BMW F 650 GS User Manual
Repair Manual
F 650 GS
BMW AG Motorcycle Division
After Sales
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 towards 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-
•
sembly, Repair, Assembly, Installation.
The entire contents are divided into individual chapters, corresponding to the Construction Groups.
•
11 . 10
Chapter Page number within chapter
An arrow symbol followed by the chapter and page numbers is a reference to another chapter,
e.g. Ób ............................................See Group 46
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.
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 (ETC), 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. [With heat-
ed handlebar grips].
Please refer to the following pages as well for a description of other symbols used and how to work with it.
BMW AG Motorcycle Division
After Sales
Published by: BMW AG Sparte Motorrad
After Sales
UX-VS-2
D - 80788 München
All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written
permission.
Errors and omissions excepted; subject to technical amendment.
Produced in Germany
Usage
Each chapter starts with the list of contents.
The list of contents is followed by the Technical Data table.
Chapter 00 “Maintenance and general instructions” details the handover checklist and lists all tightening
torques and operating fluids.
Key to symbols
In this Workshop Manual for the F 650 GS model, the following symbols are used; their meanings are explained in the table.
Special instructions aimed at improving the work procedures
L Note:
Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance
procedures.
e Caution:
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.
Contents
Headlines for the work described in the chapter........................................... with the relevant page number
Activities
Activities
•
The bullet symbol means that work steps are described in greater detail under another headline
•
– Preceding activities
– A line indicates work steps described in greater detail under another headline or in another chapter
If the term “release” or “remove” is used:
the fastener (e.g. screw) must be slackened off and taken out
or
a component (e.g. fuel rail) must be removed to the extent that other components which it conceals (e.g.
throttle-valve rail) are accessible
If the term “loosen” or “slacken” is used:
the fastener (e.g. screw) must only be slackened off but not taken out
X Tightening torques:
Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.
BMW AG Motorcycle Division
Maintenance schedule
F 650 GS
Customer 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
3 months or at the latest after 3,000 km (1,800 miles)
Replace oil in telescopic forks
Check the coolant and restore to correct level if necessary *
)
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 20,000 km/12,000 miles)
Check clutch play, adjust if necessary
Check wheel spoke tension and tighten if necessary
more frequently if motorcycle is ridden in severe off-road conditions
Examine brake pads and discs for wear, replace if necessary *
more frequently if motorcycle is ridden in severe off-road conditions
)
Check brake fluid level at front and rear and top up if necessary *)
Check for operation of brake system and freedom from leaks; repair/replace if necessary *
Replace the brake fluid at least once a year
BMW Inspection at
1,000 km (600 miles)
BMW Service every
10,000 km (6,000 miles)
BMW Inspection every
20,000 km (12,000 miles)
20,000
km
)
BMW Annual Service
every
2years
Replace the primary front/rear brake master cylinder cup
(every 40,000 km/24,000 miles on a motorcycle with ABS)
Check wheel bearings and replace if necessary *
)
Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion *
more frequently if motorcycle is ridden in severe off-road conditions
Check chain tension and adjust if necessary *
)
Check battery acid level, add distilled water if necessary
more frequently if motorcycle is ridden in severe off-road conditions
Clean and grease the battery terminals, if necessary
Check steering head bearings and adjust *) or replace if necessary *
)
Grease the side and main stands
Grease the brake pedal
Check bolts and nuts on engine mountings, frame connections, exhaust system
mountings, swinging fork pivot, suspension levers, brake pedal, main and side
stands and quick-release axles for tightness
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
– Test ride, if necessary
)
*
Associated work invoiced separately, see Flat rates brochure, Motorcycle ’98
40,000
km
)
Order No. 01 71 0 010 183 UX-VS-2, 10/99 Printed in Germany
BMW AG Motorcycle Division
Pre-delivery Check
F 650 GS
Customer Licence plate no.
