BMW F650CS Service Manual

Repair Manual

F 650 CS

BMW Motorrad After Sales

Issued by © BMW Motorrad

After Sales UX-VS-2

Printed in Germany 06/01

Introduction

This Repair Manual will help you to perform all the main maintenance and repair work correctly and efficiently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and practical knowledge acquired at the BMW Training Centre. It is a contribution toward achieving even higher Service quality.

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.

The Repair Manual is structured in the logical sequence of the work to be performed: Removal, Disas-

•

sembling, Repair, Assembly, Installation.

The entire contents are divided into individual chapters, corresponding to the Construction Groups.

•

11 . 10

Chapter Page number within chapter

If a reference is needed to a different page or chapter, an arrow symbol is shown followed by the chapter and page numbers, e. g. (

Work to be performed during an Inspection is described in Group “00”. The various inspection routines

•

are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption.

a 12.5).

Use of the BMW special tools needed for certain tasks is described in the work instructions.

•

If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the Repair Manual. We also recommend, as an additional source of information, the Electronic Parts Catalogue (ETK), which contains clear and easy-to-follow illustrations.

If the work described here is restricted to a particular equipment specification, for instance if a specific optional extra (OE) is fitted, this is stated in square brackets at the start of the item concerned, e.g. [Heated handlebar grips].

Please refer to the following pages as well for a description of other symbols used and how to work with them.

BMW Motorrad After Sales

Issued by BMW Motorrad

After Sales UX-VS-2

D-80788 München

Produced in Germany

Use

Each chapter starts with the list of contents.

The list of contents is followed by the technical data table.

Key to symbols

In this Repair Manual for the F 650 CS model, the following symbols are used; their meanings are explained in the table.

Special instructions aimed at improving the work procedures

L Note:

Special information on operating and inspecting the motorcycle as well as maintenance and adjustment procedures.

e Attention:

Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply with them could invalidate the warranty.

d Warning:

This symbol stands for precautions and measures which are essential in order to protect the rider or other persons from possibly severe or fatal injury.

The titles of the tasks described in this chapter............. complete with page numbers

Activities

•

The bullet symbol indicates work steps that are described in greater detail under another headline

•

– Preceding activities – A line indicates work steps that are described in greater detail under another headline or in another

chapter

The term "remove" means that: the fastener (e.g. screw) must be backed off completely and removed or a component (e.g. injection rail) has to be removed to the extent that components behind it (e.g. throttle valve rail) are rendered accessible

The term "loosen" or "slacken" means that: the fastener (e.g. screw) must be backed off, but not removed

X Tightening torque:

Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.

BMW Motorrad Maintenance schedule F 650 CS

Customer Licence No. Mileage

Job Order No. Date Mechanic’s signature

Read the fault code memory with the BMW MoDiTeC

Change the engine oil [engine only] while at regular operating temperature and replace the oil filter element

Change the engine oil [engine and oil tank] while at regular operating temperature and replace the oil filter element

if motorcycle is used only for short journeys or at outside temperatures below 0°C (32°F): every 3 months or at the latest after 3,000 km (1,800 miles)

Clean oil strainer in frame

once only at 10,000 km/6,000 miles

Check the coolant and restore to correct level if necessary

Grease rubber grommets for cover insert

Replace the coolant

every 2 years

Check valve clearances, adjust if necessary

Replace the spark plug Drain the outlet hose from the air filter box

Replace intake air filter

If motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every 10,000 km (6,000 miles); check every 3,000 km (1,800 miles)

Replace fuel filter

every 40,000 km (24,000 miles)

Check clutch play, adjust if necessary

Examine brake pads and discs for wear, replace if necessary

Check front/rear circuit brake fluid

Check for operation of brake system and freedom from leaks; repair/replace if necessary

Renew brake fluid at least once a year

[ABS] Replace the primary front/rear brake master cylinder cup

every 40,000 km (24,000 miles)

Replace toothed belt

Check toothed belt and sprocket, replace if necessary

Check belt tension, adjust if necessary

Check battery acid level, add distilled water if necessary

Clean and grease the battery terminals, if necessary

Check steering head bearings and adjust *) or replace if necessary

Grease the side stand

Using a torque wrench, check that the screws and nuts of the engine mounts, manifold fastener, the frame threaded fasteners, the rear-frame threaded fasteners, and the eccentric clamp are tightened to specified torque

