Bmw f650gs 2004 мануал

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  Repair Manual F 650 GS/GS Dakar BMW Motorrad After Sales…
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  A new issue of this Repair manual will be published if amendments or additions (supplements) are needed. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.

• Page 3: Key To Symbols

  Chapter 00 “Maintenance and general instructions” lists all tightening torques and the operating fluids. Key to symbols In this Repair Manual for the F 650 GS/GS Dakar, the following symbols are used; their meanings are ex- plained in the tables.

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  Licence plate no. Order No. Mechanic’s signature Read the fault code memory with the BMW MoDiTeC Change the engine oil while at regular operating temperature; replace the oil filter element if motorcycle is used only for short journeys or at outside temperatures below 0°C (32°F): every…

• 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 – Clutch, gearshift –…

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  BMW Motorcycle Service data F 650 GS/F 650 GS Dakar Item Rated value Unit of measurement/ specification Oil capacities Engine (with filter) 2.3 (4.05/2.43) Litres (Imp. pints/US quarts) Specification: see current Service Information Litres (Imp. pints/US quarts) Telescopic fork – for each post [Dakar version only] 0.55 (0.97/0.58)

• Page 7: Table Of Contents

  Contents << Back Group / Chapter 00 Tightening torques Operating fluids 00 Pre-delivery check 00 Maintenance 11 Motor 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 17 Radiator 18 Exhaust system 21 Clutch 23 Gearbox 27 Drive chain 31 Front forks >>…

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  >> Continuation Group / Chapter 32 Steering 33 Rear wheel drive 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 61 General electrical equipment 62 Instruments 63 Lights << Back…

• Page 9: Table Of Contents

  00 Tightening torques Operating fluids Contents Page Tightening torques ……………………3 11 Engine ……………………….3 12 Engine electrics ……………………4 13 Fuel preparation and control ………………..4 16 Fuel tank and lines ……………………5 17 Radiator ……………………….5 18 Exhaust system …………………….5 21 Clutch ……………………….6 23 Transmission ……………………..6 27 Drive chain ……………………..6…

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  Contents Page 00.2…

• Page 11: Tightening Torques

  Tightening torques Model F 650 GS / GS Dakar Connection 11 Engine Freewheel housing and freewheel (clean thread + Loctite 648) Engine block Double drive gear on crankshaft (clean thread + Loctite 243) Driver (clean thread + Loctite 243) Pressure plate…

• Page 12: Engine Electrics

  Model F 650 GS / GS Dakar Connection 11 Engine Cylinder head cover Machine screw (hole for locating pin) Cylinder head to frame Cylinder head to frame, adjusting sleeve zero play, max. 5 Cylinder head to frame, locknut Model F 650 GS / GS Dakar…

• Page 13: Fuel Tank And Lines

  Model F 650 GS / GS Dakar Connection 16 Fuel tank and lines Fuel tank to rear frame (M 8 stud) Fuel filler cap to fuel tank Roll-over valve to fuel tank Bracket, activated charcoal filter to fuel tank Fuel pump to fuel tank…

• Page 14: Clutch

  Model F 650 GS / GS Dakar Connection 21 Clutch Driver (clean thread + Loctite 243) Pressure plate Engine block cover, left Model F 650 GS / GS Dakar Connection 23 Transmission Selector lever to selector shaft Model F 650 GS / GS Dakar…

• Page 15: Steering

  Model F 650 GS / GS Dakar Connection 32 Steering Handlebars to fork bridge (apply Optimoly TA to thread) Handlebar weight to handlebars Clutch fitting to handlebars, M 6 Clutch switch to handlebar fitting Pivot pin for brake lever Locknut for pivot pin, clutch lever…

• Page 16: Frame

  Model F 650 GS / GS Dakar Connection 34 Brakes Brake lines/hoses Brake hose to brake caliper Brake hose to brake lever fitting Brake hose/brake line interfaces Brake line to master brake cylinder, rear wheel ABS sensor front/rear ABS pressure modulator to holder…

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  Model F 650 GS / GS Dakar Connection 46 Frame Seat lock to rear frame Number-plate carrier to rear section of rear mudguard (clean thread + Loctite 243) Mudguards/wheel guards Front mudguard, rear section to front section Front mudguard to fork bridge…

• Page 18: Equipment

  Model F 650 GS / GS Dakar Connection 51 Equipment Ignition/steering lock to fork bridge Model F 650 GS / GS Dakar Connection 61 General electrical equipment ABS sensor cable to sliding tube ABS sensor to brake caliper mount, rear…

• Page 19: 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 00.11…

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  00.12…
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  Removing right and centre covers ………………19 Filling and charging the battery ………………..20 Checking that delivery is complete ………………21 Reading the fault code memory with the BMW MoDiTeC ……..21 Checking tyre pressures ………………….21 Adding fuel to tank ……………………21 Final inspection and function check …………….21…
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  Contents Page 00.14…
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  E000251 General view of crated motorcycle • Notify the supplier (e.g. freight company) without delay. Checking the shipping crate for Unpacking the motorcycle damage • • When the motorcycle arrives, check the crate im- Lever off the cover. • mediately for damage and if necessary examine Take out the separate pack of items.

• Page 24: Inspecting Motorcycle For Damage

  • • Use the “express handling service” to notify Install quick-release axle (2) with spacer (3). BMW AG Sparte Motorrad, UX-VS-1 Fax: 00 49 89 382-33220 • Rectify the fault. • If parts are needed, order them by using the electronic parts list.

• Page 25: Installing Windscreen

  Installing windscreen • Wheel the motorcycle clear of the wooden pallet. E000311 • [Dakar] After turning the handlebars to full left/ right lock, align the hand protectors (4) with the E000260 windscreen and the handlebar fittings. • [Dakar] Tighten fasteners (5). •…

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  Installing front mudguard, mirrors and handlebar weights E000271 • Install front mudguard. Caution: Insert four washers (arrow) between front mudguard and lower fork bridge. E000310 • Install handlebar weights (1). • Tighten clamp screw (2) on handlebar fitting. • Install each mirror and secure by tightening nut (3).
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  E000280 Filling and charging the battery Removing right and centre covers Note: Do not remove the windscreen after the side panels have been removed, as otherwise the headlight beam setting will have to be checked. • Remove the lid of the stowage compartment. •…

• Page 28: 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.

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  7.5A, 15A, 20A • Documentation • Motorcycle keys, 3 Reading the fault code memory with the BMW MoDiTeC E000300 • Oil check: if oil is not visible in the sight glass, check whether the oil tank (2) contains oil. •…

• Page 30: Final Cleaning

  Final cleaning Handing over the motorcycle • Clean the motorcycle. This is the ideal opportunity to familiarise the custo- mer with the motorcycle in order to ensure the cu- stomer’s satisfaction and safety. Note: • Do not use a steam or high-pressure water jet. The The following points must be demonstrated and high steam or water pressure could damage seals, explained to the customer:…

• Page 31: Maintenance

  00 Maintenance Contents Page Key to maintenance intervals ………………..27 Reading the fault code memory with the MoDiTeC ……….28 (Inspections I, II, III and IV) …………………….28 Changing the engine oil and oil filter element …………28 (Inspections I, II, III and IV) …………………….28 Preparatory work ………………………28 Draining engine oil…

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  Contents Page Replacing spark plugs ………………….36 (Inspection III) ……………………….36 Emptying drain hose from intake air silencer ………….36 (Inspections II and III) …………………….36 Replacing air cleaner element ………………..36 (Inspection III) ……………………….36 Replacing fuel filter ……………………37 (Inspection III, every 20,000 km/12,000 miles) ……………….37 Checking clutch play, adjusting if necessary …………..38 (Inspections I, II and III) ……………………38…

• Page 33: Motor

  Contents Page Changing brake fluid (rear brake) ……………….43 Replacing primary sealing boot front brake master cylinder ……44 (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ………..44 Replacing primary sealing boot, rear brake master cylinder ……45 (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ………..45 Checking chain, chainwheel and chain sprocket, replacing if necessary ..46 (Inspections II and III) …………………….46…

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  Contents Page 00.26…

• Page 35: 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 40,000 km …

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  Reading the fault code Changing the engine oil and 00 13 624 00 11 215 memory with the MoDiTeC oil filter element (Inspections I, II, III and IV) (Inspections I, II, III and IV) Note: If an engine failure occurs, the oil tank and feed line must be cleaned with the material used for this pur- pose in the workshop, and then blown through with compressed air.

• Page 37: Replacing Oil Filter Element

  (1). • Remove the cable for the neutral-indicator switch from its guide. • Engage the oil drain guide, BMW No. 11 7 511, on the pins (arrows) on the engine block. • Position a drip tray beneath the engine. •…

• Page 38: Checking Coolant

  Checking coolant, topping up if nec- essary Note: Mix the coolant to a ratio of 50 % antifreeze, (Inspections I, II and III) 50 % water. • Check coolant level in the expansion tank, top up Note: coolant if necessary. Check coolant level only when the engine is cold.

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  E170030 E170090 • • Disconnect the coolant hose (arrow) at the frame Slacken bleed screw (2) in cylinder head. • on the left and drain the radiator. Connect a hose to the bleed screw. • Fill the radiator until coolant escapes at the bleed screw;…
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  [Dakar] Changing oil in tele- 00 11 279 scopic forks (Inspection III) – Install stand, BMW No. 00 1 610, and place the motorcycle on the stand. – Relieve load on front wheel. E310160 • Position a drip tray beneath the telescopic forks.

• Page 41: Valve Clearances

  Pull the intake air silencer with intake air pipe and Remove spark plug. • battery carrier to the rear to remove. Use pliers, BMW No. 17 5 500, to release hose • Cover/seal the throttle valve stub. clip (5) and disconnect cylinder-head breather hose (7).

• Page 42: Adjusting Valve Clearances

  Remove the screw at the oil feed stub pipe and timing-chain sprockets are at the top. insert locating screw, BMW No. 11 6 570, to lock the crankshaft at TDC. •…

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  • Installation is the reverse of the removal proce- dure: pay particular attention to the following. • When installing the inlet camshaft, press the chain rail back against the chain tensioner if necessary. Note: TDC position: marks on the timing-chain sprockets are parallel with the cylinder head, the bores in the timing-chain sprockets are at the top.
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  Replacing spark plugs Replacing air cleaner ele- 00 12 620 00 13 630 ment (Inspection III) • Pull spark plug connector off spark plug. (Inspection III) • Remove the spark plug with the a/f 18 socket – Remove right cover ( 46.5).
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  Note the installed positions of fuel feed line (7) and fuel return line (3). • Close hose clamps with pliers, BMW No. 13 1 500. Tightening torques: Fuel filter to frame ………. 9 Nm Oil tank to intake air silencer ……9 Nm Air filter box to frame ……..

• Page 46: Gearbox

  Tap the spokes and listen for differences in the pitch of the sound. • If spokes are loose, tighten them with spoke nip- ple wrench, BMW No. 36 3 800. Vertical runout……max. 2 mm (0.08 in) Lateral runout……max. 2 mm (0.08 in) E000240 •…

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

• Page 48: Checking The Brake Discs

  Checking the brake discs 00 34 633 Brake pads, rear brake • Press the brake caliper against the brake disc in • order to force the piston back. Carefully check the brake discs for cracks, dam- age, deformation and scoring. E340021 E000080 •…

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  Checking the brake fluid level and Brake fluid level (rear brake) topping up if necessary (Inspections II and III) Checking brake fluid level (rear brake) Note: The volume of the brake fluid (MIN/MAX) is sufficient for brake-pad thicknesses from new to the wear lim- it.
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  Manual. If the BMWMoDiTeC is not used there is a danger of • Using resetting tool, BMW No. 34 1 500, and residual air remaining in the control circuits of the strips of metal sheet (1) (approx. 9 mm/0.35 in ABS system.
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  Changing brake fluid (rear brake) • Installation is the reverse of the removal proce- dure: pay particular attention to the following. • • Press the brake caliper against the brake disc in Before reassembling, carefully wipe the rim of order to force the piston back. the reservoir, the rubber gaiter and the cover to remove all traces of brake fluid.

• Page 52: 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. Important: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint.

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  Replacing primary sealing boot, rear brake master cylinder (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) – Place the motorcycle on its main (centre) stand. Important: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint.
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  Checking chain, chainwheel and Checking chain tension, 27 71 005 chain sprocket, replacing if neces- adjusting if necessary sary (Inspections I, II, III and IV) Checking chain tension (Inspections II and III) 27 71 005 – Remove the sprocket cover. •…
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  Adjusting chain tension Checking battery acid level, 27 71 005 61 20 029 adding distilled water if necessary (Inspections II, III and IV) Warning: Battery acid is highly caustic! Protect your eyes, face, hands, clothing and the paintwork! Checking battery acid level 61 20 029 –…
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  Cleaning and greasing the Checking and adjusting 61 21 520 32 00 454 battery terminals, if necessary steering head bearing play, renewing if necessary (Inspection IV) – Remove left, right and centre covers ( 46.5). (Inspections II and III) Checking steering head bearing play Important: •…
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  E000220 • Slacken round nut (6) with pin-wrench adapter, BMW No. 31 6 521, then tighten to 25 Nm. • Turn forks back and forth twice from lock to lock, and leave the forks at the full left lock position.

