Page 1
Repair Manual
F 650 GS
BMW AG Motorcycle Division
After Sales
Page 2
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
Page 3
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.
Page 4
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
Page 5
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
Page 6
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
Page 7
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
Page 8
Page 9
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
Page 10
2
Page 11
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
Page 12
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
Page 13
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
Page 14
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
Page 15
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
Page 16
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
Page 17
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
Page 18
>> 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
Page 19
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
Page 20
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
Page 21
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
Page 22
00.4
Page 23
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
Page 24
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
Page 25
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
Page 26
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
Page 27
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
Page 28
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
Page 29
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
Page 30
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
Page 31
Model F 650 GS
Connection Nm
51 Equipment
Ignition/steering lock to fork bridge 21
61 General electrical equipment
ABS sensor cable to sliding tube 9
ABS sensor to brake calliper mount, rear 9
Clutch switch to handlebar fitting 5
Brake light switch to handlebar fitting 3
Brake light switch, footbrake, to frame 5
Wiring harness with electronic equipment box to frame 7
Lid of electronic equipment box to frame 4
Positive/ground leads, battery 7
Battery holder to battery tray 9
Voltage regulator to bracket 7
Horn to fork bridge 18
Ground terminal for wiring harness to engine block,
right 8
62 Instruments
Instrument cover to instrument cluster 2
63 Lights
Front turn indicator with cover to cockpit fairing 3
Rear light cluster to number-plate carrier 4
00.13
Page 32
00.14
Page 33
Key to maintenance intervals
Maintenance intervals consist of the first Inspection
(after the first 1,000 km/600 miles), the BMW Service, BMW Inspection and BMW Annual Service.
Inspection 1,000 km/600 miles
BMW Running-in Check after the first 1,000 km
(600 miles).
BMW Service
After the first 10,000 km/6,000 miles and each additional 20,000 km/12,000 miles (at 18,000 miles ...
30,000 miles ... 42,000 miles).
BMW Inspection
After the first 20,000 km/12,000 miles and each additional 20,000 km/12,000 miles (at 24,000 miles ...
36,000 miles ... 48,000 miles).
BMW Annual Service
Certain tasks maintenance depend on elapsed time
as well as the distance the bike has covered. They
should therefore be carried out at least once a year
(e.g. replacing brake fluid).
If these tasks cannot be carried out during a Service
or an Inspection, a BMW Annual Service must be
performed.
In this Repair Manual, the individual maintenance intervals are shown by the following codes:
— Inspection at 1,000 km (600 miles)......................I
— BMW Service at 10,000 km (6,000 miles)...........II
— BMW Inspection at 20,000 km (12,000 miles) .. III
— BMW Annual Service........................................ IV
00.15
Page 34
00 13 624 Reading the fault code
memory with the MoDiTeC
00 11 215
Changing the engine oil and
oil filter element
(Inspections I, II, III and IV)
E000050
Unclip diagnosis plug (arrow) behind cover on
•
right.
Connect the diagnosis unit to the diagnosis plug.
•
Read out the fault memory.
•
Carry out repairs as specified.
•
(Inspections I, II, III and IV)
L Note:
If an engine failure occurs, the oil tank and feed line
must be cleaned with the material used for this purpose in the workshop, and then blown through with
compressed air.
00 11 215
– Remove left cover.
a ....................................................See Group 46
– Remove engine guard.
– Remove cover for chain sprocket from engine.
00 11 215
Preparatory work
Draining engine oil
d Warning:
Observe the hazard avoidance instructions for running internal combustion engines in enclosed spaces.
Warm up the engine to operating temperature.
•
Place a suitable container in position to catch the
•
oil.
3
212
E000110
Slacken drain plug (2) in oil tank.
•
Remove retaining screw (1).
•
Remove clamps (3).
•
Pull out the oil tank, tilt it to the left and slacken
•
drain plug (2).
Use the spark-plug wrench (toolkit) to remove
•
the filler cap from the oil tank.
Fully drain the tank.
•
Remove the oil drain plug from the engine and
•
fully drain the oil from the engine.
00.16
Page 35
00 11 215 Replacing oil filter element
1
00 11 215 Filling with engine oil
Install the oil drain plug in the oil tank with a new
•
sealing ring and tighten.
Install the oil drain plug in the engine with a new
•
sealing ring and tighten.
Fill the oil tank with 2 l (3.5 Imp. pints/2.1 US
•
2
quarts) of engine oil and install the filler cap.
3
11 7 511
E000190
Remove the left-hand screw (3) securing the oil-
•
filter cover (1).
Remove the cable for the neutral indicating
•
switch from its guide.
Engage the oil drain guide, BMW No. 11 7 511,
•
on the pins (arrows) on the engine block.
Position a drip tray beneath the engine.
•
Remove the screws (2) and remove the oil-filter
•
cover.
Remove the filter element.
•
Fully drain the oil and clean the oil-filter housing.
•
e Caution:
Dispose of the used oil and oil filter in an environmentally compatible manner.
Fit a new filter element onto the oil-filter cover.
•
Coat the O-ring of the new filter element lightly
•
with oil.
Check the O-ring of the oil-filter cover for dam-
•
age and replace if necessary.
Install the oil-filter cover complete with filter ele-
•
ment.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
d Warning:
Observe the hazard avoidance instructions for running internal combustion engines in enclosed spaces.
Run the engine for thirty seconds.
•
Add another 0.3 l (0.53 Imp. pints/0.32 US
•
quarts) of engine oil to the oil tank.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
E000010
e Caution:
Make sure that when the engine is at operating temperature, the oil level is not above the specified
level (arrow).
Check the oil level with the engine at operating
•
temperature and top up if necessary.
L Note:
Do not reinstall the engine guard, cover and chain
sprocket cover at this stage, if other maintenance
work has to be performed on assemblies normally
concealed by these components.
X Tightening torques:
Oil filter cover...............................................10 Nm
Cover for chain sprocket................................2 Nm
Operating fluids:
Brand-name HD oil, API classification SF, SG or SH;
suffix letters CD or CE are permitted; alternatively,
brand-name HD oil of CCMC classification G4 or
G5; suffix PD2 is permitted.
Engine oil capacity:
For filter
change.......... 2.3 l (4.05 Imp. pints/2.43 US quarts)
X Tightening torques:
Oil tank drain plug........................................ 21 Nm
Engine oil drain plug..................................... 40 Nm
Engine guard to frame.................................... 9 Nm
00.17
Page 36
Checking coolant, topping up if necessary
(Inspections I, II and III)
L Note:
Check coolant level only when the engine is cold.
Do not refill the coolant expansion tank if valve clearance still has to be checked/adjusted.
Checking coolant
Check coolant level through the sight glass in the
•
left cover.
Top up the coolant if the level is below the MIN
•
mark.
Adding coolant
– Remove left cover.
a ....................................................See Group 46
L Note:
Mix the coolant in a mix ratio of 50 % antifreeze,
50 % water.
Check coolant level in the expansion tank, top up
•
coolant if necessary.
Maximum level........................................................A
Minimum level.........................................................B
Installation is the reverse of the removal proce-
•
dure.
17 00 035
(Inspection IV, every 2 years)
– Remove left cover.
a ....................................................See Group 46
– Place motorcycle on side stand.
– Position a drip tray beneath the engine.
Changing coolant
A
B
E000020
e Caution:
Anti-freeze protection must be guaranteed to at
least -30 °C (-22 °F). Use only nitrite-free long-term
antifreeze and corrosion inhibitor.
Do not top up expansion tank past the MAX
mark (A).
Check antifreeze concentration in the expansion
•
tank, top up antifreeze if necessary.
1
E000210
Remove drain plug (1) from water pump.
•
Hold a funnel below the drain and open the radi-
•
ator cap.
Drain off all the coolant.
•
00.18
Page 37
2
E170030
Disconnect the coolant hose (arrow) at the frame
•
on the left and drain the radiator.
1
E000020
Remove fastener (1), lift out the expansion tank
•
and drain off all coolant.
e Caution:
Dispose of old coolant in an environmentally compatible manner.
E170090
Slacken bleed screw (2) in cylinder head.
•
Connect a hose to the bleed screw.
•
Fill the radiator until coolant escapes at the bleed
•
screw; repeatedly squeeze the coolant hoses to
expel the air.
Tighten bleed screw (2).
•
Top up coolant until the level reaches the top of
•
the filler neck (arrow).
Top up expansion tank to the MAX mark.
•
Capacity
Cooling
system ..........1.2 l (2.11 Imp. pints/1.27 US quarts)
In expansion
tank............+ 0.1 l (1.17 Imp. pints/0.11 US quarts)
Antifreeze
Use only nitrite-free long-term antifreeze and corrosion inhibitor.
Concentration
Antifreeze.........................................................50%
Water ...............................................................50%
Run the engine for a short time, then switch it off.
•
Check coolant level and top up if necessary.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
Do not install and refill the coolant expansion tank if
valve clearance still has to be checked.
Install the expansion tank.
•
Install the drain plug with a new sealing ring and
•
tighten.
Place motorcycle on its centre stand.
•
L Note:
Do not reinstall the cover at this stage, if other maintenance work has to be performed.
X Tightening torques:
Drain plug .................................................... 10 Nm
Expansion tank to radiator ............................. 9 Nm
Bleed screw................................................. 12 Nm
00.19
Page 38
00 11 279 Changing oil in telescopic
forks
(Inspection III)
– Place motorcycle on its centre stand.
– Lift front wheel clear of the ground.
Remove the sealing caps from the fork legs.
•
1
5
E310020
2
E310030
Slacken clamp screws (1, 2) at top/bottom fork
•
bridges.
3
4
E310010
Pull the fork legs up and tighten the clamp
•
screws.
Position a drip tray beneath the telescopic forks.
•
Slacken oil drain plugs (5) on left and right.