Final inspection with road safety and functional check:

– Clutch, gearshift – Steering – Front and rear brakes – Side stand contact switch – Condition of tyres and wheels, tyre pressures – Lights and signalling equipment, indicator and warning lights, instruments – Optional equipment – Test ride, if necessary

*) Write up on separate invoice; Not part of standard service procedure

BMW Inspection

at 1,000 km/600 miles

BMW Maintenance

Service every

10,000 km/6,000 miles

BMW Inspection

every 20,000 km/

12,0 0 0 miles

BMW

Annual Service

UX-VS-2, 07.2001

BMW recommends Castrol

BMW Motorrad Pre-delivery check F 650 CS

Customer Licence No.

Job Order No. Mechanic’s signature

Check the shipping pallet for damage

Unpack the motorcycle

Inspect motorcycle for damage

Check complete specification delivery:

– tools – handbooks and documents – keys – optional extras

Motorcycle complete

BMW Pre-delivery check

Battery:

– remove – add battery acid – charge – grease the terminal posts – re-install (mark date)

Check tyre pressure

Fuel the motorcycle

Safety/operating check as final inspection:

– Oil inspection – Clutch, gearshift – Steering – Hand brakes and foot brakes – Check lights and signalling equipment, warning and indicator lights, instruments, ABS – Test ride, if necessary

Confirm delivery inspection in “Maintenance Booklet“

Final cleaning

Vehicle delivered on:

UX-VS-2, 07.2001

BMW recommends Castrol

BMW Motorrad Service data F 650 CS

Item Desired value Units / Specifications

Oil capacities

Engine (incl. filter) 0.5 (0.88/0.53)

Engine (incl. filter) and oil tank 2.5 (4.4/2.64)

Coolant

Cooling system 1.3 (2.29/1.37) Litres (Imp. pints/US quarts) Reservoir 0.1 (0.18/0.11) Litres (Imp. pints/US quarts)

Brake Fluid DOT 4

Valve clearance

Inlet 0.03-0.11 (0.0012-0.004) mm (in) Exhaust 0.25-0.33 (0.010-0.013) mm (in)

Spark plugs NGK DR8 EB

Electrode gap 0.6...0.7 (0.02...0.03) mm (in)

Engine idle speed 1,400 rpm

Clutch cable play

Cable at grip 1.0 - 2.0 (0.004 - 0.008) mm (in)

Tyre pressure

Solo front/rear 2.2/2.5 (31.91/36.26) bar (psi) fully loaded front/rear 2.2/2.5 (31.91/36.26) bar (psi)

Tightening torques

Engine oil drain plug 40 Nm Oil filter cover 10 Nm Drain plug, on-frame oil tank 21 Nm Oil lines to frame 42 Nm Oil strainer to frame 80 Nm Water pump drain screw 10 Nm Vent screw 12 Nm Expansion tank to radiator 9 Nm Cylinder head cover 10 Nm Spark plugs 20 Nm Camshaft bearing cap 10 Nm Chain guide 10 Nm (Loctite 243) Fuel filter to stowage-compartment frame 9 Nm Intake air pipe to intake air silencer 9 Nm Suspension strut to angled lever 41 Nm Eccentric clamp Initial tightening 10

Brake caliper to swinging arm 21 Nm Struts to swinging arm 41 Nm Swinging-fork pivot axle 100 Nm Adjusting screw steering head bearing 25

Clamp screw for fork bridge steering head 23 Nm Engine to frame at rear 50 Nm Cylinder head to frame 41 Nm Cylinder head to frame, locknut 100 Nm Engine shell to engine 55 Nm Engine shell to engine, bottom, with bottom truss 55 Nm Engine shell to bracing tube 24 Nm Rear frame to main frame 24 Nm (Loctite 2701) Exhaust manifold to cylinder head 20 Nm Silencer to exhaust manifold 55 Nm

50% 50%

Back off through

angle of rotation 60

Litres (Imp. pints/US quarts)

Specification: see latest

Service Information

Litres (Imp. pints/US quarts)