• Page 58: Side Stand

  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 59: 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 fasteners of frame – Main and side stands – Exhaust mountings –…

• Page 60: 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: Thread depth must comply with legal regulations concerning minimum tyre tread depth.

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  11 Motor Contents Page Technical Data ……………………..5 Cutaway view of engine ………………….11 Engine oil circuit …………………….12 Valve gear ……………………….13 Valves, components ……………………14 Oil pumps, components ………………….15 Removing and installing cylinder head, engine installed ……..16 Preparatory work ………………………
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  Contents Page Disassembling and assembling cylinder head …………..27 Removing valves ……………………..27 Bore for bucket tappet ……………………27 Checking valve guide for wear ………………….28 Removing valve guide ……………………28 Installing valve guide …………………….29 Checking valve seat for wear ………………….29 Installing valve stem seal ……………………30 Checking valve for wear ……………………30 Installing valves ……………………..31 Removing cylinder…
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  Contents Page Removing and installing grooved ball bearings of balancing shaft ……41 Removing and installing main bearings …………….41 Removal ……………………….41 Installation ……………………….42 Assembling engine ……………………43 Installing crankshaft and balancing shaft …………….43 Shimming crankshaft …………………….43 Installing double drive gear …………………..44 Installing oil pump gears ………………….45 Installing clutch ……………………..46…
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  11.4…
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  Technical Data F 650 GS / GS Dakar Engine, general Type Single-cylinder four-stroke, double overhead camshafts driven by roller chain, 4 valves operat- ed by bucket tappets, balancing shaft, liquid- cooled cylinder and cylinder head, integral water pump, 5-speed gearbox and dry sump lubrica- tion.
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  Technical Data F 650 GS / GS Dakar Connecting rod Wear limit, connecting rod Radial clearance Big-end bore mm (in) 0.08 (0.003) Small-end bore mm (in) 0.05 (0.002) Big end bearing endplay Installed dimension mm (in) 0.30…0.65 (0.012…0.026) Wear limit mm (in) 0.80 (0.031)
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  Technical Data F 650 GS / GS Dakar Valve seat angle Inlet ° 45 Exhaust ° 45 Included valve angle Inlet ° 15 Exhaust ° 18 Valve seat width Inlet mm (in) 1.05…1.35 (0.041…0.053) Wear limit mm (in) 1.60 (0.063) Exhaust mm (in) 1.25…1.55 (0.049…0.061)
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  Technical Data F 650 GS / GS Dakar Piston Piston dia. “A” Installed dimension mm (in) 99.975…99.985 (3.9361…3.9365) Wear limit mm (in) 99.940 (3.9347) Installed clearance mm (in) 0.015…0.040 (0.0006…0.0016) Wear limit mm (in) 0.090 (0.0035) Piston dia. “B” Installed dimension mm (in) 99.985…99.995 (3.9365…3.9369)
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  Technical Data F 650 GS / GS Dakar Piston pin Piston pin dia. Wear limit mm (in) 21.98 (0.865) Piston-pin play in piston-pin bore mm (in) 0.015…0.029 (0.0006…0.0011) Wear limit mm (in) 0.050 (0.0020) in bore (piston) mm (in) 0.012…0.021 (0.0005…0.0008) Wear limit mm (in) 0.050 (0.0020)
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  11.10…
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  Cutaway view of engine E110550 11.11…
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  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…
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  Valve gear E110440 11.13…
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  Valves, components E110450 11.14…
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  Oil pumps, components E110460 11.15…
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  Removing and installing cyl- 11 12 116 inder head, engine installed Note: If an engine failure occurs, the oil tank and oil lines must be cleaned with the material used for this pur- pose in the workshop, and then blown through with compressed air.
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  Remove fastener for oil lines (2) from the cylinder Turn crankshaft to top dead centre position with head. an Allen key. • Use pliers, BMW No. 17 5 500, to open the clamp securing the breather hose at the cylinder head cover. Note: •…
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  E110480 • Remove screws securing cylinder head to E110420 frame (arrow). • Use pin wrench, BMW No. 11 6 661, to slacken • Remove chain guide (1). the locknut. • Remove upper section of camshaft carrier (2). •…
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  • When looping the timing chain over the camshaft sprockets, make sure that the sprockets are at the TDC position. • Before installing the cylinder head cover, remove all traces of the gasket and clean the sealing face with degreasing agent. Also clean the groove and the seating faces for the gasket.
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  E110520 • Oil the piston rings and press the sliding piston ring sleeve, BMW No. 11 6 510, over the piston rings from above so that the piston projects from E110500 the sliding sleeve by about 2 mm (0.08 in).

• Page 81: Removing Engine

  Removing engine 11 00 050 Preparatory work 11 00 050 – Drain coolant ( 00.30). – Place motorcycle on its centre stand. – Secure front wheel in position. – Remove seat. – Remove intake air silencer ( 13.6). • Disconnect battery negative terminal. –…

• Page 82: Front Forks

  Note: When locating pin, BMW No. 11 0 661, is inserted and the floating bearing stud is pulled out 22.5 cm E110050 (8.86 in), the rear swinging fork remains in place in the frame, but the engine is free.

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  Lay the engine on its left side, as viewed in the forward direction of travel. • Secure engine adapter, BMW No. 11 0 640, to the right side of the engine without a spacer. • Position the assembly stand beside the lifting platform.
• Page 84
  Turn crankshaft to top dead centre position with an Allen key. • Remove screws (5) and lock the crankshaft with locating screw, BMW No. 11 6 570. Important: If there is any mechanical damage, the oil tank and the oil lines must be cleaned.
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  “B”. 00 2 590 F110040 • Measure bearing play with Plastigage type PG-1, BMW No. 00 2 590. • Tighten camshaft mount to specified torque. E110090 Tightening torque: Camshaft mount……….. 10 Nm Distance “B”…
• Page 86
  11 12 116 Removing cylinder head Checking timing chain for wear • Remove front chain rail (1). • Release the coolant line hose clips with pliers, BMW No. 17 5 500. • Secure timing chain with cable tie. • Remove starter ( 12.9).
• Page 87
  If the wear limit, distance “B”, is exceeded, first 11 34 020 Removing valves • inspect the tensioner rail and the two guide rails Use suction cup, BMW No. 11 3 251, to pull out for score-marks and renew them if necessary. the bucket-type tappets. •…
• Page 88
  BMW No. 00 1 900, to check the temperature. imum tilt clearance across the camshaft axis. • Use drift, BMW No. 11 0 571, to drive out the Tilt clearance: valve guide toward the combustion chamber. Max. tilt clearance ……. 0.4 mm (0.016 in) Intl.
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  F110151 • Heat the cylinder head to 100 °C (212 °F). • Using driving-in tool, BMW No. 11 0 571, drive F110160 valve guide (1) into the cylinder head until valve guide projection is as specified. • Check valve seat width “A” and contact pattern Projection: for wear.
• Page 90
  E110120 For wear limits, see Technical Data. • • Install bottom valve spring retainer (1). Check grooves for valve collets. • Use a drift, BMW No. 11 6 650, to insert valve stem seal (2). 11.30…

• Page 91: Removing Cylinder

  Secure adapter plate, BMW No. 11 0 521, E110140 support, BMW No. 11 5 691, spindle, BMW No. 11 5 692, nut, BMW No. 11 5 693, • and thrust plate, BMW No. 11 0 522. Check cylinder face and sealing faces for dam- •…

• Page 92
  11 25 050 inder • Remove piston pin circlips. • Press out piston pin with drift, BMW No. 11 6 581. Note: Mark exhaust-valve side on piston crown. Disassembling piston 11 25 671 • Remove piston rings with piston ring pliers.

• Page 93: Determining Piston Ring Gaps

  • Release the central locking screw, insert and Assembling pistons 11 25 671 tighten handle, BMW No. 12 5 500. Note: The “Top” must face towards the piston crown. Install the piston rings with their gaps offset by 120 °.

• 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 assem- 12 11 077 Assembling freewheel bling freewheel Disassembling freewheel 1. Machine screw 2. Magnet rotor 3. Freewheel 4. Lock ring 5. Freewheel housing 6. Freewheel gear Warning: Securing screws (1) are secured with Loctite 648 and considerable torque is required to release them. •…
• Page 96
  Turn engine round in assembly fixture. • Remove fastener for left engine block scover and • remove cover. Using locating ring, BMW No. 21 4 600, prevent clutch cage (4) and driver (3) from moving and Removing pressure plate unscrew hex nut. •…
• Page 97
  Removing and installing oil 11 41 000 Installing oil pump pump Removing oil pump F110370 7. Inner rotor E110270 8. Outer rotor 9. Cover • Remove circlip (1) from angled gear. 10.Markings • Remove the retaining rings of the oil-pump 11.Needle roller gears (2) and disengage the oil-pump gears.
• Page 98
  Removing double drive gear E110320 • Swivel assembly fixture so that clutch side is E110290 uppermost. • Remove knurled nuts (4). Note: Retaining screw (arrow) must be installed. Important: Do not tilt engine housing: this can cause damage • Remove hex nut (1). to bearing shell.

• Page 99: Removing And Installing Crankshaft Gear

  Press off compensating gear with pressure pad, BMW No. 11 6 502, and pressure pad, BMW No. 11 0 561. BMW No. 11 6 503, to pull off the crankshaft gear. • Installation is the reverse of the removal proce- dure: pay particular attention to the following.

• Page 100
  • Using bearing puller plate, BMW No. 11 6 561, E230040 spindle, BMW No. 11 6 562, and spreader sleeve, BMW No. 11 6 564, pull off the ball bear- ing. • Note: Installation is the reverse of the removal proce- To protect the gasket surfaces of the engine block, dure: pay particular attention to the following.
• Page 101
  Using bearing puller plate, BMW No. 11 6 561, 00 5 500 spindle, BMW No. 11 6 562, and spreader sleeve, BMW No. 11 6 563, pull off the ball bear- ing. • Heat the right of the engine block to 80 — 100 °C (176 — 212 °F).
• Page 102
  The end gap of the bearing bushing must always face the balancing shaft. Before driving in, fit both bearing halves with O-ring on mandrel. • Coat bearing bushings with Optimoly TA and drive in with drift, BMW No. 11 0 551, working from the inside. 11.42…
• Page 103
  • Secure right side of engine housing in engine bracket with magnet side facing downwards. F111041 • Using depth gauge, BMW No. 00 2 550, meas- ure distance from crankshaft web to housing mating face = dimension “B”. E110330 •…
• Page 104
  • Lock the crankshaft in the TDC position with lo- • Fit left engine housing and install fasteners. cating screw, BMW No. 11 6 570. Note: Note the two fasteners in the oil filter housing. • Cut off protruding gasket.
• Page 105
  Installing oil pump gears 11 41 000 E110350 • Install angled gear (1) with washer and circlip. • Install washers (4) of oil pump gears and slide needle rollers (5) into position. • Install oil pump gears (3) and install the circlips (2).
• Page 106
  Insert driver (7) and coat internal splines with Optimoly MP 3. • • Fit retaining washer (8); it must engage securely. Insert locating ring, BMW No. 21 4 600. • • Clean threads of countershaft and hexagon Tighten hex nut and bend tabs of retaining nut (9), coat threads with Loctite 243 and washer (8).
• Page 107
  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
  Three Bond 1209 and install in cover of engine block. • Fit gasket. • Screw assembly handle, BMW No. 12 5 500, into the central hole in the right engine cover. • Fit right engine housing cover and install secur- ing screws.

• Page 109: Installing Piston

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

• Page 110
  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 install at the correct valves. • Measure thickness of shim plates with microme- ter and note down thickness. • Place lower part of camshaft mount (1) on cylin- der head.
• Page 113
  • Connect the oil lines to the cylinder head. • Remove locating pin, BMW No. 11 6 570, and insert screw plug with sealing ring. • Install the spark plug.

• Page 114: Installing Engine

  • Tighten locknut (3) using special wrench, Important: BMW No. 11 6 661. Never start the engine after it has been dismantled • Tighten fastener (4). and re-assembled until the engine oil circuit has been bled.

• Page 115
  Bleeding engine oil circuit • Remove oil filter. E110560 • Remove check valve (1). • Remove spark plug. • Turn engine over with the starter motor until oil emerges at the filter chamber. • Install check valve. • Install oil filter. •…
• Page 116
  12 Engine electrics Contents Page Technical Data ……………………..3 Ignition magneto ………………………5 Ignition magneto, components …………………6 Removing ignition magneto ………………..7 Removing right engine housing cover ……………….7 Removing and installing ignition trigger …………….8 Removing and installing stator ………………..8 Installing magnetic ignition trigger ………………8 Installing magnet rotor ……………………8…
• Page 117
  12.2…
• Page 118
  Technical Data F 650 GS / GS Dakar Ignition system Type Fully transistorised ignition integrated in BMS. Ω 190 —300 Inductive sensor Ignition Ignition system BMS (mapped characteristic control) Speed limitation rpm 7,500 Ignition coil Primary coil mΩ 500 ±50…
• Page 119
  12.4…
• Page 120
  Ignition magneto E120050 12.5…
• Page 121
  Ignition magneto, components E120040 1. Ignition signal sensor 2. Freewheel housing 3. Lock ring 4. Freewheel gear 5. Starter countershaft 6. Freewheel 7. Magnet rotor 8. Stator winding 12.6…
• Page 122
  12 5 500 Note: Use temperature measuring device, BMW No. 00 1 900, to check the temperature. • Using puller, BMW No. 12 5 510, pull off magnet rotor. E110180 • Remove the central locking screw, insert and tighten handle, BMW No. 12 5 500.
• Page 123
  Removing and installing igni- • 12 11 060 Installation is the reverse of the removal proce- dure: pay particular attention to the following. tion trigger • Coat the rubber grommet of the stator with Three Bond 1209 before inserting it into the cover.
• Page 124
  Removing and installing or • Fit gasket. 12 41 020 • Screw assembly handle, BMW No. 12 5 500, dismantling starter motor into the central hole in the right engine cover. • Fit right engine housing cover and install secur- Removing and installing ing screws.
• Page 125
  Remove front cover (5). E120070 • Remove armature (3) from housing (1). • Using puller, BMW No. 00 8 400, pull the ball bearing (4) off the armature shaft. Note: Note: Make sure that the mark on the housing (arrow) is The insulation should be 0.5 mm (0.0197 in) deeper…
• Page 126
  Replacing spark plug • 12 12 011 Disengage the clamp securing the breather hose and disconnect the hose from the intake air si- 00.36) lencer. • Press the oil tank slightly to the left and carefully disconnect the intake air silencer from the throt- Replacing ignition lead 12 12 085 tle valve stub.