•
Allow all the oil to drain off.
•
e Caution:
Dispose of used oil in an environmentally compatible manner.
Install the oil drain plugs (5) with new sealing
•
rings and tighten.
Fill with specified quantity of oil.
•
Install plugs in left and right forks, complete with
•
snap rings.
Slacken clamp screws (1, 2) at top/bottom fork
•
bridges and lower the fork legs.
Tighten clamp screws at top and bottom fork
•
bridges.
Install the sealing caps.
•
Oil content of each fixed fork tube
...................0.60 l (1.06 Imp. pints/0.62 US quarts)
Operating fluids:
Telescopic fork...................BMW telescopic fork oil
X Tightening torques:
Oil drain plug.................................................. 6 Nm
Clamp screws,
top/bottom fork bridges ............................... 21 Nm
d Warning:
Note that plugs (4) at left and right are spring-loaded. Wear protective goggles when removing and installing.
Press plug (4) down and remove snap ring (3).
•
Carefully allow the plug to ride up and remove.
00.20
Page 39
00 11 602 Checking and adjusting
valve clearances
(Inspections I, II and III)
00 11 601 Checking valve clearances
Preparatory work
– Remove left, right and centre covers.
– Remove the battery.
Removing the intake air silencer together with
the intake air pipe
Remove the fastener for the intake air silencer
•
from the oil tank.
Remove the fasteners for the intake air silencer
•
from the retainer.
Remove the starter relay from the holder.
•
Slacken the fasteners for the lid of the electronic
•
equipment box.
Remove the fasteners for the battery tray.
•
Disengage the clamp securing the breather hose
•
and disconnect the hose from the intake air silencer.
Press the oil tank slightly to the left and carefully
•
disconnect the intake air silencer from the throttle flap stub.
Pull the intake air silencer with intake air pipe and
•
battery carrier to the rear to remove.
Cover/seal the throttle flap stub.
•
Exposing cylinder head
1
2
3
4
5
7
Disconnect ignition coil at plug (2).
•
Pull spark plug connector off spark plug.
•
Remove screws securing ignition coil (1) to cylin-
•
der head cover.
Disengage throttle cable from adapter (arrow).
•
Remove circlip (6) from throttle-cable holder and
•
disengage throttle cable.
Disengage cover (4) from the anchorages on
•
main frame on each side and remove.
Remove spark plug.
•
Use pliers, BMW No. 17 5 500, to release hose
•
clip (5) and disconnect cylinder-head breather
hose (7).
6
E000030
Exposing the radiator
E000150
L Note:
When temporarily securing the expansion tank,
make sure that the cap is above the level of the coolant.
Disconnect the expansion tank from the radiator,
•
pull it to one side and temporarily secure it to the
handlebar with a cable tie or similar.
Unclip the MoDiTeC plug from its holder.
•
Disconnect plug for fan.
•
Disengage the clips at top and bottom and re-
•
move the fan.
Protect the interior of the radiator with cardboard
•
or similar.
L Note:
Note the position of the two anchorages for ignition
coil (1) on the cylinder-head cover.
Remove 8 fasteners (3) and remove the cylinder-
•
head cover with gasket.
Turning crankshaft to TDC position
Remove the central threaded plug in the magnet-
•
ic housing.
Use an Allen key to turn the crankshaft clockwise
•
to the TDC position.
00.21
Page 40
Checking valve clearance
E000170
E000160
Use a feeler gauge (arrow) to determine valve
•
clearance.
Make a note of the valve clearances, or adjust
•
them if necessary.
Valve clearances:
Inlet valve............... 0.05...0.10 m (0.002...0.004 in)
Exhaust valve ...... 0.25...0.30 mm (0.010...0.012 in)
00 11 602
Adjusting valve clearances
11 7 503
11 7 502
11 7 501
11 7 504
Turn the bucket tappet until the shim (arrow) can
•
be levered out at the groove in the bucket tappet.
11 7 503
E000040
Secure thruster, BMWNo.117503, on the
•
shaft by tightening the screw (arrow).
Position thruster, BMW No. 11 7 503, on the
•
edge of the bucket tappet.
Press down the bucket tappet and secure shaft,
•
BMW No. 11 7 502, with clamp block,
BMW No. 11 7 504.
E000170
Secure yoke of valve-clearance adjuster,
•
BMWNo.117501, to the cylinder head.
Seal the aperture in the cylinder head with the
•
cover plate (arrow).
Turn the camshaft until the points of the cams
•
are up.
L Note:
Thruster toward outer edge of cylinder head.
Install shaft, BMW No. 11 7 502, thruster,
•
BMWNo.117503, and clamp block,
BMWNo.117504.
00.22
L Note:
If the shim is too tight to be removed easily, the
hold-down assembly is sitting on the shim instead of
on the edge of the bucket tappet. If this happens
back off the hold-down assembly and repeat the
procedure.
Release the shim with a screwdriver or similar
•
tool, then use magnetic holder,
BMW No. 11 7 505, to remove.
Page 41
Before installing new shim, check thickness with
•
a micrometer.
Position the shim in the bucket tappet.
•
Carefully release the clamp on the shaft, then re-
•
move the shaft and the hold-down assembly.
Installing the intake air duct
e Caution:
Check that the shim is correctly seated in the bucket
tappet.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Installing cylinder head cover
Before installing the cylinder head cover, remove
•
all traces of the gasket and clean the sealing face
with degreasing agent. Also clean the groove
and the seating faces for the gasket.
Installing fan shroud
2
1
E000180
Engage the tabs at the top and bottom of fan
•
shroud (2) in the hooks on the radiator (1).
4
3
5
6
E130090
Introduce the fits of intake air silencer (5) with air
•
filter element (6) and intake air duct (4) into the
guide on the battery tray (3)/connecting flange.
If necessary, top up the coolant level in the ex-
•
pansion tank.
Valve clearances:
Inlet valve ............... 0.05...0.10 m (0.002...0.004 in)
Exhaust valve ...... 0.25...0.30 mm (0.010...0.012 in)
X Tightening torques:
Cylinder head cover to cylinder head........... 10 Nm
Ignition coil to cylinder head........................... 9 Nm
Lid of electronic equipment box ..................... 4 Nm
Spark plug in cylinder head.......................... 20 Nm
Oil tank to intake air silencer .......................... 9 Nm
Intake air silencer to frame ............................. 9 Nm
Connecting flange, air filter box
to battery tray................................................. 5 Nm
Expansion tank to radiator ............................. 9 Nm
Trim panel/cover............................................ 3 Nm
Installing intake air silencer
L Note:
Do not reinstall the intake air silencer at this stage, if
the fuel filter has to be removed.
Make sure that the intake pipe is correctly seated on
the throttle flap stub.
00.23
Page 42
00 12 620 Replacing spark plugs
(Inspection III)
Pull spark plug connector off spark plug.
•
Remove the spark plug with the a/f 18 socket
•
wrench.
Installation is the reverse of the removal proce-
•
dure.
X Tightening torques:
Spark plug.................................................... 20 Nm
00 13 630
Replacing air cleaner
element
(Inspection III)
– Remove right cover.
Remove connecting flange from air filter box.
•
1
Emptying drain hose from intake air
silencer
(Inspections II and III)
Have a funnel and drip tray ready.
•
E000130
Remove the plug (arrow) and drain off all the oil.
•
e Caution:
Dispose of used oil in an environmentally compatible manner.
2
E000140
Pull intake air duct (1) out of the holder.
•
Remove air filter element (2).
•
Clean the intake air silencer.
•
Assembly is the reverse of the disassembly pro-
•
cedure.
X Tightening torques:
Connecting flange.......................................... 5 Nm
00.24
Page 43
00 16 617 Replacing fuel filter
(Inspection III, every 20,000 km/12,000 miles)
d Warning:
Comply with safety precautions when handling or
working with fuel; note that the fuel lines are
pressurised.
– Remove left cover.
Slacken the hose clamps.
•
d Warning:
Fuel escapes from the filter when the lines are disconnected.
Disconnect fuel lines (3, 5, 7) from the filter.
•
Remove clamp (4) from the fuel filter.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
2
E000110
Remove clips (2) and fastener (1) and pull the oil
•
tank out of the holder.
Remove the BMS control unit from the holder.
•
5
3
4
6
1
e Caution:
Note the installed positions of fuel feed line (7) and
fuel return line (3).
Close hose clamps with pliers,
•
BMWNo.131500.
X Tightening torques:
Fuel filter to frame .......................................... 9 Nm
Oil tank to intake air silencer .......................... 9 Nm
Air filter box to frame...................................... 9 Nm
Connecting flange, air filter box
to battery tray................................................. 5 Nm
13 3 010
7
Remove the fastener securing the fuel filter to
•
frame (6).
Close off fuel supply line (7) and the line to the
•
fuel injector (5) with hose clips,
BMW No. 13 3 010.
E130100
00.25
Page 44
21 00 004 Checking clutch play,
adjusting if necessary
Checking wheel spoke tension,
adjusting if necessary
(Inspections I, II and III)
A
1
E000240
Release lever (1) on the gearbox must be located
•
on the splines such that when it is pressed for-
ward as far as the release point, distance “A” is
as specified.
Distance “A”................. 47...52 mm (1.85...2.05 in)
2
3
B
(Inspection II)
Strike the spokes and listen for differences in the
•
pitch of the sound.
If spokes are loose, tighten them with spoke nip-
•
ple wrench, BMWNo.363800.
Vertical runout..........................max. 2 mm (0.08 in)
Lateral runout...........................max. 2 mm (0.08 in)
E000200
Adjust dimension “B” by turning adjusting
•
screw (2) on the clutch handlebar lever.
Lock adjusting screw (2) with knurled nut (3).