Order No. Mechanic’s signature
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)
BMW
Pre-delivery check
Check that the delivery is complete:
– Toolkit
– Documentation
– Motorcycle keys
– Optional extras
Read the fault code memory with the BMW MoDiTeC
Check tyre pressures
Fill fuel tank
Final inspection as functional check:
– Oil inspection
– Engine idle speed
– Clutch, gearshift
– Steering
– Hand brakes and foot brakes
– Check lights and signalling equipment, warning and indicator lights,
instruments, ABS
– Test ride, if necessary
Order No. 01 71 0 010 183 UX-VS-2, 10/99 Printed in Germany
BMW AG Motorcycle Division
Service data
F 650 GS
Item Rated value Unit of
Oil capacities
Engine (with filter)
2.3 (4.05/2.43)
measurement/
specification
Litres (Imp. pints/US quarts)
Specification: see current
Service Information
Telescopic fork – for each post
Coolant
Cooling system (entire)
Expansion tank
Brake fluid DOT 4
Valve clearances
Measured cold (max. 35 °C/95 °F)
Spark plugs
Electrode gap
Idle speed 1350 +100 rpm
Clutch cable play
Hand lever cable
0.60 (1.06/0.63)
1.3 (2.29/1.37)
0.1 (0.18/0.11)
Inlet: 0.10-0.15
(0.004-0.006)
Exhaust: 0.25-0.30
(0.010-0.012)
0.6...0.7 (0.02...0.03)
1.0 - 2.0
(0.004 - 0.008)
Litres (Imp. pints/US quarts)
BMW telescopic fork oil
Litres (Imp. pints/US quarts)
Litres (Imp. pints/US quarts)
Composition:
Water: 50%
Antifreeze: 50%
Antifreeze protection
to –25 °C ( –13 °F)
mm (in)
mm (in)
NGK D8 EA
mm (in)
mm (in)
Tyre pressure (on cold tyres)
solo
when fully loaded
Tightening torques:
Engine oil drain plug
Engine water drain plug
Oil tank drain plug
Oil filter cap
Valve cap
Camshaft bracket
Spark plug
Telescopic fork oil drain plug
Round nut, steering bearing
Steering bearing locking tube
Flanged nut on locking tube
Fork stabilizer clamping screws
Front quick-release axle
Clamping screws for front quick-release axle
Rear quick-release axle
Brake caliper at fork slider tube
Swinging arm bearings
Deflection lever/frame
Deflection lever/spring strut
Deflection lever/tension strut
Swinging fork/tension strut
front/rear
1.9/2.1 (27/30)
2.1/2.3 (30/33)
40
10
21
10
10
10
20
6
25
65
65
21
80
21
100
41
100
50
47
71
41
bar (psi)
bar (psi)
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Order No. 01 71 0 010 252 UX-VS-2, 10.99 Printed in Germany
F 650 GS
Instructions for pre-delivery check
BMW AG Sparte Motorrad
After Sales
UX-VS-2
Hufelandstr. 6
D-80937 München Edition: 11/99
Contents Page
62
General view of crated motorcycle ....................................................................................3
Checking the shipping crate for damage .............................................................................3
In case of damage in Germany .................................................................................................3
In case of damage in importer markets ................................................................................3
Unpacking the motorcycle ......................................................................................................3
Inspecting motorcycle for damage ....................................................................................4
Installing remaining items on motorcycle ......................................................................4
Installing windscreen .....................................................................................................................4
Installing front mudguard, mirrors and handlebar weights ...........................................4
Filling and charging the battery ...........................................................................................5
Removing right and centre covers ..........................................................................................5
Filling and charging the battery ................................................................................................6
Checking that delivery is complete ....................................................................................7
Reading the fault code memory with the BMW MoDiTeC .....................................7
Checking tyre pressures ..........................................................................................................7
Adding fuel to tank ......................................................................................................................7
Final inspection and function check .................................................................................7
Final cleaning .................................................................................................................................8
Handing over the motorcycle ................................................................................................8
1
2
E000250
General view of crated motorcycle
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.
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. 089/14327-632
Fax. 089/14327-639
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 (0)89 14327 632
Fax. (+) 89/14327-639
Notify the supplier (e.g. freight company) without
•
delay.
Unpacking the motorcycle
Lever off the cover.
•
Take out the separate pack of items.
•
Force off cross-struts with a suitable lever.
•
e Caution:
Do not hammer out the cross-strut panels or the
motorcycle may be damaged.
Remove the end panels.