• 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 and installing air temperature sensor ……………5 Replacing air filter element ( 00.36) …………….6 Removing and installing intake air silencer …………..6 Removing and installing intake air pipe ……………..6…

• Page 128
  13.2…
• Page 129
  Technical Data F 650 GS / GS Dakar Fuel grade Super (premium), unleaded. 95 octane (RON) Mixture preparation Manifold injection Fuel pressure bar (psi) 3.5±0.2 (50.76±2.8) Throttle stub pipe intl. dia. mm (in) 46 (1.81) Air filter Paper filter Intake stub pipe mm (in) 43 (1.70)
• Page 130
  13.4…
• Page 131
  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 00 13 630 00.36) Removing and installing 13 72 130 intake air silencer – Remove left, right and centre covers ( 46.5). – Remove intake air pipe ( 13.5). • Disengage the rubber strap holding the battery. E130090 •…
• Page 133
  13.6). • Disconnect the plug of fuel injector (1). • Use a hose clamp, BMW No. 13 3 010, to close off fuel line (3). • Slacken the hose clip securing the fuel line and disconnect the line from the throttle valve stub.
• Page 134
  Disconnect the plugs for fuel injector (2), throttle- valve potentiometer (4) and throttle-valve actuator (3). • Note: Use a hose clamp, BMW No. 13 3 010, to close It is not necessary to adjust the throttle-valve poten- off fuel line (5). • tiometer after installation (self-teaching system).
• Page 135
  Connecting flange ………. 5 Nm Fasteners, cover/ • trim panel for turn indicator ……3 Nm Connect a test pressure gauge, BMW No. 16 1 500, between fuel feed line and tank outlet. • Start engine and allow to run in neutral. Fuel pressure: Specification ….
• Page 136
  Remove left, right and centre covers ( 46.5). • Comply with safety precautions when handling or Use a hose clamp, BMW No. 13 3 010, to close working with fuel; note that the fuel lines are pressu- off the fuel feed line. rised.
• Page 137
  16 Fuel tank and lines Contents Page Technical Data ……………………..3 Removing and installing fuel tank ………………5 Removing fuel tank …………………….5 Installing fuel tank ………………………7 Removing and installing fuel filler cap …………….7 Removing and installing roll-over valve …………….8 Replacing fuel filter ( 00.37) ………………..8 Removing and installing fuel pump…
• Page 138
  16.2…
• Page 139
  Technical Data F 650 GS /GS Dakar Fuel tank Type Plastic tank with cover Tank capacity l (Imp. gal/US gal) 17.3 (3.8/4.6) (including 4 l (0.88/1.06) reserve) Type of fuel Super (premium), unleaded. 95 octane (RON) Fuel pump Type Peripheral-gear pump…
• Page 140
  16.4…
• Page 141
  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
  (2) are correctly routed. Warning: Do not use screw-type hose clamps on the fuel hos- es, because they could damage the hoses and result in a fire hazard. • Close hose clamps with pliers, BMW No. 13 1 500. 16.7…
• Page 144
  • Roll-over valve to fuel tank ……3 Nm Close off fuel supply line (5) and the fuel return line (4) with hose clips, BMW No. 13 3 010. • Open the hose clips (arrows) and disconnect the fuel lines from the fuel-pump unit.

• Page 145: Removing And Installing Fuel Pump

  E160061 • Release ring (1) using wrench, BMW No. 16 1 021. • Remove fuel-pump unit (3) with gasket (2). • Installation is the reverse of the removal proce- dure: pay particular attention to the following.

• Page 146
  Removing and installing fuel-evapo- Removing and installing 16 13 001 ration control valve activated charcoal filter [USA version] [USA version] – Place motorcycle on its centre stand. – Place motorcycle on its centre stand. – Remove seat. – Remove seat. •…

• Page 147: Radiator

  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 F 650 GS / GS Dakar Cooling system Cooling system capacity Total capacity l (Imp. pints/ 1.3 (2.29/1.37) US quarts) Coolant circuit l (Imp. pints/ 1.20 (2.11/1.27) US quarts) Coolant expansion tank l (Imp. pints/ 0.10 (0.18/0.11) US quarts)
• Page 150
  17.4…
• Page 151
  Coolant circuit E170010 17.5…
• Page 152
  Thermostat, components E170020 1. Coolant-temperature sensor 2. Thermostat housing 3. Thermostat 4. Cover 5. O-ring 6. Spring clip 17.6…
• Page 153
  18.6). – Remove left footrest ( 46.19). • • Remove the gear shift pedal. Using hose clip pliers, BMW No. 17 5 500, – Remove starter ( 12.9). remove hose clips (13). • • Disengage clutch cable from release lever.

• Page 154: Adding Coolant

  Pack the space between the sealing rings with Shell Retinax EP2. • Drive inner sealing ring onto its seat with drift, BMW No. 11 6 540. • Drive in outer sealing ring flush with the friction face, using the appropriate adapter.

• Page 155
  Removing and installing coolant-tem- Antifreeze Use only nitrite-free long-term antifreeze and corro- perature sensor sion inhibitor. – Drain coolant ( 00.30). • Concentration Place motorcycle on its centre stand. Antifreeze …………50% Water ……………50% • Run the engine for a short time, then switch it off. •…
• Page 156
  Connect pump, BMW No. 17 0 500, with adapt- and pull it to one side. • er and neck, BMW No. 17 5 520, to filler neck. Disconnect the coolant hose from the radiator • Pressure-test the system; the pressure must re- and the expansion tank.

• 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: 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 159
  18.2…
• Page 160
  Technical Data F 650 GS / GS Dakar Exhaust system Emission control 3-way catalytic converter Silencer (muffler) Reflection/absorption-type silencer 18.3…
• Page 161
  18.4…
• Page 162
  E180032 Removing and installing • 18 00 020 Installation is the reverse of the removal proce- dure: pay particular attention to the following. exhaust system Removing and installing right- 18 11 301 hand silencer • Remove number plate. • Remove the fastener (arrow) securing the silenc- er to the rear frame.
• Page 163
  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 164
  Replacing guard for silencer • Uniformly tighten the fasteners securing the 18 12 212 manifold to the cylinder head. – Remove the lid of the glove compartment. E180021 E630010 • Tighten clamp (1) for the silencer, making sure • that the clamp is correctly positioned (arrow). Remove the fastener (arrow) securing the turn in- •…
• Page 165
  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 166
  21.2…
• Page 167
  Technical Data F 650 GS / GS Dakar 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: Lined plate distortion mm (in) 0.25 (0.010)
• Page 168
  21.4…
• Page 169
  Clutch, components E210010 21.5…
• Page 170
  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 release lever. Remove circlip (7) with circlip pliers.
• Page 171
  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 172
  (10), coat threads with Loctite 243 and in- stall nut. Height of lined plate cluster • Insert locating ring, BMW No. 21 4 600……….min. 27.5 mm (1.08 in) • Tighten hex nut and bend tabs of retaining Height of complete plate cluster washer (9).
• Page 173
  Pressure plate to driver …….. 10 Nm • Remove keeper (6) for releaser shaft (7). • Withdraw releaser shaft from cover. 21 4 610 E210050 • Using puller, BMW No. 21 4 610, pull out both needle roller bearings and the sealing ring to- gether. 21.9…
• Page 174
  Insert releaser shaft. • Cover the splines on the releaser shaft with slide- on sleeve, BMW No. 21 4 620. • Using drift, BMW No. 21 4 630, drive in sealing ring. Installing clutch 21 21 000 • Align splines on water pump driven gear with driving gear on balancing shaft.
• Page 175
  23 Gearbox Contents Page Technical Data ……………………..3 Gearbox shafts, components ………………..5 Gear shift pedal, components ………………..6 Removing and installing gearbox ………………7 Removing selector shaft with pawl and index lever …………7 Removing selector forks ………………….7 Removing selector drum ………………….7 Removing, disassembling and reassembling gearbox shafts ……8 Removing gearbox shafts ………………….8…
• Page 176
  23.2…
• Page 177
  Technical Data F 650 GS / GS Dakar 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…
• Page 178
  23.4…
• Page 179
  Gearbox shafts, components E230050 23.5…
• Page 180
  Gear shift pedal, components F239030 23.6…
• Page 181
  E230010 Removing and installing Removing selector drum 23 00 100 23 00 651 gearbox • Withdraw selector drum (4). Important: If there is any mechanical damage, the oil tank must be cleaned. – Remove engine ( 11.21). – Disassemble engine ( 11.24).
• Page 182
  • 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 183
  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 184
  Renew gears only together with the corresponding meshing gears. Edges of ring grooves must not be rounded. Always renew circlips and install them only with spe- cial pliers, BMW No. 23 4 500. • Assembly is the reverse of the disassembly pro- cedure.

• Page 185: Replacing Gearbox Mainshaft Bearings

  • 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 186: Installing Gearbox Shafts

  • 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 187
  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 188
  • 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 189
  27 Drive chain Contents Page Technical Data ……………………..3 Removing and installing chain, chainwheel and chain sprocket …….5 Removing and installing chain ………………..5 Removing and installing chain guide rail ………………..5 Removing and installing chain takeup roller ………………5 Removing chainwheel ……………………6 Removing chain sprocket ………………….6 Removing and installing chain guide rail with swinging fork installed…
• Page 190
  27.2…
• Page 191
  Technical Data F 650 GS / GS Dakar Chain drive Number of teeth on chain sprocket Number of teeth on chainwheel Secondary ratio 1:2.937 Secondary drive O-ring chain 5/8″ x 1/4″ Chain links Chain length mm (in) 1,000 (39.4) Roller diameter mm (in) 10.16 (0.40)
• Page 192
  27.4…
• Page 193
  E270020 Removing and installing 27 71 000 Tightening torques: chain, chainwheel and chain Swinging-fork pivot shaft……100 Nm sprocket Strut to swinging fork ……..41 Nm Rear quick-release axle……100 Nm Chain tensioning screws ……10 Nm Wheel cover bracket to swinging fork….. 9 Nm Important: Always renew the chain, chainwheel and chain 27 72 009 Removing and installing chain guide rail…
• Page 194
  Remove screws (3) and remove the chainwheel. Unscrew central nut (5). • Remove the locking washer (4). • Use puller, BMW No. 00 8 400, to pull the Tightening torques: sprocket off the mainshaft. • Chainwheel to carrier ……..21 Nm Installation is the reverse of the removal proce- dure: pay particular attention to the following.
• Page 195
  Removing and installing chain 27 72 009 guide rail with swinging fork installed • Remove the sprocket cover. • Remove the rear quick-release axle. • Remove the chain from the chainwheel and chain sprocket. • Remove the fasteners securing the chain guide rail to the swinging fork.
• Page 196
  31 Front forks Contents Page Technical Data ……………………..3 Telescopic fork, components ………………..5 [Dakar] Changing oil in telescopic forks ……………..6 Removing and installing telescopic fork ……………..7 Removing telescopic fork ………………….7 Installing telescopic fork ………………….8 Disassembling telescopic fork ………………..10 Removing fixed tube ……………………..10 Disassembling fixed tube ……………………
• Page 197
  31.2…
• Page 198
  Technical Data F 650 GS F 650 GS Dakar Front forks Front wheel caster mm (in) 113 (4.449) 123 (4.842) Steering lock angle ° 40 Front suspension travel mm (in) 170 (6.69) 210 (8.268) (normal-load position, 85 kg (187 lbs) load) Length of suspension spring in fork mm (in) 515.1 (20.279)
• Page 199
  31.4…
• Page 200
  Telescopic fork, components E310070 31.5…
• Page 201
  [Dakar] Changing oil in tele- 00 11 279 scopic forks – Install stand, BMW No. 00 1 610, and place the motorcycle on the stand. – Relieve load on front wheel. E310160 • Position a drip tray beneath the telescopic forks.
• Page 202
  [GS] Release ABS sensor cable from clip (4). Remove round nut with upper taper roller bear- • Remove brake hose with ABS sensor cable from ing, using socket, BMW No. 31 6 521. • clip (3) on sliding tube. Remove front forks.