•
Dimension “B” ............. 1.0...2.0 mm (0.04...0.08 in)
00.26
Page 45
Checking brake pads and discs for
wear, replacing if necessary
Replacing brake pads
(Inspections II and III)
Checking brake pads for wear
Brake pads, front brake
E000060
Visually inspect the brake pads.
•
– The brake pad wear marks (arrows) must be
clearly visible.
e Caution:
Do not operate the brake when dismantled.
Do not permit the brake pads to wear past the specified minimum thickness.
Always replace the brake pads as a complete set.
00 34 630 Brake pads, front brake
Press the brake calliper against the brake disc in
•
order to force the pistons back.
1
32
E340030
Brake pads, rear brake
E000070
Measuring brake pad thickness (arrows)
•
Minimum pad thickness ................. 1 mm (0.04 in)
Remove keeper (3).
•
Drive out retaining pin (2).
•
Remove the brake pads.
•
Remove fasteners (1) and remove brake calliper.
•
4
E340010
Make sure that spring (4) is correctly seated and
•
installed right way round: engraved arrow must
point in forward direction of travel.
Install the brake pads.
•
Install the keeper and the retaining pin.
•
Install brake calliper.
•
Operate brake several times until brake pads are
•
correctly seated.
X Tightening torques:
Brake calliper to fork slider tube................... 41 Nm
00.27
Page 46
00 34 633 Brake pads, rear brake
Press the brake calliper against the brake disc in
•
order to force the pistons back.
Checking the brake fluid level and
topping up if necessary
(Inspection II)
L Note:
The volume of the brake fluid (MIN/MAX) is sufficient
for lining thicknesses from new to the wear limit. It is
not normally necessary to top up the fluid to accommodate lining wear.
1
2
A level below MIN indicates the possibility of other
faults.
Brake fluid level (front brake)
E340020
Remove keeper (1).
•
Drive out retaining pin (2).
•
Remove brake pads.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Operate brake several times until brake pads are
•
correctly seated.
Checking the brake discs
Carefully check the brake discs for cracks, dam-
•
age, deformation and scoring.
E000080
Measure the thickness of the brake discs at sev-
•
eral points with a calliper gauge.
Checking brake fluid level (front brake)
3
E000120
Turn the handlebars so that the cover of the res-
•
ervoir is horizontal.
– The brake fluid must be between the top of the
sight glass and the centre of the sight
glass (arrow).
Topping up brake fluid level (front brake)
Release fasteners (3).
•
Remove cover complete with rubber gaiter.
•
Add brake fluid up to the top of the sight glass.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Wipe the rim of the reservoir, the rubber gaiter
•
and the cover to remove brake fluid.
Brake fluid grade .........................................DOT 4
Brake disc wear limits
Front brake disc ........................... 4.5 mm (0.18 in)
Rear brake disc............................ 4.5 mm (0.18 in)
00.28
Page 47
Brake fluid level (rear brake)
Checking brake fluid level (rear brake)
Checking operation of brake system
and freedom from leaks, repairing/
replacing if necessary
(Inspection III)
1
E0000090
Maximum level ............................................ “MAX”
Minimum level .............................................. “MIN”
Topping up brake fluid level (rear brake)
Take off cover (1) with rubber gaiter.
•
Top up the brake fluid level to the “MAX”
•
mark (arrow).
Wipe the rim of the reservoir, the rubber gaiter
•
and the cover to remove brake fluid.
Check all brake lines for damage and correct
•
routing.
Wipe down all threaded unions on the brake lines
•
and check them.
Apply firm pressure to the brake lever and brake
•
pedal and keep this pressure applied for a few
moments.
Release the brakes and check the brake lines for
•
leaks.
d Warning:
Defective lines and threaded unions in the brake
system must always be replaced without delay.
Brake fluid grade .........................................DOT 4
00.29
Page 48
00 34 606 Changing brake fluid
(Inspection IV)
e Caution:
Refer to notes on the hazards involved in handling
brake fluid.
Do not allow brake fluid to come into contact with
painted parts of the motorcycle, because brake fluid
destroys paint.
Changing brake fluid (front brake)
1
E000120
Brake fluid grade .........................................DOT 4
X Tightening torques:
Bleed screw................................................... 7 Nm
Changing brake fluid (rear brake)
2
E0000090
Remove cover (2) complete with rubber gaiter
•
and top up the level of brake fluid in the reservoir.
Connect the brake bleeding device to the bleed
•
screw on the brake calliper.
Open the bleed screw by half a turn.
•
Turn the handlebars so that the cover of the res-
•
ervoir is horizontal.
Remove cover (1) complete with rubber gaiter
•
and top up the level of brake fluid in the reservoir.
Connect the brake bleeding device to the bleed
•
screw on the brake calliper.
Open the bleed screw by half a turn.
•
e Caution:
While bleeding the system, do not allow the brake
fluid level to drop below the centre of the sight glass
(arrow), as otherwise air will be drawn into the brake
system. Bleed the system again if this happens.
Draw off brake fluid until it emerges clear and
•
free from air bubbles.
Tighten the bleed screw.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Before reassembling, carefully wipe the rim of
•
the reservoir, the rubber gaiter and the cover to
remove all traces of brake fluid.
e Caution:
Brake fluid level must not drop below the MIN mark
during the bleeding process, otherwise air will be
drawn into the brake system. Bleed the system
again if this happens.
Draw off brake fluid until it emerges clear and
•
free from air bubbles.
Tighten the bleed screw.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Before reassembling, carefully wipe the rim of
•
the reservoir, the rubber gaiter and the cover to
remove all traces of brake fluid.
Brake fluid grade .........................................DOT 4
X Tightening torques:
Bleed screw................................................... 7 Nm
00.30
Page 49
Replacing primary sealing boot,
front brake master cylinder
(Inspection III, every 40,000 km/24,000 miles for
motorcycles with ABS)
– Place the motorcycle on its main (centre) stand.
e Caution:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle, because brake fluid
destroys paint.
5
6
7
Drain the front brake system.
•
Remove the hand-brake lever.
•
1
2
Remove thrust pin (2) with boot (1) and spring.
•
Carefully force back the brake piston.
•
4
E340120
E340140
Remove spring (6) with insert (5).
•
e Caution:
Note the washer between the brake piston and the
boot.
Remove front boot (7).
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
e Caution:
Sealing lips of the boots toward the pressure chamber.
Install new front boot.
•
Prior to installation, coat the brake piston and the
•
boots with the assembly fluid supplied.
Lightly grease the thrust pin with
•
Shell Retinax A.
Fill and bleed the brake system.
•
X Tightening torques:
Pivot pin of handbrake lever........................... 7 Nm
Locknut of handbrake lever............................ 7 Nm
3
Remove retaining ring (3).
•
Use pliers to remove brake piston (4).
•
E340130
00.31
Page 50
Replacing primary sealing boot, rear
brake master cylinder
(Inspection III, every 40,000 km/24,000 miles for
motorcycles with ABS)
– Place the motorcycle on its main (centre) stand.
e Caution:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle, because brake fluid
destroys paint.
Drain the rear brake system.
•
1
2
E340250
3
4
5
6
E340290
Remove spring (4) with insert (3).
•
e Caution:
Note the washer between the brake piston and the
boot.
Remove front boot (5).
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
e Caution:
Sealing lip of the boot toward the pressure chamber.
Disengage piston thrust rod (1).
•
Remove the piston thrust rod complete with
•
sealing boot (2).
Carefully force back the brake piston.
•
Remove the circlip.
•
Use pliers to remove the brake piston.
•
L Note:
Replace O-ring (6) prior to installation.
Install new front boot.
•
Prior to installation, coat the brake piston and the
•
boots with the assembly fluid supplied.
Lightly grease the thrust rod with
•
Shell Retinax A.
Fill and bleed the brake system.
•
00.32
Page 51
Inspecting front and rear wheel
bearings, replacing if necessary
(Inspection III)
27 71 005
Checking chain tension,
adjusting if necessary
(Inspections I, II, III and IV)
27 71 005 Checking chain tension
L Note:
Check play when bearings are cold.
Lift front/rear wheel of the ground.
•
Tilt the front/rear wheel to and fro on the axle.
•
– No play should be detected.
Replace the bearings if play is detected.
•
Checking chain, chainwheel and
chain sprocket, replacing if necessary
(Inspections II and III)
– Remove the sprocket cover.
Check chainwheel and chain sprocket for distor-
•
tion.
1
2
– Place the unloaded motorcycle on its main (cen-
tre) stand.
e Caution:
Check and adjust the chain tension only when the
motorcycle is unloaded.
E000100
Chains stretch unevenly, so turn the rear wheel
•
to find the point at which chain deflection midway
along the run between chainwheel and rear
sprocket is least.
At this point, push the chain up as far at it will go
•
and measure chain deflection.
3
F000230
– good (1)
–replace (2)
–replace (3)
e Caution:
Always replace the chain, chainwheel and sprocket
as a set.
Chain deflection ............ 35...45 mm (1.38...1.77 in)
00.33
Page 52
27 71 005 Adjusting chain tension
61 20 029
Checking battery acid level,
adding distilled water if necessary
(Inspections II, III and IV)
d Warning:
Battery acid is highly caustic.
3
Protect your eyes, face, hands, clothing and the
paintwork.
2
1
E270010
Loosen quick-release axle nut (2).
•
e Caution:
When tensioning the chain, make sure that wheel
alignment is correct. Check that the same number of
notch marks are visible in window (3) on each side
of the swinging fork.
Adjust chain slack with chain tensioning
•
screws (1).
Firmly tighten quick-release axle nut (2).
•
Check chain tension.
•
Tighten chain tensioning screws (1).
•
Chain slack ................... 35...45 mm (1.38...1.78 in)
L Note:
Allow time for chain spray to take effect after spraying on. Avoid contamination of rider’s clothing.