Specification: see latest

Service Information

Water

Anti-freeze

protection to –25 °C

measured cold (max. 35 °C/95 °F)

tyres cold

Nm Nm

UX-VS-2, 07.2001

BMW recommends Castrol

<< Back

Group / Chapter

00 Tightening torques, Operating fluids 00 Pre-delivery check 00 Maintenance

11 Engine

12 Engine electrics

13 Fuel preparation and control

16 Fuel tank and lines

17 Radiator

18 Exhaust system

21 Clutch

23 Gearbox

27 Chain/belt drive

31 Front forks

>> Continuation

Group / Chapter

32 Steering

33 Rear wheel drive

34 Brakes

36 Wheels and tyres

46 Frame

>> Continuation

51 Equipment

61 General electrical equipment

62 Instruments

63 Lights

<< Back

00 Tightening torques,

Operating fluids

Contents Page

Tightening torques ......................................................................................................................3

11 Engine ...........................................................................................................................................3

12 Engine electrics ........................................................................................................................4

13 Fuel preparation and control ...............................................................................................5

16 Fuel tank and lines ...................................................................................................................5

17 Radiator ........................................................................................................................................5

18 Exhaust system .........................................................................................................................6

21 Clutch ............................................................................................................................................6

23 Transmission ..............................................................................................................................6

27 Chain/belt drive .........................................................................................................................7

31 Front fork ......................................................................................................................................7

32 Steering ........................................................................................................................................7

33 Rear wheel drive .......................................................................................................................8

34 Brakes ...........................................................................................................................................8

36 Wheels and tyres ......................................................................................................................9

46 Frame ..........................................................................................................................................10

51 Equipment .................................................................................................................................11

61 General electrical equipment ............................................................................................12

62 Instruments ...............................................................................................................................12

63 Lights ...........................................................................................................................................12

Table of operating fluids .........................................................................................................13

00.1

00.2

Tightening torques

Model F 650 CS

Connection

11 Engine

Freewheel housing and freewheel Nm 35

(clean thread + Loctite 648)

Engine block Nm 10

Double drive gear on crankshaft Nm 180

(clean thread + Loctite 243)

Driver to countershaft Nm 140

(clean thread + Loctite 243)

Pressure plate Nm 10

Magnetic hub to crankshaft Nm 180

(clean thread + Loctite 243)

Chainwheel to main shaft Nm 140

(clean thread + Loctite 243)

Signal transmitter Nm 8

Ignition cover Nm 10

Cylinder base Nm 10

Fastener for chain tensioner Nm 40

Oil circuit

Oil filter cover Nm 10

Oil pressure switch Nm 12

(clean thread + Loctite 243)

Strainer cover to housing half Nm 8

Drain plug, on-frame oil tank Nm 21

Engine oil drain plug Nm 40

Oil supply/oil return lines to engine Nm 42

Oil pump cover Nm 6

(clean thread + Loctite 243)

Oil pressure valve Nm 24

Oil retaining valve Nm 24

Cylinder head

Collar nuts for cylinder head Nm 60

Collar screws for cylinder head Nm 33

Machine screws (chaincase) Nm 10

Camshaft bearing cap Nm 10

Chain sprockets to camshafts Nm 60

threads oiled

Chain guide to camshaft bearing cap Nm 10

(clean thread + Loctite 243)

00.3

Model F 650 CS

Connection

11 Engine

Cylinder head cover Nm 10

Machine screw (hole for locating screw) Nm 25

Model F 650 CS

Connection

12 Engine electrics

Spark plug Nm 20

Magnetic hub to crankshaft Nm 180

(clean thread + Loctite 243)

Signal transmitter Nm 8

Engine block cover, left/right Nm 10

Starter to clutch cover Nm 10

Positive lead to starter motor Nm 9

Positive contact to starter motor Nm 4

Necked-down bolt, starter housing Nm 6

Cable cover to engine block Nm 9

Cable holder to ignition cover Nm 8

Stator to ignition cover Nm 10

(clean thread + Loctite 243)