• Page 203: Installing Telescopic Fork

  (arrow). • Align the mark on pin-wrench adapter, BMW No. 31 6 521, with the right-hand end of the marked arc. Note: 40 mm (1.575 in) around the circumference of the locking plate corresponds to an angle of rotation of 60°.

• Page 204
  • [GS] Fit caps to fork legs. • [Dakar] Lightly oil threads of screw plugs. Note: Check O-rings of screw plugs for damage and renew if necessary. Warning: Screw plugs are spring-loaded. • [Dakar] Install and tighten screw plugs on left and right.
• Page 205
  E310081 Disassembling telescopic fork • 31 42 503 [GS] Remove sealing caps (1). Removing fixed tube • Remove clamp (6). Warning: • Remove fork stabiliser (5). Note that plugs (3) at left and right are spring-load- • Slacken clamping screws (4) at lower fork ed.
• Page 206
  F310100 Disassembling fixed tube • Clamp slider tube in vice with protective jaws. • Remove spacer and spring with washer from fixed tube. • Remove dust cap (1). • Lever out circlip (2) with screwdriver. Note: Catch escaping oil in a suitable container. •…
• Page 207
  [GS] ……….215 mm (8.46 in) [Dakar] ……..218 mm (8.58 in) 31 4 620 F310060 • Place two straight-edges, BMW No. 31 4 620, across the upper and lower ends of the fixed tubes. Important: Replace distorted fork bridges.
• Page 208
  Checking parallel alignment of fixed tubes Checking fixed tube runout F310080 F310070 • Place both ends of fixed tube in V-blocks. Note: The fork bridge must slide smoothly over the fixed tubes. Warning: Do not attempt to straighten bent fixed tubes. •…
• Page 209
  F310091 Assembling telescopic fork 31 42 503 Assembling fixed tube • Fit damper tube (6) with piston ring (5) and spring (4) into fixed tube. • Fit guide piece (3) onto damper tube (6). Note: Lightly oil slide bushes with fork oil before assembly. •…
• Page 210
  Note: • Drive dust sleeve (6) into the slider tube with the Lightly oil slide bushes with fork oil before assembly. convex side of drift, BMW No. 31 3 650. • Tighten shock absorber retaining screw (1) in the •…
• Page 211
  ….0.62 l (1.09 Imp. pints/0.65 US quarts) Screw plugs/screws are spring-loaded. [Dakar] ..0.56 l (0.98 Imp. pints/0.59 US quarts) • [GS] Press plugs down and insert retaining rings Oil grades ……BMW telescopic-fork oil to secure. • [Dakar] Lightly oil threads of screw plugs. Tightening torques: Oil drain plug……….
• Page 212
  E310081 Assembling telescopic fork • Install fork stabiliser (5), noting positions of the screws (length). Hand-tighten the screws. • Screw in the quick-release axle all the way, but do not tighten. • Place lower fork bridge in position. Hand-tighten clamping screws (4). •…
• Page 213
  (2), using a suitable mandrel. head mandrel, BMW No. 46 5 607, puller, BMW No. 31 4 820, two spacers, BMW No. 31 6 510, and lever, BMW No. 46 5 605, and make sure the bearing race is correctly seated. 31.18…
• Page 214
  E310140 • Use universal puller, BMW No. 00 7 500, jaws, BMW No. 31 3 672, and thrust piece, BMW No. 31 3 671, to pull the bearing off the steering tube. • Place new dust cap in position. •…
• Page 215
  32 Steering Contents Page Technical Data ……………………..3 Removing and installing left and right handlebar fittings ……..5 Removing and installing left handlebar fitting …………..5 Removing and installing clutch switch ……………….6 Removing and installing right handlebar fitting …………..7 Removing and installing handlebars ……………..9 Removing and installing clutch cable …………….10…
• Page 216
  32.2…
• Page 217
  Technical Data F 650 GS / GS Dakar Steering Type One-part tubular handlebars with cross-tie Steering lock angle ° 40 Steering tube diameter mm (in) 22 (0.87) Width across handlebars (handlebars only, mm (in) 770 (30.3) without grips) 32.3…
• Page 218
  32.4…
• Page 219
  E320040 Removing and installing left and right handlebar fittings Note: To avoid damage, use a protective apron for the tank, BMW No. 16 1 600. Removing and installing left handlebar fitting – Place motorcycle on its centre stand. – Remove seat.

• Page 220: 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 ( 46.5). • Release clutch switch on handlebar fitting. • Cut through the cable ties securing the cables at the handlebar and the multi-function switch.

• Page 221
  E320050 Removing and installing right handle- bar fitting – Place motorcycle on its centre stand. – Remove seat. – Remove left, right and centre covers ( 46.5). – [Dakar] Remove hand protectors ( 46.8). • Cut the cable tie at the handlebar. Important: Refer to notes on the hazards involved in handling brake fluid.
• Page 222
  • 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 223
  E320110 Removing and installing han- 32 71 008 Important: dlebars Note the position of the clamping blocks. Wide hole – Remove left handlebar fitting ( 32.5). spacing (arrow) to the front. – Remove right handlebar fitting ( 32.7). • Remove impact pad (1). •…
• Page 224
  E320140 Removing and installing 32 72 330 clutch cable E320160 • Make sure that slots in adjusting screw, locknut E320150 and lever fitting (arrow) are in line. • Pull back cable shroud (2). • • Disengage clutch cable (5) from release lever. Pull the cable forward through the slot and disen- •…
• Page 225
  Important: Make sure that the clutch cable is not kinked when installed. E000200 • After installing the cable, adjust clutch clearance by setting distance “B” by turning adjusting screw (2) on the clutch handlebar fitting. • Lock adjusting screw (2) with knurled nut (3). Distance “B”…

• Page 226: Throttle Cable

  E320170 Removing and installing • 32 72 305 Remove cover (4). • Remove fastener for throttle cable (1) from in- throttle cable strument cluster housing. • – Remove seat. Disengage throttle-cable adapter (3) and disen- – Remove left cover ( 46.5).

• Page 227
  Checking and adjusting Adjusting steering head bear- 32 00 454 32 00 454 steering head bearing play, ing play renewing if necessary (Inspections II and III) Important: Cover or mask off the instrument cluster and trim to Checking steering head bear- 32 00 454 prevent scratches.
• Page 228
  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 229
  Removing and installing left and right handlebar levers Removing and installing left 32 72 070 and right handlebar levers E000200 • After installing the cable, adjust clutch clearance by setting distance “B” by turning adjusting screw (4) on the clutch handlebar fitting. •…

• Page 230: Rear Wheel Drive

  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 reaction links …………….8 Removing and installing needle roller bearing in reaction link…

• Page 231
  33.2…
• Page 232
  Technical Data F 650 GS F 650 GS Dakar Rear suspension Suspension strut Central suspension strut pivoted to lever system. Spring base and rebound damping continuously adjustable. Suspension travel at wheel mm (in) 165 (6.50) 210 (8.268) at suspension strut mm (in) 47.5 (1.87)
• Page 233
  33.4…
• Page 234
  Removing and installing sus- • 33 53 000 Remove brake fluid reservoir from rear frame. • Remove lower fasteners securing rear frame to pension strut main frame. • – Remove exhaust manifold ( 18.6). Slightly pretension the strap. • • Secure front wheel in position.
• Page 235
  Removing and installing rear 33 17 350 swinging fork – Remove ABS sensor ( 34.15). – Remove rear wheel ( 36.7). E330080 • Remove the fastener securing the spring strut to frame (1). • Pull the spring strut with adjusting knob to the rear and remove.
• Page 236
  ABS sensor to holder ……..9 Nm F330100 Important: Protect mating faces (arrow) of the swinging fork from scratches by covering with masking tape or similar. • Drive needle roller races out of rear swinging fork with drift, BMW No. 33 6 661. 33.7…
• Page 237
  Link to angled lever ……..71 Nm F330120 • Press in the outer needle roller races with drift, BMW No. 33 6 651, and spacing sleeve, BMW No. 33 6 652. • Fit bearing bushes and sealing rings into swing- ing fork.
• Page 238
  • Press in sealing rings (3) with drift, • Drive out needle roller bearing (2) with drift, BMW No. 33 6 671, and spacing ring, BMW No. 33 6 620. BMW No. 33 6 672. • Fit bearing bushing (1).
• Page 239
  To simplify driving out, heat the angled lever to 100 °C (212 °F). Use temperature measuring device, BMW No. 00 1 900, to check heat rise. • Drive out needle roller bearings (8, 9) with drift, BMW No. 33 6 620.
• Page 240
  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 241
  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 242
  34 Brakes Contents Page Technical Data ……………………..3 Removing and installing front brake caliper …………..5 Removing and installing front brake pads ( 00.39) …………5 Removing and installing front brake pistons ……………6 Removing and installing front brake disc …………….7 Checking brake disc for wear ( 00.40) …………….7 Checking front brake disc for lateral runout…
• Page 243
  Contents Page Removing and installing rear ABS sensor …………..15 Removing and installing rear ABS sensor ring …………16 Removing and installing ABS control unit …………..16 Removing and installing front brake lines/hoses (with ABS) ……17 Removing and installing brake lines ………………17 Removing and installing front brake hoses …………….18 Removing and installing rear brake lines/hoses (with ABS) …….19…
• Page 244
  Technical Data F 650 GS / GS Dakar Brakes Brake fluid DOT 4 Brake actuation hydraulic Front wheel Front brake 2-piston floating caliper with rigidly mounted disc Brake disc dia. mm (in) 300 (11.81) Brake disc thickness mm (in) 5 (0.20) Minimum thickness mm (in) 4.5 (0.18)
• Page 245
  34.4…
• Page 246
  Removing and installing • 34 11 021 Installation is the reverse of the removal proce- dure. front brake caliper Note: Important: Replace sealing rings for brake line. Refer to notes on the hazards involved in handling brake fluid. • Press the brake caliper against the brake disc in Important: order to force the piston back.
• Page 247
  Keep the brake pistons parallel with their bores Do not insert your fingers between the pistons; when installing. risk of injury. • Using piston compressor BMW No. 34 1 500, if • Carefully press out brake pistons (5), using a necessary press the pistons fully back. •…
• Page 248
  • Remove retaining screws (1) from brake disc. BMW No. 36 3 600. • • [ABS] Remove sensor ring (2). Using dial gauge, BMW No. 00 2 510, measure • Remove brake disc. lateral runout. • Remove separators (3). Lateral runout “A” ….max. 0.25 mm (0.010 in)
• Page 249
  Removing and installing rear • 34 21 222 Installation is the reverse of the removal proce- dure. brake caliper Note: Important: Replace sealing rings for brake line. Refer to notes on the hazards involved in handling brake fluid. • Remove wheel cover together with chain cover. Important: •…
• Page 250
  Do not insert your fingers between the pistons; risk • of injury. Using piston compressor BMW No. 34 1 500, if necessary press the pistons fully back. • Carefully press out brake piston (3), using a compressed air gun at the brake line connection.
• Page 251
  E340110 Note: • Retaining screws (1) are secured with Loctite 243 Attach dial gauge holder, BMW No. 00 2 500, to and should be heated if necessary before removal. the rear swinging fork. • Using dial gauge, BMW No. 00 2 510, measure •…
• Page 252
  Removing and installing front brake Removing and installing 32 72 119 master cylinder handbrake lever ( 32.15) – Place the motorcycle on its main (centre) stand. Replacing primary sealing boot, rear brake master cylinder ( 00.45) Important: Refer to notes on the hazards involved in handling brake fluid.
• Page 253
  Removing and installing rear 34 31 001 brake master cylinder Important: Top up brake fluid and bleed brake system. – Place the motorcycle on its main (centre) stand. Operate brake several times until brake pads are bedded. Important: Refer to notes on the hazards involved in handling brake fluid.
• Page 254
  Removing and installing Checking play at piston thrust rod, 35 21 000 footbrake lever adjusting if necessary Checking play at piston thrust rod E340040 • E340270 Remove footrest plate (1). • Disengage piston thrust rod (4). • • Remove hexagon fit bolt (2). With no load applied to the brake pedal, i.e.

• Page 255: 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 ( 46.5). E340260 • Insert feeler gauge (1) 0.2 mm (0.008 in) thick be- tween the lug of the brake pedal and the stop on the frame (arrow).