61 20 029
– Remove left, right and centre covers.
Check the battery fluid level.
•
– The battery fluid level must be between
maximum “UPPER LEVEL” and
minimum “LOWER LEVEL”.
61 20 029
Open the battery caps.
•
Checking battery acid level
Adding distilled water
e Caution:
Use only distilled water to top up the acid level in the
battery. Never top up with diluted sulphuric acid.
Top up with distilled water until the fluid level
•
reaches the “UPPER LEVEL” mark.
Replace the battery caps securely.
•
Installation is the reverse of the removal proce-
•
dure.
X Tightening torques:
Quick-release shaft nut .............................. 100 Nm
Chain tensioning screws .............................. 10 Nm
00.34
Page 53
61 21 520 Cleaning and greasing the
battery terminals, if necessary
(Inspections III and IV)
L Note:
Disconnecting the battery clears all entries (such as
errors, adaptations) from the BMS control unit memory.
– Remove left, right and centre covers.
e Caution:
Disconnect the battery only with the ignition
switched off.
Disconnect the negative battery cable first, then the
positive cable.
1
2
32 00 454
Checking and adjusting
steering head bearing play,
replacing if necessary
(Inspections II and III)
Checking steering head bearing play
Lift front wheel clear of the ground.
•
E360010
Move fixed fork tubes forward (arrows).
•
Adjust the steering head bearing if play is per-
•
ceptible.
E610020
Disconnect ground cable (2) from the battery.
•
Disconnect positive cable (1) from the battery.
•
Clean the battery terminals and grease them with
•
acid-proof battery grease.
Acid-proof battery terminal grease
................................................e.g. Bosch Ft 40 V1
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
e Caution:
Connect the positive battery cable first, then the
negative cable.
Route the positive cable vertically (arrow) to the
•
battery post. Make sure that all battery cells are
visible through the inspection port in the cover.
00.35
Page 54
32 00 454 Checking and adjusting
steering head bearing play,
replacing if necessary
(Inspections II and III)
32 00 454
Adjusting steering head
bearing play
e Caution:
Cover or mask off the instrument cluster and trim to
prevent scratches.
1 2
E320010
Remove impact pad (2).
•
Remove clamp blocks (1).
•
Remove the handlebar and place it in front of the
•
instrument cluster.
6
31 6 521
E000220
Slacken round nut (6) with pin-wrench adapter,
•
BMW No. 31 6 521, then tighten to 25 Nm.
Turn forks back and forth twice from lock to lock,
•
and leave the forks at the full left lock position.
Mark a 40 mm (1.58 in) arc with adhesive tape or
•
similar (arrow) around the circumference of the
locking plate at the steering head.
Align the mark on pin-wrench adapter,
•
BMW No. 31 6 521, with the right-hand end of
the marked arc.
L Note:
40 mm (1.58 in) around the circumference of the
locking plate corresponds to an angle of rotation
of 60 °.
Turn the round nut clockwise until the pointer on
•
pin-wrench adapter, BMW No. 31 6 521, reaches the left-hand end of the marked arc.
Remove the mark/adhesive tape from the locking
•
plate.
3
4
E320020
Unscrew hex nut (5).
•
Release clamping screws (3) at upper fork
•
bridge.
Remove the upper fork bridge complete with the
•
ignition lock.
Remove counter-tube (4).
•
e Caution:
Check the mating faces of the fork bridge and
knurled nut, rub down with an oilstone if necessary
and clean.
Tighten counter-tube (4).
•
Install fork bridge.
•
Tighten locknut (5).
•
Tighten the clamping screws at fork bridge (3).
5
•
Check play and freedom of movement.
•
00.36
Page 55
E000230
L Note:
Use the punch marks (arrow) to align the handlebars
as shown.
Greasing the side and main stands
and the brake pedal lever
(Inspections II and III)
Side stand
d Warning:
Begin by tightening the front securing screws (as
viewed in the forward direction of travel) of the clamp
blocks, then tighten the rear securing screws.
Install handlebars and impact pad.
•
Take the load off the front wheel and perform fi-
•
nal check.
– With the front wheel off the ground, the weight of
the forks must be enough to turn the steering all
the way to the left and right full lock positions as
soon as the steering is moved away from the
straight-ahead position.
– If local points of stiffness are detected when the
handlebar is moved to and fro, renew the steering head bearings.
X Tightening torques:
Initial torque, round nut ................................ 25 Nm
Back off through angle of rotation .................... 60 °
Counter-tube to steering head bearing......... 65 Nm
Hexagon nut to counter-tube ....................... 65 Nm
Clamp screws at fork bridge......................... 23 Nm
Handlebar to fork bridge ..............................23 Nm
E460010
Grease bearing bush (arrow) with a grease gun
•
until fresh grease emerges at the lubricated faces.
If very dirty and stiff to move, remove the side
•
stand and grease its pivots.
Main (centre) stand
E460020
Grease bearing bushes (arrows) with a grease
•
gun until fresh grease emerges at the lubricated
faces.
Lubricant:
for pivot bushing .............. Staburags NBU 30 PTM
If very dirty and stiff to move, remove the main
•
stand and grease its pivots.
00.37
Page 56
Brake pedal
Checking security of threaded
fasteners
3
2
1
E340040
Remove hexagon fit bolt (2).
•
Remove bushing (1).
•
Grease the bushing and the fit bolt.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
e Caution:
Check operation of brake-light switch (3).
X Tightening torques:
Brake pedal to frame.................................... 21 Nm
Lubricant:
for pivot bushing............... Staburags NBU 30 PTM
(Inspections I, II, III and IV)
Check the security of the following threaded fas-
•
teners:
– Engine mounting bolts and nuts
– Threaded t frame
– Main and side stands
– Exhaust mountings
– Swinging fork pivots
– Angled lever
– Brake pedal
– Quickrelease axles
X Tightening torques:
Engine/crankcase
to main frame at rear.................................... 41 Nm
Engine/cylinder head to main frame at top ... 41 Nm
Engine/crankcase to engine mounting
at front ......................................................... 41 Nm
Engine mounting to main frame.................... 21 Nm
Footrest plate to main frame......................... 21 Nm
Engine guard to frame.................................... 9 Nm
Rear frame to main frame............................. 21 Nm
Centre stand to main frame.......................... 41 Nm
Side stand undersection to main frame........ 21 Nm
Exhaust manifold to cylinder head................ 20 Nm
Silencer to exhaust manifold
(Torca clamp)............................................... 55 Nm
Silencer to rear frame................................... 21 Nm
Spring strut to angled lever .......................... 47 Nm
Angled lever to frame................................... 41 Nm
Strut to angled lever..................................... 71 Nm
Strut to swinging arm................................... 41 Nm
Swinging-arm axle...................................... 100 Nm
Footbrake lever to frame .............................. 21 Nm
Clamp of front quick-release axle................. 23 Nm
Front quick-release axle to fork leg .............. 80 Nm
Rear quick-release axle to swinging arm.... 100 Nm
00.38
Page 57
Final inspection with road safety
and functional check
(Inspections I, II, III and IV)
Road safety check
Check wheels and tyres.
•
Check tyre pressures and correct if necessary.
•
Tyre tread depth (recommended minimum value)
d Warning:
It must comply with legal regulations concerning
minimum tyre tread depth.