•
Remove the side panels.
•
e Caution:
Make sure that the motorcycle cannot topple.
Remove the straps at front and rear.
•
e Caution:
Remove nails projecting from the base of the crate
or lying on the base or on the floor.
3
Dispose of the packing materials in an environ-
•
mentally responsible manner as described in
Circular 23/91 - Sales.
Check the contents of the enclosed package:
•
– Front mudguard with fasteners and washers
– Windshield
– Mirrors with clamping screws and nuts
– Handlebar weights with screws
– Rider's Manual
– Service and Technical booklet
– Booklet listing service centres in Europe
– BMW emergency service sticker
– Handling instructions for batteries
Inspecting motorcycle for damage
Check for defects.
•
Use the “express handling service” to notify
•
BMW AG Sparte Motorrad, UX-VS-1
Fax: 00 49 89 382-33220
Rectify the fault.
•
If parts are needed, order them by using the
•
electronic parts list.
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
If the parts that are needed do not appear in the
•
electronic parts list (e.g. parts for official-user
motorcycles),
send an order form to:
Fax number 030-3396-2262
X Tightening torques:
Windscreen to cockpit fairing......................... 2 Nm
Installing front mudguard, mirrors
and handlebar weights
E000270
Install front mudguard.
•
3
2
Installing remaining items on
motorcycle
Installing windscreen
Wheel the motorcycle clear of the wooden pallet
•
.
E000260
Tighten the windscreen securing screws.
•
1
E000310
Install handlebar weights (1).
•
Tighten clamp screw (2) on handlebar fitting.
•
Install each mirror and secure by tightening
•
nut (3).
X Tightening torques:
Front mudguard to fork bridge ....................... 3 Nm
Clamp screw to handlebar fitting.................. 21 Nm
Union nut of mirror ....................................... 18 Nm
Handlebar weight to handlebar ...................... 9 Nm
4
5
6
4
1
3
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.
2
E000280
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).
•
5
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.
•
Top up the battery acid to the upper level mark.
•
Allow the battery to stand for at least an hour.
•
Shake the battery slightly to allow the remaining
•
air bubbles to escape.
If necessary, top up again to the upper level mark
•
with battery acid.
Recharge the battery and allow to stand for
•
24 hours.
Charge current (amps)
.........................10 % of rated battery capacity (Ah)
Check the acid level and, if necessary, top up
•
with distilled water to the upper level mark.
Make a note of the charging date on the battery.
•
E000290
e Caution:
Connect the positive battery terminal first, then the
negative terminal.
Apply acid-proof grease to the battery terminal
•
posts.
Install the battery.
•
Install right and centre covers.
•
Install seat.
•
X Tightening torques:
Right/left covers with centre cover
to mounting frame.......................................... 2 Nm
Right/left covers to centre cover .................... 2 Nm
Centre cover to main frame at front................ 2 Nm
6
Checking that delivery is complete
Adding fuel to tank
All optional extras
•
Toolkit:
•
– Reversible screwdriver
– Small star screwdriver
– 3 open-ended wrenches
a/f 8×10, 14×19, 24
– Extension for open-ended wrenches
– Spark plug wrench
– Wrench for socket-head screws, a/f 8
– 3 Torx wrenches
Torx T25, T30, T45
– 3 fuses
7.5A, 15A, 20A
Documentation
•
Motorcycle keys, 3
•
Reading the fault code memory with
the BMW MoDiTeC
Fill up with fuel.
•
Final inspection and function check
L Note:
When the motorcycle arrives, the oil level in the tank
might be below the sight glass.
2
E000300
1
E000340
Unclip diagnosis plug (1) behind cover on right.
•
Connect the diagnosis unit to the diagnosis plug.
•
Read out the fault memory.
•
Perform all requisite repair work.
•
Clip diagnosis plug into position behind cover on
•
right.
Checking tyre pressures
Check/correct tyre pressures.
•
Tyre pressures:
Solo .....................................front 1.9 bar (27.0 psi)
.............................................rear 2.1 bar (29.9 psi)
Oil check: if oil is not visible in the sight glass,
•
check whether the oil tank (2) contains oil.
Clutch
•
Check gear shift action.