• Page 256
  Removing and installing Removing and installing rear 34 51 610 34 52 111 front ABS sensor ring ABS sensor – Place motorcycle on its centre stand. – Remove seat. • Important: Remove wheel cover together with chain cover. Do not operate the brake with the wheel removed. –…
• Page 257
  34.21). Important: All work on the ABS control unit must be carried out Tightening torques: by an authorised BMW workshop. ABS sensor to holder ……..9 Nm Wheel cover bracket to swinging fork….. 9 Nm – Remove rear frame ( 46.14).
• Page 258
  Removing and installing front brake Important: lines/hoses (with ABS) Top up brake fluid and bleed brake system. Operate brake several times until brake pads are bedded. Important: If the vehicle is equipped with ABS, the brake sys- tem has to be bled using the BMWMoDiTeC, and the Control Units, Toolbox ABS, routine;…
• Page 259
  Important: Refer to notes on the hazards involved in handling brake fluid. • Drain the brake system. • Disconnect brake hose from brake caliper. E340180 • Disconnect brake line to brake caliper (4) and brake line to brake master cylinder (3) at inter- face.
• Page 260
  Removing and installing rear brake lines/hoses (with ABS) Important: If the vehicle is equipped with ABS, the brake sys- tem has to be bled using the BMWMoDiTeC, and the Control Units, Toolbox ABS, routine; this proce- dure is supplementary to that described in the Re- pair Manual.
• Page 261
  Checking/adjusting front 34 52 544 Important: ABS sensor gap Top up brake fluid and bleed brake system. Operate brake several times until brake pads are bedded. Important: Check the ABS sensor gap if the ABS sensor, sen- sor ring, wheel bearing, front wheel, telescopic fork, spacer, quick-release axle, or brake disc has been Tightening torques: replaced.
• Page 262
  Checking and adjusting gap 34 52 544 of speed/rear ABS sensor Important: Check the speed/ABS sensor gap if the ABS sen- sor, sensor ring, brake-caliper holder, spacer sleeve, rear wheel, or wheel bearing has been re- placed. – Take the weight off the rear wheel. •…
• Page 263
  36 Wheels and tyres Contents Page Technical Data ……………………..3 Removing and installing front wheel ……………..5 Removing front wheel ……………………5 Installing the front wheel ………………….5 Removing and installing front wheel bearing …………..6 Removing left-hand wheel bearing ………………….6 Removing right-hand wheel bearing ………………..6 Installing wheel bearings ……………………7 Removing and installing rear wheel ……………….7…
• Page 264
  36.2…
• Page 265
  Technical Data F 650 GS F 650 GS Dakar Wheels and tyres Rim size Front 2.50″x19″ 1.60″x21″ Rear 3.00″x17″ Vertical runout mm (in) 2.0 (0.079) Lateral runout mm (in) 2.0 (0.079) Maximum permissible imbalance g (oz.) 5 (0.20) Tyre size…
• Page 266
  36.4…

• Page 267: Front Wheel

  Removing and installing Installing the front wheel 36 30 300 36 30 300 front wheel Removing front wheel 36 30 300 Important: – Place motorcycle on its centre stand. When installing, avoid damage to ABS sensor, sen- – Take load off front wheel/lift clear of ground. sor ring, brake disc and brake pads.

• Page 268: 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 269
  • Install the spacer bushing. • Drive in the right-hand wheel bearing with drift, BMW No. 36 6 600, until seated, making sure that the load is supported only on the left-hand wheel bearing. Note: The left-hand bearing must be seated on the stop in the wheel hub.

• Page 270: Wheel Bearings

  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 271
  • Drive in the right-hand wheel bearing with drift, BMW No. 36 6 600, making sure that the load is supported only on the left-hand wheel bearing. Note: The left-hand bearing must be seated on the stop in the wheel hub.
• Page 272
  – Remove and install front wheel ( 36.5). • Remove tyre. Note: Use nipple tensioner, BMW No. 36 3 800. Outer left spokes • Release spoke nipple (1). • Pull spoke (2) out of wheel hub. Inner left spokes •…
• Page 273
  F360130 • Outer right spokes Installation is the reverse of the removal proce- • Release spoke nipple (1). dure: pay particular attention to the following. • Release spoke nipple (2). – After installing, centre the wheel rim ( 36.13). • Turn spoke (3) outwards.
• Page 274
  Pull spoke (8) out of wheel hub. • Installation is the reverse of the removal proce- Note: dure: pay particular attention to the following. Use nipple tensioner, BMW No. 36 3 800. – After installing, centre the wheel rim ( 36.13). Outer left and right spokes •…
• Page 275
  36 3 600 F360150 Checking and centering front 36 32 528 Note: and rear wheel rims Apply the dial gauge, BMW No. 00 2 510, only to – Remove the wheels. the machined inner surface of the wheel rim. Checking rims •…
• Page 276
  Centering lateral runout Centering vertical runout F360160 F360160 Important: Important: Never attempt to eliminate all the lateral runout at Spokes which protrude from the spoke nipples must only one or two spokes. be shortened. • Correct vertical runout “H” by tightening the Note: spokes at left and right (arrow).
• Page 277
  [Rear wheel] Remove chainwheel carrier com- plete with chainwheel from the rear-wheel hub. • Level the balancing unit, BMW No. 36 3 600, at bubble gauge (2) in the baseplate. • Pass the balancing shaft, BMW No. 36 3 617, through the wheel bearings.
• Page 278
  46 Frame Contents Page Technical Data ……………………..3 Removing and installing fairing ………………..5 Removing and installing covers ………………..5 Removing and installing left and right covers ………………5 Removing and installing centre cover ………………..5 Removing and installing cockpit fairing ……………..6 Removing and installing fairing bracket ………………..7 [Dakar] Removing and installing hand protectors ………….8 Removing and installing engine guard…
• Page 279
  46.2…
• Page 280
  Technical Data F 650 GS F 650 GS Dakar Frame Frame Bridge-type frame with bottom truss Type plate location Main frame upper rail, right Frame No. location On right of steering head Max. height (windscreen) mm (in) 1,265 (49.80) 1,412 (55.59) Maximum width (across mirrors) mm (in) 890 (35.039)
• Page 281
  46.4…

• Page 282: Removing And Installing Fairing

  E460044 Removing and installing fairing 46 63 Removing and installing centre cover – Remove left and right covers. • Removing and installing covers Remove screws (2) securing the centre cover. 46 63 • Lift off the centre cover (5). • –…

• Page 283
  E460050 Removing and installing cockpit • 46 63 Remove the fasteners securing the cockpit fairing (2). fairing • Disconnect multi-pin plug (5). • – Remove left and right covers ( 46.5). Pull the rubber boot to the rear. • Pull the socket of the sidelight out of the head- light housing.
• Page 284
  • Installation is the reverse of the removal proce- 46 63 198 Removing and installing fairing dure: pay particular attention to the following. bracket • [Dakar] Align retainer (11) in fairing bottom – Remove instrument cluster ( 62.6). • section (8). Unclip connector for turn indicator.
• Page 285
  [Dakar] Removing and installing Removing and installing front 46 63 46 61 000 hand protectors mudguard – Place motorcycle on its centre stand. – Place motorcycle on its centre stand. [GS] E000311 E460043 • Release fasteners (2). • Remove hand protector (1). [Dakar] •…
• Page 286
  Removing and installing left/right Removing and installing left/right 46 63 46 63 rear trim panel grip – Remove seat. – Open the stowage compartment. – Remove left/right silencer ( 18.5). • Remove turn-indicator cover. • Disconnect cable and pull through. •…
• Page 287
  Removing and installing number- 46 63 plate panel – Open the stowage compartment. E460180 • Remove nuts (3). • Disconnect plugs. • Remove tail light. E460170 • Remove 2 fasteners (1) at bottom. E460180 • [Dakar] Remove spray guard (4). E460190 •…
• Page 288
  Removing and installing base of Removing and installing seat latch 46 63 46 63 stowage compartment and partition – Remove seat. – Remove seat. – Remove number plate panel ( 46.10). – Remove left and right grips ( 46.9). E460160 •…
• Page 289
  Removing and installing rear 46 62 200 mudguard – Remove exhaust manifold ( 18.6). – Remove chain takeup roller ( 27.5). E460150 • Release fasteners (1). E460140 • Release fasteners (2). • Remove mudguard. • Installation is the reverse of the removal proce- dure.
• Page 290
  Raising, removing and installing rear frame Raising rear frame – Remove exhaust manifold ( 18.6). • Secure front wheel in position. E330070 Important: Do not raise the rear frame all the way, as it is seated against the lock of the seat (arrow). •…
• Page 291
  Disconnect the plug for rear light/turn indicator (5). • Close off fuel supply line (1) and the fuel return line (2) with hose clips, BMW No. 13 3 010. • Open the hose clips (arrows) and disconnect the fuel lines from the fuel-pump unit.
• Page 292
  • Close hose clamps with pliers, BMW No. 13 1 500. Tightening torques: Oxygen sensor to exhaust……45 Nm Exhaust manifold to cylinder head….20 Nm Clamp for silencer ……..

• Page 293: Removing Frame

  E460080 Removing frame 46 51 120 – Remove engine ( 11.21). – Remove battery ( 61.10). – Remove throttle stub pipe ( 13.8). – Remove oil tank. – Remove rear frame ( 46.14). • Remove heat shield for exhaust from footrest. E130100 •…

• Page 294
  E460090 E460240 • • Remove starter relay (5). Unclip cable for ABS sensor from holder for • Release fasteners (7). Remove battery holder (8). pressure modulator. • • Remove fastener (6) securing electrics box cover. Disconnect plug (12) from pressure modulator. •…
• Page 295
  • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Note: After installing the rear swinging fork, do not fully tighten the stud in the swinging-fork pivot until the engine is installed. After installing the brake lines, install the rear frame first, before installing the engine.
• Page 296
  E460250 Removing and installing right Removing and installing left 46 71 061 46 71 061 footrest footrest • • Remove 3 screws (4). Remove 3 screws (3). • • Remove footrest (5). Remove footrest (2). • • Remove keeper (8). Disassemble the right footrest in the same way as the left footrest.
• Page 297
  Release fasteners (1, 2). • • Installation is the reverse of the removal proce- Use hook, BMW No. 46 5 721, to disengage dure: pay particular attention to the following. springs (3). Remove plate (6) with the springs. • Remove retaining ring (1).
• Page 298
  Removing and installing main 46 52 000 (centre) stand E460220 Important: Note spring loading. • Use hook, BMW No. 46 5 721, to disengage springs (5). • Remove fasteners (1) on left and right. • Remove the main stand •…
• Page 299
  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 300
  51.2…
• Page 301
  Technical Data F 650 GS / GS Dakar 51.3…
• Page 302
  51.4…
• Page 303
  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 304
  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 305
  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 306
  61 General electrical equipment Contents Page Technical Data ……………………..3 Wiring harness ……………………..5 View from left ……………………….5 View from right ……………………..6 [Dakar] General view, left side ………………..7 [Dakar] General view, right side ………………..8 Component positions in electronic equipment box ……….9 Relay positions in electronic equipment box …………..9 Connectors, electronics box…
• Page 307
  Contents Page [GS] Removing and installing voltage regulator …………15 [Dakar] Removing and installing voltage regulator ……….15 61.2…
• Page 308
  Technical Data F 650 GS / GS Dakar General electrical equipment Circuit voltage V 12 Battery A/h 12 61.3…
• Page 309
  61.4…
• Page 310
  Wiring harness View from left E619011 61.5…
• Page 311
  View from right E619020 61.6…
• Page 312
  [Dakar] General view, left side 61.7…
• Page 313
  [Dakar] General view, right side 61.8…
• Page 314
  Component positions in electronic E619012 equipment box Connectors, electronics box 5 Ignition light switch Relay positions in electronic equip- 6 Brake light switch ment box 7 Multi-function switch, right 8 Multi-function switch, left 1 Relief relay 9 Clutch switch 2 BMS relay 10 ABS switch 3 Diode relay 4 Flasher unit…
• Page 315
  Removing and installing bat- Removing and installing bat- 61 21 010 61 21 100 tery tery carrier – Place motorcycle on its centre stand. Warning: – Remove seat. Battery acid is highly caustic. – Remove left, right and centre covers ( 46.5).
• Page 316
  Replacing fuses Removing and installing 61 13 011 electronic equipment box Motorcycle fuses – Remove seat. • Open the cover of the fuse box. – Remove battery carrier ( 61.10). • • Replace the defective fuse. Disconnect the expansion tank from the radiator, pull it to one side and leave it to dangle from the Fuses hose.
• Page 317
  Removing and installing side Removing and installing 61 31 302 61 31 310 stand switch rear-brake switch for brake light – Place motorcycle on its centre stand. – Remove seat. – Remove engine guard ( 46.8). – Remove right cover ( 46.5).
• Page 318
  Removing and installing • 61 31 300 Remove the fasteners securing the oil tank and allow the oil tank to dangle to one side on the front-brake switch for brake light hoses. • Remove the starter relay from the holder. •…
• Page 319
  Removing and installing • 61 33 000 Installation is the reverse of the removal proce- dure: pay particular attention to the following. horn • Clean the threads of the neutral-indicator switch and coat with Loctite 243. – Remove front mudguard ( 46.8).
• Page 320
  [GS] Removing and installing volt- [Dakar] Removing and installing age regulator voltage regulator – Place motorcycle on its centre stand. – Place motorcycle on its centre stand. – Secure front wheel in position. – Secure front wheel in position. – Remove seat.
• Page 321
  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 322
  62.2…
• Page 323
  Technical Data F 650 GS / GS Dakar 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 Neutral W5/1.2 — 12V 1.2W Oil pressure W5/1.2 — 12V 1.2W Water temperature W5/1.2 — 12V 1.2W…
• Page 324
  62.4…
• Page 325
  E620050 Telltale/warning lights 1. Water temperature 2. Oil pressure 3. Neutral 4. High (main) beam headlight 5. Fuel gauge 6. ABS 7. Flashing turn indicator 8. Speedometer lighting 9. Revolution counter lighting 62.5…
• Page 326
  Removing and installing instru- Replacing telltale/warning lights 62 11 200 ment panel – Place motorcycle on its centre stand. – Remove instrument panel. – Remove left and right covers ( 46.5). Note: Note washers and rubber ring. • Remove the windscreen. •…
• Page 327
  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 328
  63 Lights Contents Page Technical Data ……………………..3 Removing and installing headlight ………………5 Removing and installing rear light ………………5 Replacing bulb ……………………..6 Bulb for low-beam headlight/high-beam headlight …………6 Bulb, parking light ………………………6 Flashing turn indicator ……………………7 Rear lights ……………………….7 Checking and adjusting headlight beam throw …………7 Vertical adjustment …………………….7…
• Page 329
  63.2…
• Page 330
  Technical Data F 650 GS / GS Dakar Lights Headlight Halogen headlight with 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…
• Page 331
  63.4…
• Page 332
  E630020 Removing and installing Removing and installing rear 63 12 090 63 21 380 headlight light • – Place motorcycle on its centre stand. Remove the lid of the stowage compartment. • – Remove left and right covers ( 46.5). Remove the number plate holder complete with the rear light from the frame.
• Page 333
  • 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 334
  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 •…

• Page 1

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• Page 2

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• Page 3
  We congratulate you on your choice of a motorcycle from We hope that you will enjoy rid- BMW and welcome you to the ing your BMW and that all your community of BMW riders. journeys will be pleasant and Familiarise yourself with your new safe.