Front wheel ...................................... 2 mm (0.08 in)
Rear wheel....................................... 3 mm (0.12 in)
Tyre pressures (tyres cold)
Solo
Front wheel ................................. 1.9 bar (27.0 psi)
Rear wheel ................................. 2.1 bar (30.0 psi)
With full load
Front wheel ................................. 2.1 bar (30.0 psi)
Rear wheel .................................. 2.3 bar (33.0 psi)
Roadworthiness check
– Clutch, gear shift
– Steering
– Handbrake and foot brake
– Lights and signalling equipment, telltale and
warning lights, instruments
– Side-stand switch
– If necessary, test ride
00.39
Page 58
00.40
Page 59
11
11 Motor
Contents Page
Technical Data ............................................................................................................................... 5
Sectional view of engine ........................................................................................................11
Engine oil circuit .........................................................................................................................12
Valve gear .......................................................................................................................................13
Valves, components ..................................................................................................................14
Oil pumps, components ..........................................................................................................15
Removing and installing cylinder head, engine installed .....................................16
Preparatory work ...........................................................................................................................16
Removing camshafts ...................................................................................................................18
Removing cylinder head ............................................................................................................18
Removing cylinder, engine installed ................................................................................20
Removing engine ........................................................................................................................21
Preparatory work ...........................................................................................................................21
Removing engine ..........................................................................................................................22
Transferring engine to assembly frame ...............................................................................22
Lowering engine ..........................................................................................................................23
Preparatory work ...........................................................................................................................23
Lowering the engine ....................................................................................................................24
Disassembling engine ..............................................................................................................26
Removing cylinder head ............................................................................................................26
Removing camshafts .........................................................................................................................26
Checking camshaft for wear ..............................................................................................................27
Removing and installing timing-chain sprockets ................................................................................27
Checking centrifugal decompressor lever .........................................................................................27
Disassembling and assembling the centrifugal decompressor ..........................................................27
Removing cylinder head ....................................................................................................................28
Checking timing chain for wear .........................................................................................................28
11.1
Page 60
Contents Page
Disassembling and assembling cylinder head .................................................................29
Removing valves ...............................................................................................................................29
Bore for bucket tappet ......................................................................................................................29
Checking valve guide for wear ...........................................................................................................30
Removing valve guide .......................................................................................................................30
Installing valve guide .........................................................................................................................31
Checking valve seat for wear .............................................................................................................31
Installing valve stem seal ...................................................................................................................32
Checking valve for wear ....................................................................................................................32
Installing valves .................................................................................................................................33
Removing cylinder ........................................................................................................................33
Checking cylinder .........................................................................................................................33
Removing piston ............................................................................................................................34
Disassembling piston ..................................................................................................................34
Determining clearance of piston in cylinder ......................................................................34
Determining piston ring gaps ..................................................................................................35
Determining piston pin clearance ..........................................................................................35
Assembling pistons ......................................................................................................................35
Removing ignition magnet ........................................................................................................35
Removing countershaft for starter .........................................................................................36
Disassembling and assembling freewheel .........................................................................37
Disassembling freewheel ...................................................................................................................37
Assembling freewheel .......................................................................................................................37
Removing clutch ............................................................................................................................38
Removing pressure plate ...................................................................................................................38
Removing clutch plates .....................................................................................................................38
Removing and installing oil pump ..........................................................................................39
Removing oil pump ...........................................................................................................................39
Inspecting oil pump ...........................................................................................................................39
Installing oil pump .............................................................................................................................39
Removing double drive gear ....................................................................................................40
Removing crankshaft and balancing shaft .........................................................................40
Checking crankshaft for wear ............................................................................................................41
Removing compensating gear ................................................................................................41
Removing and installing crankshaft gear ...........................................................................41
Removing and installing gearbox mainshaft bearings ..................................................42
Removing and installing gearbox compensating shaft bearings .............................42
Removing and installing grooved ball bearings
of gearbox compensating shaft ..............................................................................................43
11.2
Page 61
Contents Page
Removing and installing main bearings ..............................................................................43
Removal ............................................................................................................................................43
Installation .........................................................................................................................................44
Assembling engine ....................................................................................................................45
Installing crankshaft and balancing shaft ...........................................................................45
Shimming crankshaft .........................................................................................................................45
Installing double drive gear .......................................................................................................46
Installing oil pump gears ............................................................................................................47
Installing clutch ..............................................................................................................................48
Installing clutch cage .........................................................................................................................48
Installing driver ..................................................................................................................................48
Installing pressure plate ....................................................................................................................49
Installing countershaft for starter motor ..............................................................................49
Installing magnetic ignition trigger .........................................................................................50
Installing piston ..............................................................................................................................51
Installing cylinder ...........................................................................................................................52
Installing cylinder head ...............................................................................................................52
Installing camshaft and adjusting valves ............................................................................54
Installing engine ..........................................................................................................................56
Bleeding engine oil circuit .................................................................................................................56
11.3
Page 62
11.4
Page 63
11
Technical Data F 650 GS
Engine, general
Type Single-cylinder four-stroke, double overhead
camshafts driven by roller chain, 4 valves operated by bucket tappets, balancing shaft, liquidcooled cylinder and cylinder head, integral water
pump, 5-speed gearbox and dry sump lubrica-
tion.
Cylinder bore mm (in) 100 (3.94)
Stroke mm (in) 83.0 (3.27)
Displacement cc 652
Compression ratio 11.5 : 1
Power output kW (hp) 37 (50)
at 6500 rpm
Max. torque Nm 60
at 5000 rpm
Idle speed rpm 1400
Max. continuous engine speed rpm 7000
Max. engine speed rpm 7500
Crankshaft (main) bearings Plain bearing
Engine lubrication Dry sump, with oil pump
Cylinder Light alloy, “Nikasil” coated
Piston Cast aluminium with
3 rings
Oil filter Full-flow type
Oil pump 2 trochoid pumps, driven from primary output
Oil capacity l (Imp.pints/
US quarts) 2.3 (4.05/2.43)
Oil pressure (idle speed) bar (psi) ≥ 0.5 (7.11)
(oil temperature 80 °C/176 °F)
Permissible oil consumption l/100km
(miles per
Imp. pint/
miles per
US quart) 0.1 (350/590)
11.5
Page 64
Technical Data F 650 GS
Crank gear
Crankshaft - main bearing play
On installation
Wear limit
Wear limit, main bearing bore diameter
Wear limit
Main bearing journal diameter
Bearing play
Runout at crankpin
Clutch end
Magnet end
Connecting rod
Wear limit, connecting rod
Radial play
Big end bore
Small end bore
Connecting rod - axial play
On installation
Wear limit
Small-end bearing - axial play
On installation
Wear limit
Compensating shaft
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
0.030...0.070 (0.0012...0.0028)
0.10 (0.004)
46.08 (1.814)
47.97 (1.888)
0.10 (0.004)
0.03 (0.001)
0.05 (0.002)
0.08 (0.003)
0.05 (0.002)
0.30...0.65 (0.012...0.026)
0.80 (0.031)
22.015...22.025 (0.8668...0.8671)
22.04 (0.868)
Bearing journals
Wear limit 19.96 (0.786)
Cylinder head
Camshaft journals I/E
Wear limit
Camshaft bearing play I/E
Wear limit
Valves
Valve clearances with engine cold
(max. 35 °C/95 °F)
Inlet valves
Exhaust valves
Valve timing (at 3 mm/0.12 in valve
clearance)
Inlet opens
Inlet closes
Exhaust opens
Exhaust closes
Valve head dia.
Inlet
Exhaust
Stem dia.
Inlet
Wear limit
Exhaust
Wear limit
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
21.967...21.980 (0.8649...0.8654)
21.950 (0.8642)
0.020...0.060 (0.0008...0.0023)
0.090 (0.0035)
0.05...0.10 (0.002...0.004)
0.25...0.30 (0.010...0.012)
13° after TDC
25° after BDC
25° before BDC
13° before TDC
36 (1.41)
31 (1.22)
4.90...4.94 (0.193...0.194)
4.89 (0.193)
4.90...4.94 (0.193...0.194)
4.89 (0.193)
Valve stem play - installed clearance
Inlet
Wear limit
Exhaust
Wear limit
11.6
mm (in)
mm (in)
mm (in)
mm (in)
0.016...0.058 (0.0006...0.0023)
0.130 (0.0051)
0.031...0.073 (0.0012...0.0029)
0.145 (0.0057)
Page 65
Technical Data F 650 GS
Valve seat angle
Inlet
Exhaust
Included valve angle
Inlet
Exhaust
Valve seat width
Inlet
Wear limit
Exhaust
Wear limit
Valve guide
Inlet Intl. dia.
Wear limit
Exhaust Intl. dia.
Wear limit
Bucket tappets (wear limit)
Extl. dia.
Radial clearance in cylinder head
Guide dia. in cylinder head
Valve spring
On installation (free length) mm (in) min. 40.5 (1.60)
Wear limit mm (in) 39.0 (1.54)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
°°45
45
°°15
18
1.05...1.35 (0.041...0.053)
1.60 (0.063)
1.25...1.55 (0.049...0.061)
2.2 (0.09)
5.006...5.018 (0.1971...0.1976)
5.080 (0.2000)
5.006...5.018 (0.1971...0.1976)
5.080 (0.2000)
33.400 (1.3150)
0.200 (0.0079)
33.600 (1.3229)
Camshafts
Wear limit
Inlet and exhaust
Bearing journal diameter
Cam height I
Cam height E
Wear limit I
Wear limit E
Bearing bore dia. in camshaft mount
Oil pressure control valve
Coil spring length, relaxed mm (in) min. 14.0 (0.55)
Oil retaining valve
Coil spring length, relaxed mm (in) min. 14.5 (0.57)
Pistons
Piston diameter
“A”
On installation
Wear limit
Installed clearance
Wear limit
“B”
On installation
Wear limit
Installed clearance
Wear limit
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
21.95 (0.864)
39.35...39.45 (1.545...1.553)
39.15...39.25 (1.541...1.545)
39.25 (1.545)
39.05 (1.537)
22.040 (0.8677)
99.975...99.985 (3.9361...3.9365)
99.940 (3.9347)
0.015...0.040 (0.0006...0.0016)
0.090 (0.0035)
99.985...99.995 (3.9365...3.9369)
99.950 (3.9351)
0.015...0.040 (0.0006...0.0016)
0.090 (0.0035)
11.7
Page 66
Technical Data F 650 GS
Piston rings
1st groove Rectangular-section ring
Ring thickness
Ring thickness wear limit
End gap
End-gap wear limit
Groove-height wear limit
Ring float
Ring float, wear limit
2nd groove Micro-taper ring
Ring thickness
Ring thickness wear limit
End gap
End-gap wear limit
Groove-height wear limit
Ring float
Ring float, wear limit
3rd groove Spring-steel oil control ring
End gap
End-gap wear limit
Groove-height wear limit
Ring float
Ring float, wear limit
Piston pin
Piston pin dia.