Ignition coil bracket to cylinder head cover Nm 9

00.4

Model F 650 CS

Connection

13 Fuel preparation and control

Air intake pipe to cylinder head Nm 21

Fuel filter to stowage-compartment frame Nm 9

Injector holder to throttle valve Nm 5

Fuel hose to injection nozzle holder Nm 3

Fuel return hose to pump unit Nm 3

Intake air pipe to intake air silencer Nm 9

Throttle flap to intake stub Nm 1

Throttle-valve potentiometer to throttle valve stub

Throttle valve actuator to throttle-valve stub

Model F 650 CS

Connection

16 Fuel tank and lines

Fuel tank to rear frame (M 8 stud) Nm 21

Fuel filler cap to fuel tank Nm 3

Roll-over valve to fuel tank Nm 2

Clamps, activated charcoal filter bracket Nm 9

Fuel pump to fuel tank Nm 30

Model F 650 CS

Connection

17 Radiator

Nm 3

Nm 5

(clean thread + Loctite 243)

Expansion tank to radiator Nm 9

Radiator to main frame at top Nm 9

Fan to fan shroud Nm 3

Water pump drain screw Nm 10

Coolant hoses to radiator/engine/frame Nm 3

Breather hose to expansion tank Nm 2

Left engine block cover to engine block Nm 10

Water pump cover Nm 10

Temperature sensor in cylinder head Nm 15

Vent screw Nm 12

00.5

Model F 650 CS

Connection

18 Exhaust system

Oxygen sensor to exhaust elbow Nm 45

Exhaust manifold to cylinder head Nm 20

Silencer to exhaust manifold (Torca clamp)

Silencer to rear frame Nm 41

Guards to silencer Nm 5

Model F 650 CS

Connection

21 Clutch

Driver Nm 140

Pressure plate Nm 10

Engine block cover, left Nm 10

Release lever to release shaft Nm 10

Model F 650 CS

Connection

23 Transmission

Nm 55

(clean thread + Loctite 243)

Gear pedal to frame Nm 21

Shaft lever to selector shaft Nm 9

00.6

Model F 650 CS

Connection

27 Chain/belt drive

Drive sprocket cover to engine Nm 2

Belt cover to swinging arm Nm 9

Eccentric clamp Nm 21

Initial tightening Nm 10

Belt sprocket to gearbox output shaft Nm 180

(clean thread + Loctite 638)

Model F 650 CS

Connection

31 Front fork

Clamp screws, upper fork bridge and steering head clamp

Clamp screws at lower fork bridge Nm 23

Bracket to fork leg Nm 5

Damper retaining screw Nm 20

Adjusting screw

Preload Nm 25

Back off through angle of rotation

Model F 650 CS

Connection

32 Steering

Handlebars to fork bridge Nm 23

Handlebar weight to handlebar Nm 9

Handlebar fitting to handlebar Nm 9

Cover of multi-function switch Nm 1

Nm 23

° 60

Pivot pin of clutch lever Nm 3

Locknut for pivot pin of clutch lever Nm 5

Pivot pin of handbrake lever Nm 7

Locknut of handbrake lever Nm 7

Guide to fork bridge Nm 5

00.7

Model F 650 CS

Connection

33 Rear wheel drive

Suspension strut to frame Nm 58

Wrench angle ° 45 ± 15

Suspension strut to angled lever Nm 41

Swinging-fork pivot axle Nm 100

Struts to swinging arm Nm 41

Struts to angled lever Nm 41

Angled lever to frame Nm 58

Wrench angle ° 45 ± 15

Belt pulley to damper housing Nm 28

Damper fastener Nm 160

Eccentric clamp Nm 21

Initial tightening Nm 10

Model F 650 CS

Connection

34 Brakes

Bleed screw to brake caliper front/rear Nm 7

Brake caliper to fork slider tube Nm 41

Brake light switch to handlebar fitting Nm 3

Handlebar fitting to handlebar Nm 9

Brake light switch to frame Nm 5

Brake disc to front wheel Nm 10

(clean thread + Loctite 2701)

Brake disc to rear wheel drive shaft Nm 11

(clean thread + Loctite 2701)

Brake caliper to swinging arm Nm 21

Brake master cylinder to main frame Nm 10

Locknut for fork end to pushrod Nm 9

Bracket, rear, to main frame Nm 9

(clean thread + Loctite 2701)