• Page 4: Table Of Contents

  Grip heating ….52 Warnings issued by the on- BMW Motorrad ABS ..53 Technical data ….7 board computer .

• Page 5
  General instructions ..82 Cleaning easily damaged BMW Motorrad service ..142 Power socket ….82 components .

• Page 7: General Instructions

  General instructions Overview ……6 Abbreviations and symbols ..6 Equipment .

• Page 8: Overview

  BMW optional ex- overview of your motorcycle. All tras originally ordered. Indicates the end of an maintenance and repair work on item of information.

• Page 9: Equipment

  This Rider’s Manual are quoted to the Rider’s Manual describes option- standards and comply with the al extras (OE) offered by BMW tolerance requirements of the and selected optional accessor- Deutsches Institut für Normung ies (OA). This explains why the e.V.

• Page 11: General Views

  General views General view, left side ….11 General view, right side … . . 13 Underneath the seat .

• Page 13: General View, Left Side

  General view, left side Power socket ( Seat lock ( Engine-oil filler neck and oil dipstick (…

• Page 15: General View, Right Side

  General view, right side Fuel filler neck ( Brake-fluid reservoir, rear Vehicle Identification Num- ber (VIN) (on steering-head bearing) Type plate (on steering- head bearing) Brake-fluid reservoir, front Coolant level indicator (be- hind side panel) ( Coolant filler neck (behind side panel) ( Adjuster for spring preload, rear (…

• Page 16: Underneath The Seat

  Underneath the seat Location of first-aid kit (OA) Toolkit Payload table Table of tyre pressures Helmet holder ( Rider’s Manual Tool for adjusting spring preload (…

• Page 17: Underneath The Trim Panel

  Underneath the trim panel Battery ( 118) Intake air silencer ( 116)

• Page 18: Handlebar Fitting, Left

  Handlebar fitting, left with on-board com- puter Operating the on-board computer ( with BMW Motorrad Operating the ABS Horn Flashing turn indicators, left ( Hazard warning flashers High-beam headlight and headlight flasher (…

• Page 19: Handlebar Fitting, Right

  Handlebar fitting, right Emergency off switch (kill switch) ( Starter button ( with heated handlebar grips Grip heating ( Flashing turn indicators, right ( Hazard warning flashers Cancel button, flashing turn indicators ( Pushbutton, cancel hazard warning flashers (…

• Page 20: Instrument Panel

  Instrument panel Telltale lights ( Speedometer Operation of the clock Multifunction display Operating the odometer with on-board com- puter Operation of the stopwatch Telltale light, anti-theft alarm (OE) Sensor for instrument light- with on-board com- puter Warning light for engine rpm ( Rev.

• Page 21
  The instrument-cluster lighting has automatic day and night switchover.

• Page 22: Headlight

  Headlight Low-beam headlight High-beam headlight Side light…

• Page 23: Status Indicators

  Status indicators Standard status indicators ..22 Status indicators with on-board computer ……23 Status indicators with tyre pressure monitoring (RDC) .

• Page 24: Standard Status Indicators

  Standard status Telltale lights Service-due indicator indicators Multifunction display High-beam headlight If the next service is due in less Flashing turn indicators, than one month, the date for the next service 1 is shown briefly left Clock ( after the Pre-Ride Check com- Idle Odometer and tripmeters pletes.

• Page 25: Status Indicators With On

  Gear indicator ( preferably an authorised BMW the forecast due date 2. If the Coolant temperature Motorrad dealer. countdown distance to the odo-…

• Page 26: (Rdc)

  Standard warnings Coolant temperature The horizontal bars above Mode of presentation the temperature symbol indicate the coolant temperature. Fuel capacity The horizontal bars above the fuel-pump symbol in- dicate the remaining quantity of fuel. The top bar is larger than Tyre-pressure readout the others and the quantity of fuel it represents is significantly…

• Page 27
  The possible warnings are listed on the next page. Warning symbols 1 and 2 can appear on the multifunction dis- play. Text warnings such as 3, for example, appear in the odo- meter panel and are accompan- ied by warning-triangle symbol 4. If two or more warnings occur at the same time, all the appropriate warning lights and warning sym-…
• Page 28
  Warnings, overview Telltale lights Status indicators Meaning Lights up yellow Appears on the dis- Electronic immobiliser active ( play appears on the display. Lights up Fuel down to reserve ( Lights up red Flashes Coolant temperature too high ( Lights up yellow Appears on the dis- Engine in emergency-operation mode play…

• Page 29: Electronic Immobiliser

  Coolant temperature too switched on so that the radiat- placed, preferably by an au- high or fan continues to operate. thorised BMW Motorrad dealer. General warning light shows If the coolant temperature is red. Fuel down to reserve frequently too high, have the…

• Page 30
  BMW gine runs in emergency operating Possible cause: mode. Motorrad dealer. The engine-oil level is too low. You can continue to ride, but Check the engine oil level Engine in emergency- bear in mind that the usual en- 93).

• Page 31: Warnings Issued By The On-Board Computer

  Possible cause: ABS warnings Low-beam headlight, parking light, rear-light, brake-light or Mode of presentation turn-indicator bulb defective. with BMW Motorrad ABS Visually inspect to ascertain which bulb is defective. Replacing low-beam headlight The ambient-temperature read- bulb ( 110). ing flashes.

• Page 32
  Possible national variant. The detailed descriptions relating to BMW Motorrad ABS start on page ( 76), and you will find an overview listing the possible warnings on the next page.
• Page 33
  Warnings, overview Telltale lights Status indicators Meaning Flashes Self-diagnosis not completed ( Lights up ABS deactivated ( Lights up ABS fault (…

• Page 34: Rdc Warnings

  Self-diagnosis not Possible cause: an authorised BMW Motorrad dealer. completed The rider has switched off the ABS system. with BMW Motorrad ABS RDC warnings with BMW Motorrad ABS ABS warning light flashes. Activate the ABS function with tyre pressure monitoring 53).

• Page 35
  ‘General’ warning light flashes red. The detailed descriptions relating to BMW Motorrad RDC start on page ( 78), and you will find an overview listing the possible warnings on the next page.
• Page 36
  Warnings, overview Telltale lights Status indicators Meaning Lights up yellow Appears on the dis- Tyre pressure close to limit of permitted play tolerance ( The critical pres- sure flashes. Flashes red Appears on the dis- Tyre pressure outside permitted toler- play ance ( The critical pres-…
• Page 37
  General warning light shows workshop, preferably an yellow. Warning-triangle symbol authorised BMW Motorrad appears on the display. dealer. Warning-triangle symbol appears on the display. If you are unsure whether the The critical pressure flashes.
• Page 38
  RDC toms. Under these circum- specialist workshop, preferably stances: readings. Assume that a per- an authorised BMW Motorrad manent fault has not occurred Have the fault rectified by a dealer. unless the ‘General’ warning specialist workshop, preferably…

• Page 39: Anti-Theft Alarm Warnings

  Seek the advice of a specialist only briefly after the pre- workshop, preferably an author- ride check completes. ised BMW Motorrad dealer. Possible cause: The integral battery in the tyre- pressure sensor has lost a sig- nificant proportion of its original capacity.

• Page 41: Operation

  Grip heating……52 BMW Motorrad ABS ….53…

• Page 42: Ignition Switch And Steering Lock

  Electrically powered accessor- with topcase ies remain operational for a lim- If you wish you can arrange to with BMW Motorrad ABS ited period of time. have the cases and the top- The battery can be recharged ABS self-diagnosis is case fitted with locks that can via the on-board socket.

• Page 43: Electronic Immobiliser Ews

  The motorcycle’s electronics keys only through an authorised Handlebars locked. exchange certain continuously BMW Motorrad dealer. The keys Key can be removed. changing signals with the elec- are part of an integrated secur- tronics in the key; these signals…

• Page 44: Clock

  been barred can subsequently be Repeatedly press the button with on-board computer cleared and reactivated for use. until the hours number is cor- rect. Clock Press and hold down the but- ton until the minutes number 3 Setting clock flashes. Attempting to set the clock Repeatedly press the button while riding the motorcycle…

• Page 45: On-Board Computer

  The following values can be dis- Press and hold down button 2 Repeatedly press button 1 until played: until the tripmeter reading is the reading shows the value reset. you want. Total distance covered 3 On-board computer Trip I Tripmeter 1 ( Trip II Tripmeter 2 ( with on-board computer…

• Page 46: Average Speed

  Average speed Average speed temporarily appears on the display. Average consumption If ambient temperature drops be- low 3 °C the temperature dis- play flashes to draw your atten- Current consumption tion to the risk of black ice form- ing. The display automatically Range switches from any other mode to the temperature reading when…

• Page 47
  Average consumption Press and hold down button 1 Press and hold down button 1 until the average-speed reading until the average-consumption Average consumption 1 is cal- is reset. reading is reset. culated by dividing the distance covered since the last reset by the corresponding amount of fuel used.
• Page 48
  The calculated range is only same as the average that can be an approximate reading. viewed on the display. Consequently, BMW Motorrad On account of the shape of the recommends that you should not tank, accurate measurement is try to use the full range before possible only when fill level is refuelling.

• Page 49: Operating Stopwatch

  Stopwatch use button 2 to operate the on- board computer. The stopwatch continues to time in the background if you switch back temporarily to the odometer reading. Similarly, the stopwatch continues timing if you temporar- ily switch off the ignition. Operating stopwatch When the stopwatch is stopped, press button 2 to…

• Page 50
  Changing button : Stopwatch operated by telltale light 1 flashes red to in- means of the INFO button on dicate that the engine is red- functions the handlebar fitting. lining. : Stopwatch operated by The signal remains active un- means of button 2 in the in- til you shift up or reduce engine strument panel.

• Page 51: Tyre Pressure Monitoring (Reifendruck-Control) Rdc

  Repeatedly press button 1 until ing on the right is the rear tyre — — pressure. appears dir- the reading shows the mode ectly after the ignition is switched you want. on, because the sensors do not : Redline warning activated. transmit tyre pressures until the : Redline warning deactiv- first time the motorcycle acceler-…

• Page 52: Turn Indicators

  Parking light When the engine is not The turn indicators are can- running you can switch on celled automatically after Switch off the ignition. the lights by switching on the ig- you have ridden for approxim- nition and either switching on the ately 10 seconds, or covered a high-beam headlight or operating distance of about 200 m.

• Page 53: Hazard Warning Flashers

  Hazard warning flashers Operating hazard warning flashers Switch on the ignition. The hazard warning flash- ers place a strain on the battery. Do not use the hazard Press button 2 to switch on Press buttons 1 and 2 at the warning flashers for longer than the right flashing turn indicator.

• Page 54: Emergency Off Switch

  Emergency off switch (kill switch) Normal operating position Grip-heating switch (run) Engine switched off. The handlebar grips have two- Emergency off switch (kill stage heating. Stage two is for You cannot start the engine switch) heating the grips quickly: it is ad- unless the kill switch is in visable to switch back to stage the run position.

• Page 55: Bmw Motorrad Abs

  ABS warning light remains Release button 1 within two seconds. BMW Motorrad ABS The ABS warning light re- The ABS function is deactiv- with BMW Motorrad ABS mains off or continues to ated. flash. Deactivating ABS function The ABS function is activated.

• Page 56: Clutch

  If you switch the ignition off between the clutch lever and the handlebar grip. then on again and the ABS light comes back on, there is a Turn adjusting screw 1 fault in the ABS. counter-clockwise to reduce the span between the clutch Clutch lever and the handlebar grip.

• Page 57: Mirrors

  Mirrors Adjusting mirror arm Push the protective cap over the threaded fastener. Adjusting mirrors Spring preload Setting It is essential to set spring pre- load of the rear suspension to suit the load carried by the mo- torcycle. Increase spring preload when the motorcycle is heavily loaded and reduce spring preload Push protective cap 1 up over…

• Page 58: Damping

  Adjust the damping characteristic to suit spring preload. If you want to increase spring preload, use the tool from the on-board toolkit to turn knob 2 clockwise. If you want to reduce spring preload, use the tool from the on-board toolkit to turn knob 2 Remove on-board toolkit 1.

• Page 59: Tyres

  Adjusting damping for Basic setting of rear-sus- rear wheel pension damping charac- Make sure the ground is level teristic and firm and place the motor- Turn adjusting screw as far cycle on its stand. as it will go clockwise, then back it off 2 turns.