•
Steering
•
Front and rear brakes
•
Check lights and signalling equipment:
•
Front and rear parking lights
•
Instrument lighting
•
Low and high headlight beams, headlight flasher
•
Brake light (operate brake at front and rear)
•
Turn signals left/right
•
Horn
•
Telltale and warning lights
•
Instruments
•
As applicable, check function of optional extras:
•
ABS: perform starting test. In the event of a fault
•
in the system, the ABS warning light comes on
as soon as the motorcycle is ridden for at least
10 seconds at a speed of 30 km/h
(approx. 20 mph) or more.
If necessary, take the motorcycle for a test ride.
•
Confirm pre-delivery check in Service and Tech-
•
nical Booklet.
See “Inspecting motorcycle for damage” if de-
•
fects are detected.
With full load......................... front 2.1 bar (29.9 psi)
.............................................rear 2.3 bar (32.7 psi)
7
Final cleaning
Handing over the motorcycle
Clean the motorcycle.
•
L Note:
Do not use a steam or high-pressure water jet. The
high steam or water pressure could damage seals,
the hydraulic system or electrical components.
L Note:
The number-plate carrier is not pre-drilled so that
number plates of any shape can be set to the best
possible position.
This is the ideal opportunity to familiarise the customer with the motorcycle in order to ensure the
customer’s satisfaction and safety.
The following points must be demonstrated and
•
explained to the customer:
– documentation and stowage space
– toolkit and stowage space
– suspension preload adjustment to suit total
weight
– checking brake fluid
– how to adjust the mirrors
–controls
– instruments and telltale lights
– optional equipment and accessories fitted
The user must be given the following information:
•
– running-in recommendations and inspection in-
tervals
– safety check
8
Contents
<< Back
Group / Chapter
00 Maintenance and general instructions ................................................ 00.1
11 Motor ....................................................................................................... 11.1
12 Engine electrics ..................................................................................... 12.1
13 Fuel preparation and control ................................................................ 13.1
16 Fuel tank and lines................................................................................. 16.1
17 Radiator .................................................................................................. 17.1
18 Exhaust system ...................................................................................... 18.1
21 Clutch ...................................................................................................... 21.1
23 Gearbox................................................................................................... 23.1
27 Drive chain............................................................................................... 27.1
W
M
B
>> Continuation
>> Continuation
Group / Chapter
32 Steering................................................................................................... 32.1
33 Rear wheel drive .................................................................................... 33.1
34 Brakes ..................................................................................................... 34.1
36 Wheels and tyres.................................................................................... 36.1
46 Frame ...................................................................................................... 46.1
51 Equipment............................................................................................... 51.1
61 General electrical equipment ............................................................... 61.1
62 Instruments............................................................................................. 62.1
63 Lights....................................................................................................... 63.1
<< Back
00
00 Maintenance and general instructions
Contents Page
Table of operating fluids ...........................................................................................................5
Tightening torques ......................................................................................................................6
Key to maintenance intervals ..............................................................................................15
Reading the fault code memory with the MoDiTeC ................................................16
(Inspections I, II, III and IV) .................................................................................................................16
Changing the engine oil and oil filter element ............................................................16
(Inspections I, II, III and IV) .................................................................................................................16
Preparatory work ...........................................................................................................................16
Draining engine oil ........................................................................................................................16
Replacing oil filter element ........................................................................................................17
Filling with engine oil ....................................................................................................................17
Checking coolant, topping up if necessary .................................................................18
(Inspections I, II and III) ......................................................................................................................18
Checking coolant ..........................................................................................................................18
Adding coolant ...............................................................................................................................18
Changing coolant .......................................................................................................................18
(Inspection IV, every 2 years) .............................................................................................................18