Shroud to frame Nm 6

Brake fluid reservoir for rear brake to rear frame

Brake pedal to frame Nm 21

Brake line distributor to main frame Nm 9

00.8

Nm 4

Model F 650 CS

Connection

34 Brakes

Brake lines/hoses

Brake hose to brake caliper Nm 18

Brake hose to rear brake caliper Nm 18

Brake hose to brake lever fitting Nm 18

Brake hoses to distributor Nm 18

Brake hose to bracket, rear Nm 18

Brake line to master brake cylinder, rear wheel

Banjo bolts, brake line Nm 18

ABS

ABS sensor front/rear Nm 9

ABS control unit to holder Nm 21

Brake lines to ABS control unit Nm 18

Brake disc and sensor ring to front wheel Nm 10

Locknut for adjustable stop, brake-light switch

Model F 650 CS

Connection

36 Wheels and tyres

Clamp nut, front quick-release axle Nm 23

Front quick-release axle to fork leg Nm 30

Nm 18

(clean thread + Loctite 2701)

Nm 4

Wheel nut to drive shaft (wheel side) Nm 160

Lightly coat the thread with Optimoly TA

00.9

Model F 650 CS

Connection

46 Frame

Covers, right and left, to main frame Nm 2

Covers, right and left, to air guide Nm 3

Cover, front, to covers, right and left Nm 1

Cover, front to main frame Nm 2

Cover, rear, to covers left and right and to stowage-compartment frame

Stowage-compartment rail to stowagecompartment frame

Stowage-compartment frame to main frame Nm 9

Turn indicators, left and right, to fairing bracket

Instrument cover to fairing holder Nm 2

Windscreen to windscreen bracket Nm 2

Windscreen bracket to fairing bracket Nm 9

Rear trim panels, left and right, to rear frame Nm 2

Rear trim panels, left and right, to seat lock Nm 2

Bracket for seat lock to rear frame Nm 3

Turn indicator, rear, to rear finisher Nm 3

Rear finisher to rear frame Nm 9

Number-plate carrier to rear finisher Nm 9

Spray guard to number-plate carrier Nm 3

Nm 2

Nm 9

Nm 3

Number-plate carrier to rear mudguard Nm 3

Cover of number-plate light to numberplate carrier

Grip to rear frame Nm 9

Luggage carrier to grab handle Nm 3

Mudguards/wheel guards

Front mudguard, front section, to front mudguard, rear section

Front mudguard, front section, to slider tube

Front mudguard, rear section, to slider tube

Rear mudguard, front section, to rear frame, front and side

Rear mudguard, front section, to rear frame, rear and centre

Belt cover to swinging arm Nm 9

Nm 1

Nm 3

00.10

Model F 650 CS

Connection

46 Frame

Frame

Drain plug, on-frame oil tank Nm 21

Oil strainer to frame Nm 80

Oil feed and return lines to main frame Nm 42

Oil tank cover to frame Nm 5

Footrest rubber to rear footrest Nm 5

Fairing bracket to main frame Nm 21

Rear frame to main frame Nm 24

(clean thread + Loctite 2701)

Engine shell to bracing tube Nm 25

Side stand to bottom truss Nm 41

Engine mounts

Engine shell to engine Nm 55

Engine shell to engine, bottom, with bottom truss

Engine to frame at rear Nm 50

Cylinder head to frame Nm 41

Cylinder head to frame, adjusting sleeve Nm zero play, max. 5

Cylinder head to frame, locknut Nm 100

Model F 650 CS

Connection

51 Equipment

Ignition/steering lock to fork bridge, top Nm 20

Mirror to clamp element Nm 18

Clamp element to handlebar fitting Nm 21

Seat hook to rear frame Nm 9

Nm 55

00.11

Model F 650 CS

Connection

61 General electrical equipment

Cable to idle-indicator switch Nm 1

Idle-indicator switch Nm 3

(clean thread + Loctite 243)

Cover for hazard warning flasher switch Nm 5

Clutch switch to handlebar fitting Nm 5

Positive/ground leads, battery Nm 7

Ignition/light switch with cap to ignition/ handlebar lock

Voltage regulator to engine shell Nm 9

Horn to fork bridge Nm 18

Ground terminal, wiring harness to engine block, right

Model F 650 CS

Connection

62 Instruments

Instrument cover to instrument cluster Nm 2

Model F 650 CS

Connection

63 Lights

Headlight to fairing bracket Nm 7

Nm 1

(clean thread + Loctite 243)