• Page 60: Headlight

  Adjusting headlight for shop, preferably an au- Check tyre pressures against driving on left/driving on thorised BMW Motorrad deal- the data below. right er, if you are unsure whether Tyre pressure, front If the motorcycle is ridden in a…

• Page 61: Seat

  Seat Adjust beam throw by tilting the headlight slightly about its Removing seat horizontal axis. Make sure the ground is level Tighten screws 1 on left and and firm and place the motor- right. cycle on its stand. Beam-throw basic setting Lift seat 2 at the front and re- lease the key.

• Page 62: Helmet Holder

  Installing seat met being damaged by the hot end silencer. If possible, attach the helmet on the right-hand side of the motorcycle. The helmet catch can scratch the panelling. Make sure the lock is out of the way when you hook the helmet Use a plastic-sheathed steel into position.

• Page 63: Riding

  Riding Safety instructions ….62 Checklist ……64 Starting .

• Page 64: Safety Instructions

  Speed neys, and to every season of alcohol or drugs will ad- If you ride at high speed, always the year. Your authorised BMW versely affect your perception bear in mind that various bound- Motorrad dealer will be glad to…

• Page 65: Catalytic Converter

  Risk of poisoning Catalytic converter Risk of fire Exhaust fumes contain carbon If misfiring causes unburned fuel Temperatures at the exhaust are monoxide, which is colourless to enter the catalytic converter, high. and odourless but highly toxic. there is a danger of overheating Flammable materials (e.g.

• Page 66: Checklist

  Tampering with the Checklist Starting control unit of the Side stand Use the following checklist to electronic engine- check important functions, set- You cannot start the motorcycle management system tings and wear limits before you with the side stand extended and ride off.

• Page 67: Starting Engine

  Starting engine with BMW Motorrad ABS engine, or use jump leads and a donor battery to start. ABS self-diagnosis is performed. ( The engine starts. If the engine refuses to start, consult the troubleshooting chart in the section entitled «Technical data». (…

• Page 68
  In the block of telltale and Phase 3 ABS self-diagnosis warning lights on the left: The rev. counter and speedo- with BMW Motorrad ABS Telltale light for high-beam meter needles both swing back BMW Motorrad ABS performs headlight to rest. At the same time, all the…

• Page 69: Running In

  This running in pro- an authorised BMW Motorrad <5000 min cedure is essential if the tyres are dealer. No full-load acceleration.

• Page 70: Riding Off-Road

  The brake pads will wear Tyre pressures reduced for You can deactivate the ABS more rapidly if you ride fre- off-road riding impair the function of the BMW Motorrad quently on unsurfaced tracks or motorcycle’s handling character- ABS for off-roading ( 53).

• Page 71
  After the motorcycle has Especially after repair and main- been washed, ridden tenance work, make sure that the with BMW Motorrad ABS through water or ridden in brake discs and brake pads are the rain, the brake discs and ABS has to intervene to keep free of oil and grease.

• Page 72: Parking Your Motorcycle

  Parking your Removing motorcycle Slowly lean the motorcycle to the side until its weight is taken from side stand motorcycle by the stand and dismount to Unlock the steering lock. Placing motorcycle on the left. From the left, grip the handle- side stand If the motorcycle is on the bars with both hands.

• Page 73: Refuelling

  Placing motorcycle on Refuelling Excessive movements could cause the centre centre stand Fuel is highly flammable. A stand to retract, and the with centre stand naked flame close to the motorcycle would topple in fuel tank can cause a fire or ex- consequence.

• Page 74: Securing Motorcycle For Transporta

  Make sure the ground is level Recommended fuel and firm and place the motor- grade cycle on its side stand. The volume of the tank can 91 ROZ/RON (Regular un- leaded) be utilised to the full only when the motorcycle is propped Usable fuel capacity on its side stand.

• Page 75
  tected against scratching. Use adhesive tape or soft cloths, for example, for this purpose. At the rear, secure the straps Risk of damaging compon- to the rear frame on both sides ents. and tighten the straps. Take care not to trap Tighten all the straps uniformly;…

• Page 77: Engineering Details

  Engineering details Brake system with BMW Motorrad ABS ……. . 76…

• Page 78: Brake System With Bmw

  BMW Motorrad ABS will ing force that can be transmit- much lower coefficients of fric- be unable to prevent the rear ted to the road can drop to zero.

• Page 79: Motorrad Abs

  The system is not op- of maintenance. Rear wheel rotating with the timised for special requirements In order to ensure that the BMW motorcycle held stationary by that apply under extreme com- Motorrad ABS is always main- applying the front brake (burn-…

• Page 80: Tyre Pressure Monitoring Rdc

  BMW Motorrad ABS is unable to stop. is always 20 °C. The air lines counteract their effects. available to the public in petrol The control unit can adminis-…

• Page 81
  A warning is also issued if tyre pressure drops sharply but stays within the permitted tolerance. Pressure adaptation Compare the RDC readings on the multifunction display with the value in the table on the inside cover of the Rider’s Manual. Then use the air line to compensate for the difference between the RDC reading and the value in the table.

• Page 83: Accessories

  Accessories General instructions ….82 Power socket ….. . . 82 Luggage .

• Page 84: General Instructions

  BMW motorcycles proved by BMW for this purpose. without constituting a safety haz- Genuine BMW parts and ac- ard. Country-specific official au-…

• Page 85: Luggage

  Luggage tem is minimised, the supply to speed limit for riding with cases the power socket is cut off ap- on the motorcycle. Correct loading proximately 15 minutes after the Payload of cases Overloading and imbal- ignition is switched off, and it is anced loads can adversely also temporarily interrupted dur- affect the motorcycle’s handling.

• Page 86
  Lashing luggage the speed limit for riding with a Maximum permissible rear softbag on the motorcycle. speed for riding with top- case fitted to the motorcycle Payload of rear softbag see label in topcase max 1.5 kg with tank rucksack Note the maximum permissible Maximum permissible speed for riding with the…

• Page 87: Cases

  Opening cases Position luggage strap 2 as Push yellow button 4 down shown here with a stuffbag as and at the same time pull the Turn key 1 in the case lock to example. lid of the case out. right angles with the forward Check that the luggage is se- direction of travel.

• Page 88
  Removing cases tion of travel and remove the key from the lock. Adjusting case volume Open the case and remove all its contents. Close case lid 5. The lid engages with an aud- Turn key 1 in the case lock to ible click.
• Page 89
  Installing cases Turn the case toward the mo- torcycle, pushing mount 9 all the way onto mushroom head 8. Pull red release lever 4 up. Latching flap 5 pops up. Fully open latching flap 5, if ne- Fully open the latching flap. cessary pulling up red release Take a firm grip of the handle lever 4.

• Page 90: Topcase

  Topcase Closing the carry handle while the topcase lock is with topcase horizontal can result in damage to the locking tongue. Opening topcase Make sure that the topcase lock is vertical when you close the carry handle. Push carry handle 3 up. The handle engages with an Push yellow button 4 forward audible click.

• Page 91
  Adjusting topcase volume Removing topcase Latching flap 5 pops up. Fully open latching flap 5. Take a firm grip of the handle and lift the topcase out of the holder. Installing topcase Open the topcase and remove Turn key 1 in the topcase lock all its contents.
• Page 92
  Push latching flap 5 fully closed and hold it in this position. Push red release lever 4 for- ward. The latching flap engages. Close the carry handle. Turn the key to the horizontal position and remove. Engage the topcase in front holders 6 of the topcase carrier plate.

• Page 93: Maintenance

  Maintenance General instructions ….92 Jump starting ….. . 117 Toolkit .

• Page 94: General Instructions

  22 ledge of motorcycle technology. Reversible screwdriver for removing the quick- If you are in doubt consult a spe- blade release axle from the front cialist workshop, preferably your With star-head and Torx wheel authorised BMW Motorrad deal- Electric torch…

• Page 95: Engine Oil

  Socket the engine will be operated with the incorrect quantity of oil. Open-ended spanners of In order to ensure that the en- various sizes gine oil level is read correctly, Adapter check the oil level only after a To accommodate the 1/ lengthy trip.

• Page 96: Brake System

  Remove the oil dipstick and preferably an authorised BMW also applies if the oil level is too check the oil level. Motorrad dealer. high. Always make sure that the oil Install the oil dipstick. level is correct. Topping up engine oil Top up the engine oil to the specified level.

• Page 97: Brake Pads

  Make sure the ground is level tem performed by a specialist and firm and place the motor- workshop, preferably an author- cycle on its stand. ised BMW Motorrad dealer. Checking operation of brakes Brake-pad wear limit, Pull the handbrake lever.

• Page 98: Brake Fluid

  Have the brake pads replaced by a specialist workshop, preferably an authorised BMW Brake-pad wear limit, rear Motorrad dealer. Brake fluid min 1.0 mm (Friction pad only, without backing plate.

• Page 99
  Check the brake fluid level in Have the defect rectified as rear reservoir 1. quickly as possible by a spe- Wear of the brake pads cialist workshop, preferably causes the brake fluid level an authorised BMW Motorrad in the reservoir to sink. dealer.

• Page 100: Coolant

  If the brake fluid level drops be- tion: Between windscreen and Top up the coolant. low the permitted level: right side panel. Have the defect rectified as quickly as possible by a spe- cialist workshop, preferably an authorised BMW Motorrad dealer.

• Page 101: Clutch

  Have the clutch checked by a specialist workshop, preferably Clutch play an authorised BMW Motorrad dealer. 1 mm (Handlebars turned Checking clutch play fully left, between handlebar Turn the handlebars all the way…

• Page 102: Tyres

  Check the clutch play ( 99). an authorised BMW Motorrad Repeat the steps in this pro- Tyres have wear indicators dealer. cedure until clutch play is set integrated into the main correctly.

• Page 103: Chain

  Chain Checking chain sag Chain deflection Make sure the ground is level Lubricating chain and firm and place the motor- Dirt, dust and inadequate cycle on its stand. 30…40 mm (Motorcycle with lubrication will result in ac- no weight applied, supported Turn the rear wheel until it celerated wear and significantly on its side stand)

• Page 104: Wheels

  Tyre recommendation Slacken locknuts 2 on left and cycle on its stand. right. For each size of tyre BMW Use adjusting screws 3 on left Motorrad tests certain makes, and right to adjust chain sag. and approves those that it Check the chain sag ( 101).

• Page 105: Remove The Front Wheel

  Motorrad dealer or on the Inter- your motorcycle, it is very import- BMW Motorrad dealer or spe- net at www.bmw-motorrad.com. ant to consult a specialist work- cialist workshop that the wheel is shop beforehand, preferably an fitted with an RDC sensor.

• Page 106: Installing Front Wheel

  BMW Motorrad ABS Roll the front wheel forward to remove. Release axle clamping screw 2. Remove axle 3, while support- Remove screw 1 and remove ing the wheel. the ABS sensor from its bore. Remove spacing bushing 4 Do not remove the grease from…

• Page 107
  BMW Motorrad ABS Slip spacing bushing 4 into Raise the front wheel, insert the left-hand side of the wheel axle 3 and tighten to specified Insert the ABS sensor into its hub. torque. bore and install screw 1. The front wheel must be…

• Page 108: Remove The Rear Wheel

  Remove the rear wheel Make sure the ground is level and firm and place the motor- cycle on its stand. Remove axle nut 2. Remove quick-release axle 6 and remove adjusting plate 7. Slacken locknuts 3 on left and right by turning them counter- clockwise.

• Page 109: Installing Rear Wheel

  Always have the security of the Install right adjusting plate 5. fasteners checked by a specialist workshop, preferably an author- ised BMW Motorrad dealer. Roll the rear wheel into the swinging arm, making sure that the brake disc passes between the brake pads.

• Page 110: Front-Wheel Stand

  Place the motorcycle on an aux- until the front forks fit between iliary stand before lifting the front them. Adjust the adapter studs wheel with the BMW Motorrad to suit the front suspension. front-wheel stand. Use locating pins 3 to set the…

• Page 111: Bulbs

  Apply uniform pressure to push the front-wheel stand down and raise the motorcycle. Bulbs General instructions A warning appears in the multi- function display if a bulb is de- fective. Align the two adapters 2 so Apply uniform pressure to push A defective bulb places that the front forks are securely the front-wheel stand down…

• Page 112
  Replacing high-beam The types of bulb fitted to your motorcycle are listed headlight bulb in the section entitled «Technical data». Do not touch the glass of new bulbs with your fingers. Use a clean, dry cloth to hold the bulbs when handling them. Dirt deposits, in particular oil and grease, interfere with heat radi- Remove cover of low-beam…
• Page 113
  Turn cover of high-beam head- Disengage spring clips 2 from Install bulb 3, making sure that light 1 clockwise to install. the fastenings and swing them alignment is correct. aside. Close and lock spring clips 2. Replacing low-beam and Remove bulb 3. high-beam headlight bulb Replace the defective bulb.
• Page 114
  Replacing parking-light Replace the defective bulb. bulb Bulb for parking light Make sure the ground is level and firm and place the motor- W5W / 12 V / 5 W cycle on its stand. Pull parking-light bulb 1 out of the headlight housing.
• Page 115
  Replacing turn indicator bulbs, front and rear Make sure the ground is level and firm and place the motor- cycle on its stand. Switch off the ignition. Insert parking-light bulb 1 into Pull the glass out of the reflect- the headlight housing. or housing at the threaded- fastener side.
• Page 116
  The LED rear light can be re- indicators, front placed only as a complete unit. R10W / 12 V / 10 W Consult a specialist workshop, preferably an authorised BMW with LED turn indicators Motorrad dealer. LED / 12 V Replacing number-plate…
• Page 117
  Remove screw 1 from the Pull the bulb out of the bulb Insert the bulb into the bulb mudguard cover and remove socket. socket. the cover. Replace the defective bulb. Bulb for number-plate light W5W / 12 V / 5 W Seat bulb holder 2 in the light Pull bulb holder 2 out of the carrier.