Wear limit mm (in) 21.98 (0.865)
Piston-pin play
in small end bore
Wear limit
in bore in piston
Wear limit
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
1.2 (0.05)
1.15 (0.045)
0.2...0.4 (0.008...0.016)
1.0 (0.04)
1.30 (0.051)
0.03...0.065 (0.0012...0.0026)
0.15 (0.045)
1.5 (0.06)
1.45 (0.057)
0.2...0.4 (0.008...0.016)
1.0 (0.04)
1.6 (0.06)
0.03...0.065 (0.0012...0.0026)
0.15 (0.045)
0.2...0.4 (0.008...0.016)
1.0 (0.04)
2.6 (0.10)
0.03...0.065 (0.0012...0.0026)
0.15 (0.045)
0.015...0.029 (0.0006...0.0011)
0.050 (0.0020)
0.012...0.021 (0.0005...0.0008)
0.050 (0.0020)
Cylinder
Bore
Cylinder “A”
Wear limit
Bore
Cylinder “B”
Wear limit
Timing chain
Wear limit
Distance from sealing face of plug to piston of chain tensioner mm (in) 9.0 (0.35)
Clutch and gearbox
Clutch friction plates (8 plates)
Size per plate on installation
Wear limit for thickness of plate assembly
(total)
Copper springs
Wear limit at 190 N mm (in) 27.4 (1.079)
Oil pump
Oil pumps primary/secondary
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
100.000...100.012 (3.9371...3.9376)
100.03 (3.9382)
100.012...100.024 (3.9376...3.9380)
100.04 (3.9387)
3.45...3.55 (0.136...0.140)
27.5 (1.082)
11.8
Page 67
Technical Data F 650 GS
Housing depth (primary)
Housing depth (secondary)
Wear limit, installed clearance (radial)
Wear limit, installed clearance (axial)
mm (in)
mm (in)
mm (in)
mm (in)
14 (0.6)
19 (0.7)
0.25 (0.010)
0.25 (0.010)
11.9
Page 68
11.10
Page 69
Sectional view of engine
11.11
E110550
Page 70
Engine oil circuit
1 Delivery pump
2 Oil tank
3 Check valve
4 Oil filter
5 Control valve
6 Low-pressure line (gearbox)
7 Low-pressure line (clutch)
8 High-pressure line (crankshaft)
9 High-pressure line (big end bearing)
10 High-pressure line (camshafts)
11 Chain tensioner
12 Spray nozzle (for piston)
13 Oil sump
14 Suction pump
11.12
F119109
Page 71
Valve gear
11.13
E110440
Page 72
Valves, components
E110450
11.14
Page 73
Oil pumps, components
11.15
E110460
Page 74
11 12 116 Removing and installing cyl-
inder head, engine installed
L Note:
If an engine failure occurs, the oil tank and oil lines
must be cleaned with the material used for this purpose in the workshop, and then blown through with
compressed air.
Preparatory work
– Remove left, right and centre covers.
a ....................................................See Group 46
– Remove the battery.
a ....................................................See Group 61
– Drain coolant.
a ....................................................See Group 00
Drain the engine oil from the oil tank.
•
– Remove engine guard.
a ....................................................See Group 46
– Remove the starter motor.
a ....................................................See Group 12
– Remove exhaust manifold and oxygen sensor.
a ....................................................See Group 18
– Expose the radiator.
a ....................................................See Group 00
– Remove the intake air duct.
a ....................................................See Group 13
– Remove intake air silencer.
a ....................................................See Group 13
Remove the battery box.
•
Remove circlip securing throttle cable to throttle
•
flap stub and disengage the throttle cable from
the guide.
Disengage throttle cable from adapter.
•
Disconnect plugs at throttle flap stub.
•
Remove the intake pipe from the cylinder head
•
and lay it carefully to one side, complete with the
throttle flap stub.
Slacken the fastener securing the lid of the elec-
•
tronic equipment box.
Disengage the cover from the anchorages on the
•
main frame on each side and remove.
Disconnect the starter coil at the plug.
•
Remove the fastener securing the ignition-coil
•
bracket and remove the ignition coil complete
with bracket.
11.16
Page 75
1
3
Remove fastener for oil lines (2) from the cylinder
•
head.
User pliers, BMW No. 17 5 500, to open the
•
clamp securing the breather hose at the valve
cover.
Remove valve cover (1).
•
Remove spark plug.
•
Remove centre screw plug on right in engine
•
block.
L Note:
TDC position: Marks on the timing-chain sprockets
are parallel with the cylinder head, the bores in the
timing-chain sprockets are at the top.
2
E110070
Turn crankshaft to top dead centre position with
•
an Allen key.
L Note:
Watch out for escaping oil and catch it in a suitable
container.
Remove screw (3) close to the oil feed stub pipe
•
and install locking screw, BMW No. 11 6 570, to
prevent the crankshaft from turning.
11.17
Page 76
11 31 022 Removing camshafts
11 12 116 Removing cylinder head
Remove the cable cover from the right-hand side
•
of the cylinder.
Remove the retainer of the spring-strut adjusting
•
knob from the frame.
Disconnect plug of oil-pressure switch.
•
– Raise the rear frame.
a ....................................................See Group 46
E110470
Disconnect the oil feed line (arrow) from the en-
•
gine.
Disconnect the oil feed hose from the oil tank.
•
Remove the oil feed line from the ABS modulator
•
frame and push it to the right.
Remove the chain tensioner.
•
Remove lower section of camshaft carrier.
•
E110480
Remove screws securing cylinder head to
•
frame (arrow).
Use pin wrench, BMWNo.116661, to slacken
•
the locknut.
L Note:
Note washers.
Back off the adjuster sleeves.
•
2
1
3
Remove chain guide (1).
•
Remove upper section of camshaft carrier (2).
•
Remove camshafts with chain sprockets.
•
Secure timing chain with retaining wire.
•
Remove front chain guide rail (3).
•
E110420
4
5
E110490
Disconnect the coolant hose from cylinder
•
head (4) and drain the last of the coolant from the
radiator.
Disconnect the plug for temperature sensor (5).
•
11.18
Page 77
When looping the timing chain over the camshaft
•
sprockets, make sure that the sprockets are at
the TDC position.
Before installing the cylinder head cover, remove
•
all traces of the gasket and clean the sealing face
with degreasing agent. Also clean the groove
and the seating faces for the gasket.
2
1
E110110
Remove machine screws for chaincase (1).
•
Disconnect plug of oil-pressure sensor.
•
Remove oil pressure switch.
•
Remove rear collar screw (2) from cylinder head.
•
Remove front collar screws from cylinder head.
•
Remove top collar screws from cylinder head.
•
Remove collar nuts from cylinder head.
•
Raise cylinder head clear of stud bolts, turn the
•
cylinder head and lift it toward the rear to remove.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
Replace cylinder head gasket.
5
9
4
11
8
16
X Tightening torques:
Engine guard to frame.................................... 9 Nm
Footrest plate to frame................................. 30 Nm
Silencer to exhaust manifold ........................ 55 Nm
Exhaust manifold to cylinder head................ 20 Nm
Intake air silencer to frame ............................. 9 Nm
Intake pipe to cylinder head ......................... 21 Nm
Lid of electronic equipment box to frame ....... 4 Nm
Ignition coil holder.......................................... 9 Nm
Oil lines to cylinder head ................................ 8 Nm
Cylinder head cover to cylinder head........... 10 Nm
Spark plug in cylinder head.......................... 20 Nm
Rear frame to main frame............................. 21 Nm
Oil line to engine block................................. 35 Nm
Timing-chain tensioner to cylinder head....... 40 Nm
Chain guide to bearing cap
(clean threads + Loctite 243)........................ 10 Nm
Camshaft bearing cap to cylinder head........ 10 Nm
Cylinder head to frame................................. 41 Nm
Cylinder head to frame adjusting sleeve
...............................................zero play max. 5 Nm
Cylinder head to frame locknut................... 100 Nm
Machine screws, chaincase ......................... 10 Nm
Collar screws, cylinder head ........................ 33 Nm
Collar nuts, cylinder head................stage 1: 20 Nm
.......................................................stage 2: 60 Nm
Starter to clutch housing.............................. 10 Nm
Oil-pressure switch in engine block
(clean threads + Loctite 243)........................ 12 Nm
Cable cover to engine.................................... 5 Nm
3
14
7
12
Initially tighten the collar nuts of the cylinder head
•
to 20 Nm (3-6) and then tighten to 60 Nm (7-10).
Tighten the fasteners of the cylinder head to cyl-
•
inder in the sequence as shown (11-16) to specified torque.
15
10
13
16
6
E110151
16
11.19
Page 78
11 11 150 Removing cylinder, engine
installed
– Remove cylinder head.
Use pliers, BMW No. 17 5 500, to open the
•
clamp securing the coolant hose to the water
pump (arrow) and disconnect the hose.
E110500
11 6 510
E110520
Oil the piston rings and press the sliding piston
•
ring sleeve, BMW No. 11 6 510, over the piston
rings from above so that the piston projects from
the sliding sleeve by about 2 mm (0.08 in).
Push the timing chain through the chain aperture
•
in the cylinder and secure the chain.
Slip the cylinder over the piston.
•
Remove sliding sleeve.
•
X Tightening torques:
Cylinder to engine block............................... 10 Nm
Ground cable to cylinder................................ 8 Nm
E110510
Disconnect ground cable (arrow) from cylinder.
•
Remove cylinder base screws.
•
Push the rear chain guide forward and carefully
•
lift the cylinder clear.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
When installing, use a new cylinder base gasket.
11.20
Page 79
Disconnect plug of side-stand switch (6).
•
Unscrew connector for idle indicator (7).
5
8
•
Disconnect the plug of ignition trigger (8).
•
Disconnect plug of oil pressure sensor in oil filter
•
housing.
Disconnect positive lead from starter motor.
•
Remove frame trussing.
•
Remove the chain from the drive sprocket.
•
7
6
11 00 050 Removing engine 11 00 050 Preparatory work
–Drain coolant.
a ....................................................See Group 00
– Place motorcycle on its centre stand.
– Secure front wheel in position.
– Remove seat.
– Remove intake air silencer.
a ....................................................See Group 13
Disconnect battery negative terminal.
•
– Remove engine guard.
– Drain engine oil.
a ....................................................See Group 00
– Remove rear wheel.
a ....................................................See Group 36
– Remove exhaust manifold.
a ....................................................See Group 18
Disconnect oil feed and return lines from oil tank.
•
E110020
10
Cut the cable tie at the adjusting-knob bracket
•
(arrow).
Remove the fastener securing the adjusting-
•
knob bracket (10).
Disconnect the plug for the temperature
•
sensor (9).
Slacken the hose clip at the throttle flap stub
•
and disconnect the throttle flap stub from the intake pipe.
Disconnect the starter coil at the plug.
•
Pull spark plug connector off spark plug.
•
9
E110030
1
2
3
4
E110010
Remove cable cover (1) from the engine.
•
Cut the cable tie (arrow) at the voltage regulator.
•
Disconnect the plug of the voltage regulator.
•
Remove voltage regulator (4).