Changing oil in telescopic forks ........................................................................................20
(Inspection III) ....................................................................................................................................20
Checking and adjusting valve clearances ....................................................................21
(Inspections I, II and III) ......................................................................................................................21
Checking valve clearances .......................................................................................................21
Preparatory work ...............................................................................................................................21
Removing the intake air silencer together with the intake air pipe ......................................................21
Exposing the radiator ........................................................................................................................21
Exposing cylinder head .....................................................................................................................21
Turning crankshaft to TDC position ...................................................................................................21
Checking valve clearance ..................................................................................................................22
00.1
Contents Page
Adjusting valve clearances .......................................................................................................22
Installing cylinder head cover ............................................................................................................23
Installing fan shroud ..........................................................................................................................23
Installing intake air silencer ................................................................................................................23
Installing the intake air duct ...............................................................................................................23
Replacing spark plugs .............................................................................................................24
(Inspection III) ....................................................................................................................................24
Emptying drain hose from intake air silencer .............................................................24
(Inspections II and III) .........................................................................................................................24
Replacing air cleaner element ............................................................................................24
(Inspection III) ....................................................................................................................................24
Replacing fuel filter ...................................................................................................................25
(Inspection III, every 20,000 km/12,000 miles) ...................................................................................25
Checking clutch play, adjusting if necessary .............................................................26
(Inspections I, II and III) ......................................................................................................................26
Checking wheel spoke tension, adjusting if necessary ........................................26
(Inspection II) .....................................................................................................................................26
Checking brake pads and discs for wear, replacing if necessary ..................27
(Inspections II and III) .........................................................................................................................27
Checking brake pads for wear ................................................................................................27
Brake pads, front brake .....................................................................................................................27
Brake pads, rear brake ......................................................................................................................27
Replacing brake pads .................................................................................................................27
Brake pads, front brake .....................................................................................................................27
Brake pads, rear brake ......................................................................................................................28
Checking the brake discs .........................................................................................................28
Checking the brake fluid level and topping up if necessary ..............................28
(Inspection II) .....................................................................................................................................28
Brake fluid level (front brake) ....................................................................................................28
Checking brake fluid level (front brake) ..............................................................................................28
Topping up brake fluid level (front brake) ...........................................................................................28
Brake fluid level (rear brake) .....................................................................................................29
Checking brake fluid level (rear brake) ...............................................................................................29
Topping up brake fluid level (rear brake) ............................................................................................29
Checking operation of brake system and freedom from leaks, repairing/
replacing if necessary ..............................................................................................................29