• Page 118: Air Filter

  Installing air filter Hold the mudguard cover in Remove screws 1. position and install screw 1. Remove air-filter cover 2. Install air filter 3. Air filter Removing air filter Remove the centre trim panel 121). Remove air filter 3. Hold air-filter cover 2 in posi- tion.

• Page 119: Jump Starting

  Install the centre trim panel ally brought into contact with the motorcycle. 121). Use only jump leads fitted with Jump starting fully insulated crocodile clips at both ends. The wires leading to the power socket do not have Jump-starting with a donor- a load-capacity rating adequate battery voltage higher than for jump-starting the engine.

• Page 120: Battery

  Compliance with the points be- BMW Motorrad has de- starter motor and the donor low is important in order to max- veloped a float charger spe- battery.

• Page 121
  Once the battery is fully electrical system. Use BMW chargers with the charged, disconnect the part numbers 71 60 7 688 864 The motorcycle’s on-board charger’s terminal clips from (220 V) or, as applicable, electronics know when the the battery terminals.

• Page 122: Installing Battery

  If you want to have the date set of short-circuits. Install screws 3 on left and consult a specialist workshop, Always proceed in the correct right. preferably an authorised BMW sequence. Connection in the wrong Motorrad dealer. Begin by removing threaded sequence increases the risk Insert the battery into the bat- fastener 1 of the negative lead.

• Page 123
  Install the centre trim panel 121). Set the clock ( 42). Removing centre trim panel Remove the seat ( 59). Remove four screws 2. Manoeuvre the centre trim panel into position. Make sure Disconnect the plug from the that all three tabs 3 on left and socket.
• Page 124
  Install screws 1 on left and right. Install the seat ( 60).

• Page 125: Care

  Care Care products ….. 124 Washing motorcycle ….124 Cleaning easily damaged compon- ents .

• Page 126: Care Products

  Washing motorcycle until the brake discs and brake Glass of the instrument panel BMW Motorrad recommends pads have dried out. Black, unpainted parts that you use BMW insect re- mover to soften and wash off insects and stubborn dirt on…

• Page 127: Paint Care

  If plastic parts are cleaned Chrome Do not use silicone sprays or using unsuitable cleaning other care products that contain Use plenty of water and BMW agents, the surfaces can be dam- silicon. shampoo to clean chrome, par- aged. ticularly if it has been exposed to…

• Page 128: Protective Wax Coating

  BMW Motorrad dealer. Com- It is time to rewax the paint- bine work for laying up/restoring work when water «puddles» on to use with a BMW service or the surface, instead of forming inspection. beads. Restoring motorcycle…

• Page 129: Technical Data

  Technical data Troubleshooting chart … . . 128 Riding specifications ….140 Threaded fasteners ….129 Engine .

• Page 130: Troubleshooting Chart

  Troubleshooting chart Engine does not start at all or is difficult to start. Possible cause Remedy Emergency off switch (kill switch) Kill switch in operating position (run). Side stand Retract the side stand ( 64). Gear engaged and clutch not disengaged. Select neutral or pull clutch lever ( 64).

• Page 131: Threaded Fasteners

  Threaded fasteners Front wheel Value Valid Brake caliper to fork leg ASA screw with washer, M10 x 40 38 Nm Clamp of quick-release axle M8 x 25 19 Nm Quick-release axle, front, in axle holder M16 x 1.5 30 Nm Rear wheel Value Valid…

• Page 132
  Mirror arm Value Valid Clamping element to clamping block 30 Nm Chain Value Valid Locknut of the final-drive chain tensioning screw 19 Nm…

• Page 133: Engine

  Engine Engine design Two-cylinder four-stroke, DOHC with chain-and- sprocket drive, 4 valves operated by cam follow- ers, balancing conrod, liquid-cooled cylinders and heads, integral water pump, 6-speed gearbox and dry sump lubrication Displacement 798 cm Cylinder bore 82 mm Piston stroke 75.6 mm Compression ratio 12 : 1…

• Page 134: Fuel

  2.9 l, with filter change 2.7 l, without filter change 0.3 l, additional, if swing-arm shaft cover is re- moved of products recommended by BMW Motorrad and generally admissible viscosity classes Castrol GPS SAE 10W-40 ~-20 °C SAE 10W-40 ~-20 °C, Operation in winter SAE 15W-40 ~-10 °C…

• Page 135: Clutch

  Permissible viscosity classes SAE 10 W-40 ~-20 °C, Operation at low temperatures SAE 15 W-40 ~-10 °C Clutch Clutch type Multiplate clutch running in oil bath Transmission Gearbox type Claw-shift 6-speed gearbox, integrated into en- gine block Gearbox transmission ratios 1.943 (35/68 teeth), Primary transmission ratio 1:2.462 (13/32 teeth), 1st gear 1:1.750 (16/28 teeth), 2nd gear…

• Page 136: Rear-Wheel Drive

  Rear-wheel drive Type of final drive Chain drive Type of rear suspension Two-arm cast-aluminium swinging arm Final drive, number of teeth (Pinion / sprocket) 17 / 41 Running gear Front wheel Type of front suspension Telescopic forks Spring travel, front 180 mm, At wheel Rear wheel Type of rear suspension…

• Page 137: Brakes

  Brake-pad material, rear Organic material Wheels and tyres Recommended tyre sets You can obtain an up-to-date list of approved tyres from your authorised BMW Motorrad dealer or on the Internet at «www.bmw-motorrad.com». Front wheel Front wheel, type Cast aluminium, MT H2 Front wheel rim size 2.50″…

• Page 138
  Rear wheel Rear wheel type Cast aluminium, MT H2 Rear wheel rim size 3.50″ x 17″ Tyre designation, rear 140 / 80 R 17 Tyre pressure Tyre pressure, front 2.2 bar, one-up, at tyre temperature: 20 °C 2.2 bar, two-up and/or with luggage, at tyre tem- perature: 20 °C Tyre pressure, rear 2.5 bar, one-up, at tyre temperature: 20 °C…

• Page 139: Electrics

  Electrics Electrical rating of on-board socket Fuses Electronic fuses protect all the circuits. If an elec- tronic fuse trips and de-energises a circuit, the circuit is active as soon as the ignition is switched on after the fault has been rectified. Battery Battery type AGM (Absorbent Glass Mat) battery…

• Page 140: Frame

  Bulbs for flashing turn indicators, front R10W / 12 V / 10 W with LED turn indicators LED / 12 V Bulbs for flashing turn indicators, rear R10W / 12 V / 10 W with LED turn indicators LED / 12 V Frame Frame type Tubular spaceframe…

• Page 141: Weights

  Rider’s inside-leg arc, heel to heel 1820 mm with dual seat, low 1780 mm, Without rider at unladen weight without lowered suspension with lowered suspension 1710 mm, Without rider at unladen weight Weights Unladen weight 199 kg, DIN unladen weight, ready for road, 90 % load of fuel Permissible gross weight 436 kg…

• Page 142: Riding Specifications

  Riding specifications Top speed max 190 km/h with power reduction max 147 km/h…

• Page 143: Service

  Service BMW Motorrad service … . 142 BMW Motorrad service quality ..142 BMW Motorrad mobility services — roadside assistance ….142 BMW Motorrad service network .

• Page 144: Bmw Motorrad Service

  To ensure that your BMW is al- BMW Motorrad mobility ably an authorised BMW Motor- ways in optimum condition, BMW rad dealer.

• Page 145: Bmw Motorrad Service

  BMW Service place to look after you and your service is approaching, on the The BMW Service is carried out motorcycle in more than 100 basis of the programmed values. once a year; the extent of servi- countries.

• Page 146: Ance Work

  Confirmation of maintenance work BMW Pre-delivery BMW Running-in Check Check Completed Completed Odometer reading Next service at the latest or, if logged beforehand, Odometer reading Stamp, signature Stamp, signature…

• Page 147
  BMW Service BMW Service BMW Service Completed Completed Completed Odometer reading Odometer reading Odometer reading Next service Next service Next service at the latest at the latest at the latest or, if logged beforehand, or, if logged beforehand, or, if logged beforehand,…
• Page 148
  BMW Service BMW Service BMW Service Completed Completed Completed Odometer reading Odometer reading Odometer reading Next service Next service Next service at the latest at the latest at the latest or, if logged beforehand, or, if logged beforehand, or, if logged beforehand,…
• Page 149
  BMW Service BMW Service BMW Service Completed Completed Completed Odometer reading Odometer reading Odometer reading Next service Next service Next service at the latest at the latest at the latest or, if logged beforehand, or, if logged beforehand, or, if logged beforehand,…
• Page 150
  BMW Service BMW Service BMW Service Completed Completed Completed Odometer reading Odometer reading Odometer reading Next service Next service Next service at the latest at the latest at the latest or, if logged beforehand, or, if logged beforehand, or, if logged beforehand,…

• Page 151: Confirmation Of Service

  Confirmation of service The table is intended as a record of maintenance and repair work, the installation of optional accessories and, if appropriate, special campaign (recall) work. Item Odometer Date reading…

• Page 152
  Item Odometer Date reading…
• Page 153
  Stowage, 15 Replacing side-light bulb, 112 Abbreviations and symbols, 6 Technical data, 137 Replacing turn indicator bulbs, 113 BMW Motorrad service, 142 Control, 16 Technical data, 137 Brake fluid Engineering details, 76 Checking fluid levels, 96 Warning for bulb failure, 28…
• Page 154
  Coolant Engine Refuelling, 71 Checking fill level, 98 Control, 17 Technical data, 132 Filler neck, 13 Starting, 64 Warning for fuel down to Fill-level indicator, 13 reserve, 27 Technical data, 131 Temperature gauge, 23, 24 Fuses, 137 Warning for engine Topping up, 99 electronics, 28 Warning for…
• Page 155
  Hazard warning flashers Mirrors Jump starting, 117 Adjusting, 55 Control, 16, 17 Mobility services, 142 Operation, 51 Motorcycle Headlight Keys, 40, 41 Laying up, 126 Beam throw, 58 Parking, 70 Driving on right/driving on left, 58 Laying up, 126 Restoring to use, 126 Overview, 20 Lights Multifunction display, 18…
• Page 156
  Stopwatch, 47 Status indicators Safety instructions See also warnings, 22 Warnings, 29 Brakes, 68 Standard status indicators, 22 General, 62 With on-board computer, 23 Parking, 70 Seat With RDC, 24 Installation, 59 Parking light, 50 Steering lock, 40 Lock, 11 Power socket, 11, 82 Stopwatch Removal, 59…
• Page 157
  Transmission, 133 Tyre pressure monitoring RDC With RDC, 32 Adhesive label for rim, 103 Weights, 139 Warnings, overview, 26, 31, 34 Engineering details, 78 Wheels and tyres, 135 Weights, 139 Operation, 49 Payload table, 14 Telltale lights, 22 Status indicators, 24 Wheels Toolkit Change of size, 103…
• Page 158

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• Page 159
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BMW AG Motorcycle Division

After Sales

BMW AG Motorcycle Division

Pre-delivery Check

F 650 GS

Check the shipping crate for damage

Motorcycle:

–unpack

–inspect for damage

–install remaining items

–clean

Battery:

–remove

–add acid

–charge

–grease terminal posts

–fit (mark with fitting date)

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

–Clutch, gearshift

–Steering

–Hand brakes and foot brakes

–Check lights and signalling equipment, warning and indicator lights, instruments, ABS

–Test ride, if necessary

BMW AG Motorcycle Division

Service data

F 650 GS

F 650 GS

Instructions for pre-delivery check

•Read the information sheet on damage in transit. motorcycle may be damaged.

•Notify the supplier without delay

• Install handlebar weights (1).

• Tighten clamp screw (2) on handlebar fitting.

• Install each mirror and secure by tightening

E000260

• Tighten the windscreen securing screws.

5

6

2

3

E000280

Filling and charging the battery

Removing right and centre covers

L 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.

•Remove the seat.

•Remove the fasteners securing turn indicator (1).

•Slacken front securing screw (2).

•Remove securing screws (5) from side cover.

•Pull side cover (4) out of the anchorage (arrow) at the bottom and lift it clear of the centre panel at the top.

•Remove securing screws (6) from centre cover.

•Remove centre cover (3).

Contents

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00 Maintenance and general instructions

00

Table of operating fluids

Tightening torques

3 1

2

E000110

•Slacken drain plug (2) in oil tank.

•Remove retaining screw (1).

•Remove clamps (3).

•Pull out the oil tank, tilt it to the left and slacken drain plug (2).

•Use the spark-plug wrench (toolkit) to remove the filler cap from the oil tank.

•Fully drain the tank.

•Remove the oil drain plug from the engine and fully drain the oil from the engine.

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