Nm 8

Number-plate light to number-plate carrier Nm 1

Rear light cluster to rear frame Nm 9

00.12

Table of operating fluids

Item Use Order number Quantity

Lubricant

Staburags NBU 30 PTM High-performance lubricating grease 07 55 9 056 992 75 g tube Optimoly MP 3 High-performance lubricating grease 07 55 9 062 476 100 g tube Optimoly TA High-temperature assembly grease 18 21 9 062 599 100 g tube Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube Retinax EP2 Grease 83 22 9 407 845 100 g tube Contact spray Contact spray 81 22 9 400 208 300 ml spray

Chain spray Lubricant

Shell HDX2 Lubricant 11 00 7 660 830 400 g tube Klüberpaste 46 MR 401 High-temperature lubricant 11 00 7 660 831 60 g tube MOLYKOTE 111 Silicon grease 11 00 7 660 832 100 g tube

Tyre mounting paste Assembly paste

Never Seez compound Lubricating paste 83 23 9 407 830 100 g tube Grease for lock cylinders Grease 81 22 9 407 421 Rubber care product Rubber care 82 14 9 407 015 60 g tube Long-life lubricant Lubricant 81 22 9 407 629 250 ml spray

Sealants

3-Bond 1110 B Surface sealant 07 58 9 056 998 5 g tube 3-Bond 1209 Surface sealant 07 58 9 062 376 30 g tube OMNI VISC 1002 Surface sealant 07 58 1 465 170 90 g tube Loctite 574 Surface sealant 81 22 9 407 301 50 ml tube Loctite 577 Thread locking compound 33 11 2 328 736 5 g tube

72 60 2 316 676 72 60 2 316 667

36 32 1 239 263 36 32 1 239 264

50 ml spray 300 ml spray

2.5 kg 100 g

Curil K 2 Heat-conductive sealant 81 22 9 400 243 250 g can

Adhesives and retaining agents

Loctite 648 Joint adhesive (narrow gap) 07 58 9 067 732 5 g bottle Loctite 638 Joint adhesive (wide gap) 07 58 9 056 030 10 ml bottle Loctite 243 Thread retainer, medium-strength 07 58 9 056 031 10 ml bottle Loctite 270 Thread retainer, strong 81 22 9 400 086 10 ml bottle Loctite 2701 Thread retainer, strong 33 17 2 331 095 10 ml bottle Loctite 454 Cyanacrylate adhesive (gel) 07 58 9 062 157 20 g tube

00.13

Item Use Order number Quantity

Cleaners

Brake cleaner Cleaners 83 11 9 407 848 600 ml spray Normal dilution Cleaners 51 91 9 057 940 1 l bottle Metal Polish Polish for chrome-plated parts 82 14 9 400 890 100 g tube

Testing agents

Penetrant MR 68

Developer MR 70

Installation aid

BMW chilling spray Cooling spray 83 19 9 407 762 300 ml spray

Crack testing agent for aluminium housings

83 19 9 407 855 500 ml spray

81 22 9 407 495 500 ml spray

00.14

00 Pre-delivery check

Contents Page

General view of crated motorcycle ...................................................................................17

Checking the shipping crate for damage ......................................................................18

In case of damage in Germany ...............................................................................................18

In case of damage in importer markets ..............................................................................18

Unpack the motorcycle ...........................................................................................................18

Inspecting motorcycle for damage ...................................................................................19

Checking that delivery is complete ..................................................................................19

Installing remaining items on motorcycle .....................................................................19

Filling and charging the battery .........................................................................................20

Removing the battery ..................................................................................................................20

Filling and charging the battery ...............................................................................................21

Checking engine oil level .......................................................................................................22

Checking tyre pressures .........................................................................................................22

Final inspection and function check ................................................................................23

Final cleaning ................................................................................................................................23

Handover .........................................................................................................................................23

00.15

00.16

General view of crated motorcycle

K14009440

00.17

Checking the shipping crate for damage

When the motorcycle arrives, check the crate im-

•

mediately for damage and if necessary examine the contents for consequential damage.

00 11

Unpack the motorcycle

Lever off the cover.

•

Take out the separate pack of items.

•

Force off cross-struts with a suitable lever.

•

In case of damage in Germany

Note the damage on the delivery slip.

•

Read the information sheet on damage in transit.