(Inspection III) ....................................................................................................................................29
Changing brake fluid .................................................................................................................30
(Inspection IV) ....................................................................................................................................30
Changing brake fluid (front brake) .........................................................................................30
Changing brake fluid (rear brake) ...........................................................................................30
00.2
Contents Page
Replacing primary sealing boot, front brake master cylinder ...........................31
(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ..........................................31
Replacing primary sealing boot, rear brake master cylinder .............................32
(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ..........................................32
Inspecting front and rear wheel bearings, replacing if necessary .................33
(Inspection III) ....................................................................................................................................33
Checking chain, chainwheel and chain sprocket, replacing if necessary .33
(Inspections II and III) .........................................................................................................................33
Checking chain tension, adjusting if necessary ........................................................33
(Inspections I, II, III and IV) .................................................................................................................33
Checking chain tension ..............................................................................................................33
Adjusting chain tension ..............................................................................................................34
Checking battery acid level, adding distilled water if necessary ....................34
(Inspections II, III and IV) ....................................................................................................................34
Checking battery acid level ......................................................................................................34
Adding distilled water ..................................................................................................................34
Cleaning and greasing the battery terminals, if necessary .................................35
(Inspections III and IV) .......................................................................................................................35
Checking and adjusting steering head bearing play,
replacing if necessary ..............................................................................................................35
(Inspections II and III) .........................................................................................................................35
Checking steering head bearing play ..................................................................................35
Checking and adjusting steering head bearing play,
replacing if necessary ..............................................................................................................36
(Inspections II and III) .........................................................................................................................36
Adjusting steering head bearing play ...................................................................................36
Greasing the side and main stands and the brake pedal lever ........................37
(Inspections II and III) .........................................................................................................................37
Side stand ........................................................................................................................................37
Main (centre) stand .......................................................................................................................37
Brake pedal .....................................................................................................................................38
Checking security of threaded fasteners ......................................................................38
(Inspections I, II, III and IV) .................................................................................................................38
Final inspection with road safety and functional check .......................................39
(Inspections I, II, III and IV) .................................................................................................................39
Road safety check ............................................................................................................................39
Tyre tread depth (recommended minimum value) ..............................................................................39
Tyre pressures (tyres cold) ................................................................................................................39
Roadworthiness check ......................................................................................................................39
00.3
00.4
00
Table of operating fluids
Item Use Order number Quantity
Lubricant
Staburags NBU 30 PTM High-performance lubricating paste 07 55 9 056 992 75 g tube
Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube
Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube
Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube
Retinax EP2
Contact spray Contact spray 81 22 9 400 208 300 ml spray
Chain spray Drive chain
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 (max. 200 °C/392 °F) 07 58 1 465 170 90 g tube
Loctite 574 Surface sealant 81 22 9 407 301 50 ml tube
Curil K 2 Heat-conductive sealant 81 22 9 400 243 250 g can
Hylomar SQ 32 M Permanently elastic sealant 81 22 9 400 339 100 g tube
Adhesives and retainers
Loctite 648 Joint adhesive (low clearance) 07 58 9 067 732 5 g bottle
Loctite 638 Joint adhesive (greater clearance) 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
Wheel, steering head and taper roller