•
Straighten tab (2) and release breather line (3).
•
L Note:
The chain drive sprocket has to be removed at this
point before engine disassembly can proceed.
Remove the chain sprocket.
•
a ....................................................See Group 27
Remove ground terminal (5) from the engine.
•
11.21
Page 80
Remove the ignition-coil bracket complete with
•
ignition coil from the cylinder head cover.
Disconnect clutch cable from release lever.
•
Disconnect breather hose for oil tank from the
•
cylinder head cover.
Remove radiator.
•
a .................................................... see Group 27
Remove the right-hand coolant hose.
•
Remove fasteners for engine shell and remove
•
engine shell with the bracket for the voltage regulator.
Remove swinging fork pivot pin.
•
Remove bottom rear engine mount fastener.
•
Secure the motorcycle by attaching two straps to
•
the front forks.
Remove the brake pedal.
•
Remove the gear shift pedal.
•
11 00 050 Removing engine
Secure adapter, BMW No. 11 0 591, to the plate
•
for the engine lifter.
Place engine lifter, BMW No. 00 1 540, under
•
engine.
E110050
Lower the engine until the cylinder head is rest-
•
ing on the radiator fastening lug (arrow).
Continue lowering the engine; the engine tilts to-
•
ward the rear.
Continue lowering the engine until the fastening
•
lug is above the cylinder head cover.
Turn the engine toward the right and push it clear
•
of the motorcycle.
Transferring engine to assembly frame
1
2
E110040
Secure the engine lifter by installing stud bolt (1)
•
through bottom bore in engine block and securing stud (2) in top bore in engine block.
Remove screws securing cylinder head to frame
•
on left and right. Use pin wrench,
BMWNo.116661, to slacken the locknuts and
back off the adjusting sleeves.
11 0 531
E110530
Secure threaded adapter, BMW No. 11 0 531, to
•
engine mount.
Detach the engine from the engine lifter, leaving
•
the engine on the lifting platform.
11.22
Page 81
Lay the engine on its left side, as viewed in the
•
forward direction of travel.
Secure engine adapter, BMW No. 11 0 640, to
•
the right side of the engine without a spacer.
Position the assembly stand beside the lifting
•
platform.
Manoeuvre the engine so that the engine adapter
•
is level with the flange of the assembly stand.
1
4
3
1
E110060
Secure engine adapter (1) to the flange of the as-
•
sembly stand (2).
Turn engine adapter.
•
2
2
11 00 050
11 00 050 Preparatory work
– Drain coolant.
a ....................................................See Group 00
– Place motorcycle on its centre stand.
– Secure front wheel in position.
– Remove seat.
– Remove intake air silencer.
a ....................................................See Group 13
Disconnect battery negative terminal.
•
– Remove engine guard.
– Drain engine oil.
a ....................................................See Group 00
– Remove rear wheel.
a ....................................................See Group 36
– Remove exhaust manifold.
a ....................................................See Group 18
Disconnect oil feed and return lines from oil tank.
•
Lowering engine
E110020
3
4
5
6
E110010
Remove cable cover (3) from the engine.
•
Cut the cable tie (arrow) at the voltage regulator.
•
Disconnect the plug of the voltage regulator.
•
Remove voltage regulator (6).
•
Straighten tab (4) and release breather line (5).
•
L Note:
The chain drive sprocket has to be removed at this
point before engine disassembly can proceed.
Remove the chain sprocket.
•
a ....................................................See Group 27
Remove ground terminal (1) from the engine.
•
11.23
Page 82
Disconnect plug of side-stand switch (2).
•
Unscrew connector for idle indicator (3).
•
Disconnect the plug of ignition trigger (4).
•
Disconnect plug of oil pressure sensor in oil filter
•
housing.
Disconnect positive lead from starter motor.
•
Remove frame trussing.
•
Remove the chain from the drive sprocket.
•
Remove radiator.
•
a .................................................... see Group 27
Remove the right-hand coolant hose.
•
Remove fasteners for engine shell and remove
•
engine shell with the bracket for the voltage reg-
ulator.
Remove swinging fork pivot pin.
•
Remove bottom rear engine mount fastener.
•
Secure the motorcycle by attaching two straps to
•
the front forks.
Remove the brake pedal.
•
Remove the gear shift pedal.
•
11 00 050 Lowering the engine
Secure adapter, BMW No. 11 0 591, to the plate
•
for the engine lifter.
Place engine lifter, BMW No. 00 1 540, under
•
engine.
6
Cut the cable tie at the adjusting-knob bracket
•
(arrow).
Remove the fastener securing the adjusting-
•
knob bracket (6).
Disconnect the plug for the temperature
•
sensor (5).
Slacken the hose clip at the throttle flap stub
•
and disconnect the throttle flap stub from the intake pipe.
Disconnect the starter coil at the plug.
•
Pull spark plug connector off spark plug.
•
Remove the ignition-coil bracket complete with
•
ignition coil from the cylinder head cover.
Disconnect clutch cable from release lever.
•
Disconnect breather hose for oil tank from the
•
cylinder head cover.
5
E110030
7
8
E110040
Secure the engine lifter by installing stud bolt (7)
•
through bottom bore in engine block and secur-
ing stud (8) in top bore in engine block.
Remove screws securing cylinder head to frame
•
on left and right. Use pin wrench,
BMW No. 11 6 661, to slacken the locknuts and
back off the adjusting sleeves.
11.24
Page 83
E110050
Lower the engine until the cylinder head is rest-
•
ing on the radiator fastening lug (arrow).
Continue lowering the engine; the engine tilts to-
•
ward the rear.
Continue lowering the engine until the fastening
•
lug is above the cylinder head cover.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Raise the engine and tilt it to the rear.
•
Manoeuvre the bottom engine mount into posi-
•
tion.
Raise the engine and manoeuvre the fasteners at
•
the cylinder head into position.
Install the bottom rear engine mount fastener.
•
Install the pivot pin of the swinging arm bearing.
•
Back off the adjusting screws for the cylinder
•
head mounts until they are seated against the
cylinder head on each side and the cylinder head
itself is centered in the frame.
X Tightening torques:
Water pump drain screw .............................. 10 Nm
Intake air silencer to frame ............................. 9 Nm
Engine guard to frame.................................... 9 Nm
Engine oil drain plug..................................... 40 Nm
Rear quick-release axle.............................. 100 Nm
Drive chain tensioning screws...................... 10 Nm
Exhaust manifold to cylinder head................ 20 Nm
Silencer to exhaust manifold ........................ 55 Nm
Footrest plate to main frame, left/right.......... 30 Nm
Cable cover to engine.................................... 5 Nm
Voltage regulator to bracket........................... 7 Nm
Chain drive sprocket to mainshaft
(clean threads + Loctite 243)...................... 140 Nm
Sprocket cover to engine ............................... 2 Nm
Ground terminal to engine block.................... 8 Nm
Connecting cable, idle indicator..................... 2 Nm
Frame trussing to engine shell...................... 21 Nm
Frame trussing to main frame....................... 21 Nm
Spring-strut adjusting knob bracket
to frame ......................................................... 9 Nm
Radiator to main frame at top......................... 9 Nm
Swinging-arm pivot .................................... 100 Nm
Frame to engine at rear................................ 41 Nm
Gearshift pedal to engine ............................. 13 Nm
Brake pedal to frame.................................... 21 Nm
Cylinder head to frame................................. 41 Nm
Cylinder head to frame adjusting sleeve
...............................................zero play max. 5 Nm
Cylinder head to frame locknut................... 100 Nm
11.25
Page 84
1
2
5
4
3
11 00 103 Disassembling engine
e Caution:
If there is any mechanical damage, the oil tank and
the oil lines must be cleaned.
11 12 516
– Remove starter motor
a ....................................................See Group 12
Remove oil lines.
•
Remove valve cover (1).
•
Remove spark plug.
•
Remove centre screw plug on right in engine
•
block.
11.26
Removing cylinder head
E110070
Turn crankshaft to top dead centre position with
•
an Allen key.
Remove screw (5) and lock the crankshaft with
•
locating screw, BMW No. 11 6 570.
L Note:
Check for secure seating with Allen key.
11 31 522 Removing camshafts
Only unfasten chain sprockets if they need to be
•
replaced.
Remove chain tensioner (3).
•
Remove chain guide (4) from between the chain
•
sprockets.
Remove fasteners securing camshaft carrier (2).
•
Page 85
Remove camshafts with chain sprockets.
•
Take off the lower camshaft carrier.
•
Checking centrifugal decompressor lever
Checking camshaft for wear
00 2 590
F110040
Measure bearing play with Plastigage type PG-1,
•
BMW No. 00 2 590.
Tighten camshaft carrier to specified torque.
•
X Tightening torque:
Camshaft carrier........................................... 10 Nm
Remove camshaft carrier and determine bearing
•
clearance using comparative scale.
Wear limits:
Cam height, inlet ..............min. 39.25 mm (1.545 in)
Cam height, exhaust .........min 39.05 mm (1.537 in)
Bearing journal dia. ........min. 21.950 mm (0.864 in)
Bearing dia.
in bearing pedestal........max. 22.040 mm (0.868 in)
Bearing play..................max. 0.090 mm (0.0035 in)
L Note:
Never stretch the spring, since this alters the predetermined spring force.
When activated, the lever must not project be-
•
yond the cam base circle by less than
distance “B”.
B
E110090
Distance “B”.................................. 0.6 mm (0.02 in)
11 31 530 Disassembling and assembling the
centrifugal decompressor
2
11 31 671 Removing and installing timing-chain
sprockets
Clamp the camshaft in a vise fitted with protec-
•
tive jaws.
Remove the fastener securing the sprocket to
•
the camshaft and remove the camshaft sprocket.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Before installing, oil the thread of the chain-
•
sprocket fastener.