•

Notify the supplier without delay (e.g. freight

•

company or DB) and also Bavaria Wirtschaftsagentur GmbH Abteilung ZW - 12 D-80788 München Tel. +49 89/14327-632 Fax. + 49 89/14327-709

In case of damage in importer markets

Note the damage on the delivery slip.

•

Comply with specific national market proce-

•

dures. In case of doubt, please submit enquiries to: Bavaria Wirtschaftsagentur GmbH Abteilung ZW - 12 D-80788 München Tel. +49 89/14327-632 Fax. +49 89 14327-709 Notify the supplier (e.g. freight company) without

•

delay.

e Attention:

Do not knock the cross-struts out or the motorcycle may be damaged.

Remove the end-walls.

•

Remove the side-walls.

•

e Attention:

Make sure that the motorcycle cannot topple.

Remove the straps at front and rear.

•

e Attention:

Remove any nails projecting from the base of the packing or lying on the base or on the floor.

Push the motorcycle forward off the pallet.

•

Remove the set of keys from the left rear footrest.

•

Dispose of the packing materials in an environ-

•

mentally responsible manner as described in Circular No. 23/91 - Sales. Check the contents of the enclosed pack of

•

items:

– Mirrors with clamping screws and nuts – Rider's Manual – Maintenance Instructions – Booklet listing service centres in Europe – BMW emergency service sticker – Handling instructions for batteries

00.18

00 11 Inspecting motorcycle for dam-

age

Check for damage.

•

Use the “express handling service” to notify

•

BMW Motorrad, UX-VS-1 Fax:+ 49 89-382-33220 Rectify the fault.

•

If parts are needed, order them through the usual

•

channel. Costs are to be processed by the warranty claim

•

system (stage 4). Defect codes:

– Parts missing 10 01 00 00 00 – Parts damaged 10 02 00 00 00 – Incorrect parts delivered 10 03 00 00 00

00 11

Installing remaining items on

motorcycle

Checking that delivery is complete

All optional extras

•

Toolkit:

•

– screwdriver, reversible blade – crosshead screwdriver, small – 3 open-end wrenches

w/f 8×10, 14, 15 – spark plug wrench – 3 Allen keys

Torx T15, T25, T30 – 4 fuses

7.5 A, 10 A, 15 A, 20 A

– Breakdown kit

Documentation

•

Vehicle keys, 3 of

•

E000310

Fit clamp screw (2) to handlebar fitting.

•

Install mirror and secure by tightening nut (1).

•

X Tightening torque:

Clamp screw to handlebar fitting.................. 21 Nm

Union nut for mirror ...................................... 18 Nm

00.19

1 2

61 21 Filling and charging the battery 61 21 010 Removing the battery

– Place the motorcycle on the auxiliary stand,

BMW No. 00 1 620.

– Remove seat.

Remove securing screws for stowage-compart-

•

ment rail (1) and remove left stowage-compartment rail; use wrench from toolkit if necessary. Remove fasteners of rear cover and remove rear

•

cover (2). Disconnect the plug for flashing turn indicator (5).

•

Remove securing screw for flashing turn indica-

•

tor (4). Remove screws securing left cover (3).

•

Remove the left cover.

•

K14000450

00.20

- UPPER LEVEL-

- LOWER LEVEL-

K14000460

61 21 Filling and charging the battery

d Warning:

Battery acid is highly caustic. Protect your eyes, face, hands, clothing and the paintwork.

Disengage the rubber strap holding the battery.

•

Disconnect the battery breather hose.

•

Remove the battery.

•

Fill all the cells with pure battery acid of

•

density 1.28 to the Upper Level mark.

Allow the battery to stand for approximately

•

30 minutes.

The battery does not achieve full charge capacity

•

from being filled, so it has to be charged with a battery charger.

L Note:

Follow the instructions for use supplied with the battery charger.

Charge current (A)

.........................10 % of rated battery capacity (Ah)

Charging time

..............................................................5-10 hours

Battery charge can be measured by checking

•

the density of the battery acid.

Acid density

Battery fully charged

............1.26-1.30 at a temperature of 20 °C (68 °F)

Shake the battery slightly to allow the gas bub-

•

bles to escape. Wait until the battery acid has settled, check that

•

no more bubbles rise and if necessary, top up the acid to the max. mark. Reinstall the plugs.

•

Make a note of the charging date on the battery.

•

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