bearing grease
83 22 9 407 845 100 g tube
72 60 2 316 676
72 60 2 316 667
50 ml spray
300 ml spray
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
Cleaners
Brake cleaner Brake cleaner 83 11 9 407 848 600 ml spray
Metal Polish Polish for parts 82 14 9 400 890 100 g tube
Testing agents
Penetrant MR 68
Developer MR 70
Installation aid
BMW chilling spray Chilling components before assembly 83 19 9 407 762 300 ml spray
Crack testing agent for aluminium
housings
Crack testing agent for aluminium
housings
83 19 9 407 855 500 ml spray
81 22 9 407 495 500 ml spray
00.5
Tightening torques
Model F 650 GS
Connection Nm
11 Engine
Freewheel housing and freewheel 35 (clean thread + Loctite 648)
Engine block 10
Double drive gear on crankshaft 180 (clean thread + Loctite 243)
Driver 140 (clean thread + Loctite 243)
Pressure plate 10
Magnet hub 180 (clean thread + Loctite 243)
Signal transmitter 8
Ignition cover 10
Cylinder base 10
Spark plug 20
Threaded connection for chain tensioner 40
Oil circuit
Oil tank to intake air silencer 9
Oil filter cover 10
Oil pressure switch 12 (clean thread + Loctite 243)
Oil tank drain plug 21
Engine oil drain plug 40
Oil supply/oil return lines to engine 35
Oil pump cover 6 (clean thread + Loctite 243)
Oil pressure valve 24
Oil retaining valve 24
00
Model F 650 GS
Connection Nm
Cylinder head
Collar nuts for cylinder head 60
Collar screws for cylinder head 33
Machine screws (chaincase) 10
Camshaft mount 10
Chain sprockets to camshafts 60 threads oiled
Chain guide to camshaft mount 10 (clean thread + Loctite 243)
Cylinder head cover 10
Machine screw (hole for locating pin) 25
Cylinder head to frame 41
Cylinder head to frame, adjusting sleeve zero play, max. 5
Cylinder head to frame, locknut 100
12 Engine electrics
Magnet hub 180 (clean thread + Loctite 243)
Signal transmitter 8
Engine block cover, left/right 10
Starter to clutch cover 10
Necked-down bolts, starter housing 6
Cable cover to engine block 4
Ignition coil and holder 9
00.7
Model F 650 GS
Connection Nm
13 Fuel preparation and control
Air intake connection to cylinder head 25
Fuel filter to frame 9
Injector holder to throttle valve 5
Connecting flange, air filter box to battery carrier 5
Intake air silencer to retainer 9
Oil tank to intake air silencer 9
Throttle-valve potentiometer to throttle flap stub 3
Throttle lifter to throttle flap stub 5 (clean thread + Loctite 243)
16 Fuel tank and lines
Fuel tank to rear frame (M 8 stud) 21
Tank cover to fuel tank 3
Roll-over valve to fuel tank 2
Bracket, activated charcoal filter to fuel tank 3
Fuel pump to fuel tank 36
17 Radiator
Air duct to frame trussing 3
Expansion tank to radiator 9
Radiator to main frame 9
Water pump drain screw 10
Left engine block cover to engine block 10
Water pump cover 10
Temperature sensor in cylinder head 15
Bleed screw 12
00
Model F 650 GS
Connection Nm
18 Exhaust system
Oxygen sensor to exhaust 45
Exhaust manifold to cylinder head 20
Silencer to exhaust manifold (Torca clamp) 55
Silencer to rear frame 21
Guard to silencer 9
21 Clutch
Driver 140 (clean thread + Loctite 243)
Pressure plate 10
Engine block cover, left 10
23 Transmission
Selector lever to selector shaft 13
27 Drive chain
Drive pinion cover to engine 2
Chain takeup roller to frame 21
Chain sprocket to chain sprocket carrier 21
Quick-release shaft nut 100
Drive chain tensioning screws 10
Central nut to main shaft 140 (clean thread + Loctite 243)
00.9
Model F 650 GS
Connection Nm
31 Front forks
Fork stabiliser to fork leg 21
Clamp screws for fork bridges, top/bottom 21
Plate for bottom fork bridge to fork bridge 9
Oil drain plug 6
Damper retaining screw 20
Knurled nut/bearing preload 25
Locknut at upper fork bridge 65
32 Steering
Handlebar to fork bridge 21
Handlebar weight to handlebar 9
Clutch fitting to handlebar, M 6 9
Clutch switch to handlebar fitting 5
Pivot pin for brake lever 6
Locknut for pivot pin, clutch lever 8
33 Rear wheel drive
Suspension strut to frame 50
Suspension strut to angled lever 47
Knob for adjusting suspension-strut damping to holder 21
Holder, suspension-strut damping to frame 9
Swinging fork pivot shaft 100
Tension strut to swinging fork 41
Tension strut to angled lever 71
Angled lever to frame 50
00
Model F 650 GS
Connection Nm
34 Brakes
Bleed screw in front/rear brake calliper 7
Brake calliper to fork slider tube 41
Brake disc and sensor ring to front wheel 9 (clean thread + Loctite 243)
Brake disc to rear wheel 9 (clean thread + Loctite 243)
Brake fluid reservoir for rear brake to rear frame 1.5
Brake pedal to frame 21
Brake lines/hoses
Brake hose to brake calliper 18
Brake hose to brake lever fitting 18
Brake hose/brake line interfaces 18
Brake line to master brake cylinder, rear wheel 18
ABS
ABS sensor front/rear 9
ABS pressure modulator to holder 21
Holder for ABS pressure modulator to frame trans-
verse tube 9
Brake line to ABS pressure modulator 18
Sensor ring to rear wheel 5 (clean thread + Loctite 243)
Brake disc and sensor ring to front wheel 9 (clean thread + Loctite 243)
36 Wheels and tyres
Clamp nut, front quick-release axle 21
Front quick-release axle to fork leg 80
Rear quick-release axle to swinging arm 100
Chain sprocket to chain sprocket carrier 21
00.11
Model F 650 GS
Connection Nm
46 Frame
Body
Fairing sections/covers 3
Fairing support bracket to frame 21
Grip to rear frame 9
End trimmer to rear frame 9
Tail to rear frame 3
Seat lock to rear frame 9
Number-plate carrier to rear section of rear mudguard 3
Mudguards/wheel guards
Front mudguard, rear section to front section 3
Front mudguard to fork bridge 3 (clean thread + Loctite 243)
Rear mudguard, front and rear sections to rear frame 9
Rear mudguard, front section to bracket for case car-
rier 21
Wheel cover, bottom, to bracket 3
Wheel cover bracket to swinging arm 9
Frame
Footrest plate to main frame 21
Footrest rubber to rear footrest 5
Retaining bracket for intake air silencer to main frame 9
Engine guard to frame trussing 9
Rear frame to main frame, top 21
Rear frame to main frame, bottom 21 (clean thread + Loctite 2701)
Centre stand to main frame 41
Side stand undersection to main frame 21
Engine mounts
Engine/crankcase to main frame at rear 41
Engine/cylinder head to main frame at top 41
Engine/crankcase to engine mounting at front 41
Engine mounting to main frame 21
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