BMW F 650 GS 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, Disassembly, 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 heated 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.

eCaution:

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

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

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)

BMW Annual Service

every 2 years

20,000 km

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)

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

Pre-delivery check

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
					measurement/
					specification
Oil capacities		2.3 (4.05/2.43)			Litres (Imp. pints/US quarts)
Engine (with filter)
					Specification: see current
					Service Information
Telescopic fork – for each post		0.60 (1.06/0.63)			Litres (Imp. pints/US quarts)
					BMW telescopic fork oil
Coolant		1.3 (2.29/1.37)			Litres (Imp. pints/US quarts)
Cooling system (entire)
Expansion tank		0.1 (0.18/0.11)			Litres (Imp. pints/US quarts)
					Composition:
					Water:	50%
					Antifreeze:	50%
					Antifreeze protection
					to –25 °C ( –13 °F)
Brake fluid					DOT 4
Valve clearances		Inlet:	0.10-0.15		mm (in)
Measured cold (max. 35 °C/95 °F)			(0.004-0.006)
		Exhaust: 0.25-0.30			mm (in)
			(0.010-0.012)
Spark plugs		0.6...0.7 (0.02...0.03)			NGK D8 EA
Electrode gap					mm (in)
Idle speed			1350 +100		rpm
Clutch cable play			1.0 - 2.0		mm (in)
Hand lever cable
		(0.004 - 0.008)
Tyre pressure (on cold tyres)			front/rear		bar (psi)
solo		1.9/2.1 (27/30)
when fully loaded		2.1/2.3 (30/33)			bar (psi)
Tightening torques:
Engine oil drain plug			40		Nm
Engine water drain plug			10		Nm
Oil tank drain plug			21		Nm
Oil filter cap			10		Nm
Valve cap			10		Nm
Camshaft bracket			10		Nm
Spark plug			20		Nm
Telescopic fork oil drain plug			6		Nm
Round nut, steering bearing			25		Nm
Steering bearing locking tube			65		Nm
Flanged nut on locking tube			65		Nm
Fork stabilizer clamping screws			21		Nm
Front quick-release axle			80		Nm
Clamping screws for front quick-release axle			21		Nm
Rear quick-release axle			100		Nm
Brake caliper at fork slider tube			41		Nm
Swinging arm bearings			100		Nm
Deflection lever/frame			50		Nm
Deflection lever/spring strut			47		Nm
Deflection lever/tension strut			71		Nm
Swinging fork/tension strut			41		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

................................................................................................8

1

.................................................................................................................................8

.................................................................................7

......................................................................................................................7

..........................................................................................................7

.....................................7

....................................................................................7

Contents	Page
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

Reading the fault code memory with the BMW MoDiTeC Checking tyre pressures

Adding fuel to tank

Final inspection and function check

Final cleaning

Handing over the motorcycle

2

E000250

	General view of crated motorcycle	• Notify the supplier (e.g. freight company) without
	Checking the shipping crate for	delay.
		Unpacking the motorcycle
	damage

•When the motorcycle arrives, check the crate immediately for damage and if necessary examine the contents for consequential damage.

In case of damage in Germany

•Lever off the cover.

•Take out the separate pack of items.

•Force off cross-struts with a suitable lever.

e Caution:

• Note the damage on the delivery slip.

Do not hammer out the cross-strut panels or the

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

•Notify the supplier without delay

(e.g. freight company or DB) and also Bavaria Wirtschaftsagentur GmbH Abteilung ZW - 12

D-80788 München

Tel. [phone]

Fax. [phone]

In case of damage in importer markets

•Note the damage on the delivery slip.

•Comply with specific national market procedures.

In case of doubt, please submit enquiries to: Bavaria Wirtschaftsagentur GmbH

Abteilung ZW - 12

D-80788 München

Tel. [phone] Fax. (+) 89/14327-639

•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 environmentally 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: [phone]

•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

Installing remaining items on motorcycle

Installing windscreen

• Wheel the motorcycle clear of the wooden pallet

.

X Tightening torques:

Windscreen to cockpit fairing .........................

2 Nm

Installing front mudguard, mirrors and handlebar weights

E000270

• Install front mudguard.

3

2

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

E000260

• Tighten the windscreen securing screws.

4

5

6

4	1

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).

5

E000290

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.

eCaution:

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

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)
With full load.........................	front 2.1 bar (29.9 psi)
.............................................	rear 2.3 bar (32.7 psi)

• 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

•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 Technical Booklet.

•See “Inspecting motorcycle for damage” if defects are detected.

7

Final cleaning

• 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.

Handing over the motorcycle

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 intervals

–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

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

Adjusting chain tension

..............................................................................................................33

..............................................................................................................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	Wheel, steering head and taper roller	83 22 9 407 845	100 g tube
	bearing grease
Contact spray	Contact spray	81 22 9 400 208	300 ml spray
Chain spray	Drive chain	72 60 2 316 676	50 ml spray
		72 60 2 316 667	300 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 (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
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	Crack testing agent for aluminium	83 19 9 407 855	500 ml spray
	housings
Developer MR 70	Crack testing agent for aluminium	81 22 9 407 495	500 ml spray
	housings
Installation aid
BMW chilling spray	Chilling components before assembly	83 19 9 407 762	300 ml spray

00.5

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

00