installing Coolant Hoses
156
Removing and Installing Fan
156
Removing and Installing Radiator
157
Removing and Installing Thermostat
157
Exhaust System
158
Exhaust System Data
160
Removing and Installing Exhaust System
162
Removing and Installing Right-Hand Silencer
162
Removing and Installing Left-Hand Silencer
162
Removing and Installing Exhaust Manifold and Oxygen Sensor
163
Replacing Guard for Silencer
164
Clutch
165
Clutch Technical Data
167
Clutch, Components View
169
Removing and Installing the Clutch
170
Disassembling and Reassembling Pressure Plate
170
Removing Clutch Plates, Driver and Clutch Cage
171
Check Clutch Discs for Wear
172
Removing and Installing Releaser Shaft
173
Gearbox
175
Gearbox Technical Data
177
Gearbox Shafts, Components View
179
Gear Shift Pedal, Components View
180
Removing and Installing Gearbox
181
Removing Selector Shaft with Pawl and Index Lever
181
Removing Selector Forks
181
Removing Selector Drum
181
Removing, Disassembling and Reassembling Gearbox Shafts
182
Removing Gearbox Shafts
182
Disassembling and Reassembling Mainshaft
182
Checking Mainshaft for Wear
183
Disassembling and Reassembling Countershaft
184
Replacing Gearbox Mainshaft Bearings
185
Checking Countershaft for Wear
185
Replacing Gearbox Countershaft Bearings
186
Installing Gearbox Shafts
186
Installing Selector Shaft
187
Installing Selector Forks
187
Installing Selector Drum
187
Drive Chain
189
Drive Chain Technical Data
191
Removing and Installing Chain, Chainwheel and Chain Sprocket
193
Removing and Installing Chain Guide Rail with Swinging Fork Installed
195
Front Forks
196
Front Forks Technical Data
198
Telescopic Fork, Components View
200
Changing Oil in Telescopic Fork
201
Removing and Installing Telescopic Fork
202
Installing Telescopic Fork
203
Disassembling Telescopic Fork
205
Disassembling Fixed Tube
206
Measuring Telescopic Fork
207
Checking Lower Fork Bridge
207
Checking Parallel Alignment of Fixed Tubes
208
Checking Fixed Tube Runout
208
Assembling Telescopic Fork
209
Assembling Fixed Tube
209
Removing and Installing Steering Head Bearing
213
Steering
215
Steering Technical Data
217
Removing and Installing Left and Right Handlebar Fittings
219
Removing and Installing Clutch Switch
220
Removing and Installing Right Handlebar Fitting
221
Removing and Installing Handlebars
223
Removing and Installing Clutch Cable
224
Removing and Installing Throttle Cable
226
Checking Steering Head Bearing Play
227
Adjusting Steering Head Bearing Play
227
Removing and Installing Left and Right Handlebar Levers
229
Rear Wheel Drive
230
Rear Wheel Drive Technical Data
232
Removing and Installing Suspension Strut
234
Removing and Installing Rear Swinging Fork
235
Removing and Installing Needle Roller Races in Rear Swinging Fork
236
Removing and Installing Reaction Links
237
Removing and Installing Needle Roller Bearing in Reaction Link
238
Removing and Installing Angled Lever
239
Brakes
242
Brakes Technical Data
244
Removing and Installing Front Brake Caliper
246
Removing and Installing Front Brake Pistons
247
Removing and Installing Front Brake Disc
248
Checking Front Brake Disc for Lateral Runout
248
Removing and Installing Rear Brake Caliper
249
Removing and Installing Rear Brake Pistons
250
Removing and Installing Rear Brake Disc
251
Checking Rear Brake Disc for Lateral Runout
251
Removing and Installing Front Brake Master Cylinder
252
Removing and Installing Rear Brake Master Cylinder
253
Removing and Installing Footbrake Lever
254
Checking Play at Piston Thrust Rod, Adjusting if Necessary
254
Removing and Installing Front ABS Sensor
255
Adjusting Play at Piston Thrust Rod
255
Removing and Installing Front ABS Sensor Ring
256
Removing and Installing Rear ABS Sensor
256
Removing and Installing Rear ABS Sensor Ring
257
Removing and Installing ABS Control Unit
257
Removing and Installing Front Brake Lines/Hoses (with ABS)
258
Removing and Installing Rear Brake Lines/Hoses (with ABS)
260
Checking/Adjusting Front ABS Sensor Gap
261
Checking and Adjusting Gap of Speed/Rear ABS Sensor
262
Wheels and Tyres
263
Wheels and Tyres Technical Data
265
Removing and Installing Front Wheel
267
Removing and Installing Front Wheel Bearing
268
Removing and Installing Rear Wheel
269
Removing and Installing Rear Wheel Bearings
270
Removing and Installing Bearing in Chainwheel Carrier
271
Removing and Installing Spokes
272
Checking and Centering Front and Rear Wheel Rims
275
Static Balancing of Front/Rear Wheel
277
Frame
278
Frame Technical Data
280
Removing and Installing Fairing
282
Removing and Installing Hand Protectors
285
Removing and Installing Front Mudguard
285
Removing and Installing Engine Guard
285
Removing and Installing Left/Right Rear Trim Panel
286
Removing and Installing Left/Right Grip
286
Removing and Installing Number Plate Panel
287
Removing and Installing Base of Stowage Compartment and Partition
288
Removing and Installing Seat Latch
288
Removing and Installing Rear Mudguard
289
Raising, Removing and Installing Rear Frame
290
Removing Frame
293
Removing and Installing Footrests
296
Removing and Installing Bottom Truss
297
Removing and Installing Side Stand
297
Removing and Installing Main (Centre) Stand
298
Equipment
299
Removing and Installing Ignition Switch/Steering Lock
303
Removing and Installing Lock for Rear Stowage Compartment
304
Removing and Installing Lock Barrel for Fuel Tank Filler Cap
304
Removing and Installing Lock Barrel
304
Replacing Mirrors
305
General Electrical Equipment
306
Electrical Equipment Data
308
Wiring Harness View
310
Component Positions in Electronic
314
Relay Positions in Electronic Equipment Box
314
Connectors, Electronics Box
314
Removing and Installing Battery
315
Removing and Installing Battery Carrier
315
Replacing Fuses
316
Removing and Installing Electronic Equipment Box
316
Removing and Installing Side Stand Switch
317
Removing and Installing Rear-Brake Switch for Brake Light
317
Removing and Installing Front-Brake Switch for Brake Light
318
Removing and Installing Horn
319
Removing and Installing Neutral-Indicator Switch
319
Removing and Installing Voltage Regulator
320
Instruments
321
Instruments Technical Data
323
Telltale/Warning Lights
325
Removing and Installing Instrument Panel
326
Replacing Telltale/Warning Lights
326
Removing and Installing Wiring Harness
327
Lights
328
Lights Technical Data
330
Removing and Installing Headlight
332
Removing and Installing Rear Light
332
Replacing Bulbs
333
Checking and Adjusting Headlight Beam Throw
334

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BMW F 650 GS 2002 Repair Manual (335 pages)

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