X Tightening torque:
Sprocket to camshaft
(thread oiled) ................................................ 60 Nm
3
1
E110100
L Note:
If the centrifugal decompressor is dismantled,
spring (3) must always be renewed.
Use a suitable punch to press shaft (1) out of
•
centrifugal weight (2).
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
After assembly, check centrifugal weight for ease
•
of movement.
11.27
Page 86
1
3
2
E110111
11 12 116 Removing cylinder head
Remove front chain rail (1).
•
Release the coolant line hose clips with pliers,
•
BMWNo.175500.
Allow the timing chain to slide into its cavity.
•
Remove the starter motor.
•
a ....................................................See Group 12
Remove collar nuts from cylinder head.
•
L Note:
If the cylinder head does not have to be dismantled,
do not separate cylinder head from cylinder.
In this case the next six work steps can be omitted.
Remove machine screws for chaincase (2).
•
Remove rear collar screw (3) from cylinder head.
•
Remove front collar screws from cylinder head.
•
Remove top collar screws from cylinder head.
•
Separate the cylinder head from the cylinder.
•
Remove cylinder head.
•
Checking timing chain for wear
A
B
F111060
Push hydraulic chain tensioner (4) in the direc-
•
tion of the tensioner rail in the guide on the cylin-
der, until resistance to movement is felt.
Measure distance (A) from the sealing face to the
•
chain tensioner piston.
4
11.28
Page 87
If the wear limit, distance “B”, is exceeded, first
•
inspect the tensioner rail and the two guide rails
for score-marks and renew them if necessary.
If a part has to be renewed, repeat the measure-
•
ment procedure described above.
If the wear limit has been exceeded, the timing
chain must be renewed.
Distance “B”........................max. 9.0 mm (0.354 in)
11 12 528
Disassembling and
assembling cylinder head
11 34 020 Removing valves
Use suction device, BMWNo.113251, to pull
•
out the bucket-type tappets.
Check that bucket tappets and guides are in per-
•
fect condition.
Bore for bucket tappet
In cylinder head........... max. 33.600 mm (1.3229 in)
Radial clearance of
bucket tappet..............max. 0.200 mm (0.0079 in)
e Caution:
Mark the bucket tappets to ensure that they are reinstalled in their original positions (risk of jamming).
1Valve
2 Lower valve spring plate
3 Valve stem seal
4Valve spring
5 Upper valve spring plate
6 Valve collets
5
4
1
6
3
2
E110120
11 5 691
11 5 692
11 0 521
11 0 522
11 0 523
E110130
L Note:
To simplify removal of the valve collets, tap the
valves sharply with a plastic-faced hammer.
Secure the cylinder head to support plate,
•
BMWNo.110523.
Secure adapter plate, BMW No. 11 0 521, sup-
•
port, BMW No. 11 5 691, spindle,
BMWNo.115692, nut, BMW No. 11 5 693,
and thrust plate, BMWNo.110522.
Press down the valves with the thrust plate.
•
Use a screwdriver to press apart and remove the
•
valve collets.
Pull the valves down to remove.
•
11.29
Page 88
Checking valve guide for wear
00 2 510
11 0 571
F110111
Insert new valve from combustion chamber side
•
into valve guide until it reaches the valve stem
seal.
Using dial gauge, BMW No. 00 2 510, posi-
•
tioned vertically on the valve axis, measure maximum play at right angles to the camshaft axis.
Play:
Max. play..................................... 0.4 mm (0.016 in)
Intl. dia. of
valve guide ....................max. 5.080 mm (0.2000 in)
11 12 591 Removing valve guide
1
2
F110140
L Note:
To facilitate removal, heat the cylinder head to
100 °C (212 °F).
Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.
Use drift, BMW No. 11 0 571, to drive out the
•
valve guide toward the combustion chamber.
e Caution:
The cylinder head has to be replaced if the bore for
the valve guide is worn.
F110121
e Caution:
Do not damage sliding surfaces on bucket tappets:
risk of jamming.
Pull off valve stem seal (1) with pliers,
•
BMWNo.111250.
Remove valve spring support (2) from cylinder
•
head.
11.30
Page 89
11 12 591 Installing valve guide
1
F110151
Checking valve seat for wear
Apply engineer’s blue or a similar product to the
•
valve seat rings.
Install relevant valve and rotate, applying slight
•
pressure.
Heat the cylinder head to 100 °C (212 °F).
•
Using driving-in tool, BMW No. 11 0 571, drive
•
valve guide (1) into the cylinder head until valve
guide projection is as specified.
Projection:
Inlet........................... 9.8...10.2 mm (0.39...0.40 in)
Exhaust..................... 9.8...10.2 mm (0.39...0.40 in)
L Note:
Only use thread-cutting oil to lubricate the reaming
tool.
Only rotate reaming tool in the cutting direction never in the opposite direction.
Withdraw reaming tool at regular intervals for cleaning: always rotate the tool in cutting direction while
removing.
Ream out valve guide with 5H7 reaming tool.
•
A
F110160
Check valve seat width “A” and contact pattern
•
for wear.
Wear limits for valve seat width “A”:
Inlet valve .................................... 1.6 mm (0.063 in)
Exhaust valve .............................. 2.2 mm (0.087 in)
Once the wear limit of the seat width has been
•
reached, or if the contact pattern is no longer
perfect, the seat can be remachined.
2
E110540
If necessary, remachine valve seat with valve
•
seat turning tool (2).
Valve seat width “B”:
Inlet valve .................................... 1.2 mm (0.047 in)
Exhaust valve .............................. 1.4 mm (0.055 in)
11.31
Page 90
11 34 800 Installing valve stem seal
Checking valve for wear
2
1
Install bottom valve spring retainer (1).
•
Use a drift, BMW No. 11 6 650, to insert valve
•
stem seal (2).
E110120
F110190
Check valve stem diameter and valve head seat
•
width.
Wear dimensions for valve:
Stem diameter
Inlet valve...........................min. 4.89 mm (0.177 in)
Exhaust valve.....................min. 4.89 mm (0.177 in)
Check valve for runout.
•
L Note:
Remove oil carbon from valve and deburr grooves
for valve collets with an oilstone.
For wear limits, see Technical Data.
Check grooves for valve collets.
•
11.32
Page 91
11 34 020 Installing valves
11 11 150
Removing cylinder
Install valve with shrink-fit tube.
•
L Note:
Remove the shrink-fit tube.
11 5 691
11 0 521
11 0 523
Install valve spring and valve spring retainer.
•
Secure the cylinder head to support plate,
•
BMW No. 11 0 523.
Secure adapter plate, BMW No. 11 0 521, sup-
•
port, BMWNo.115691, spindle,
BMW No. 11 5 692, nut, BMW No. 11 5 693,
and thrust plate, BMW No. 11 0 522.
Press down the valves with the thrust plate.
•
11 5 692
11 0 522
E110130
Separate the cylinder base from the engine
•
block.
e Caution:
When removing cylinder, make sure that the piston
does not strike the engine block.
Remove cylinder.
•
Checking cylinder
E110140
Check cylinder face and sealing faces for dam-
•
age and blow out oil ducts for chain tensioner.
L Note:
Install valve collets with a small amount of grease to
facilitate assembly.
Insert the valve collets.
•
Check bucket tappets for damage and reinstall
•
on original valves.
1
2
Measure cylinder bore at 55...65 mm
•
(2.17...2.56 in) from the upper edge with an internal micrometer at three points (1, 2, 3).
Wear limits for cylinder bore:
Cylinder A ................... max. 100.03 mm (3.9382 in)
Cylinder B ................... max. 100.04 mm (3.9387 in)
3
E110150
11.33
Page 92
11 25 050 Removing piston
Remove piston pin circlips.
•
Press out piston pin with drift,
•
BMWNo.116581.
L Note:
Mark exhaust-valve side on piston crown.
Determining clearance of piston in
cylinder
1
11 25 671
Remove piston rings with piston ring pliers.
•
Carefully clean piston.
•
Check piston for signs of damage.
•
Disassembling piston
2
Measure cylinder bore at 55...65 mm
•
(2.17...2.56 in) from the upper edge with an inter-
nal micrometer at three points (1, 2, 3).
Make a note of the largest value as
•
dimension “A”.
3
E110150
H
B
E110160
Measure piston diameter “B” at distance
•
H=16 mm (0.63 in) from the lower edge at a right
angle to the piston pin axis.
L Note:
Determine piston clearance:
Dimension “A” minus dimension “B” = piston clearance
Piston clearance:
When new ... 0.024...0.040 mm (0.0009...0.0016 in)
Wear limit......................max. 0.100 mm (0.0039 in)
11.34
Page 93
Determining piston ring gaps
12 11 070
Removing ignition magnet
Slip piston ring 60 mm (2.36 in) into cylinder from
•
top and use a feeler gauge to measure ring gap.
Wear dimension:
Ring gap (all piston rings).............. 1.0 mm (0.04 in)
Determining piston pin clearance
Measure diameter of piston pin bores in piston
•
stroke direction using an internal micrometer.
Measure both ends of piston pin with microme-
•
ter.
Wear limits:
Bore dia. in piston,
vertical ........................max. 22.030 mm (0.8673 in)
Piston pin dia. ..............min. 21.980 mm (0.8654 in)
Radial clearance in
piston............................max. 0.050 mm (0.0019 in)
11 25 671
Assembling pistons
L Note:
The “Top” must face towards the piston crown.
Install the piston rings with their gaps offset
by 120 °.
Remove retainer on right engine housing cover.
•
12 5 500
Remove the central plug and install handle,
•
BMWNo.125500.
E110180
1
2
3
E110170
1 Groove for rectangular-section ring
2 Stepped micro-taper ring
3 Groove for spring-steel oil control ring
Use feeler gauge to measure float of piston rings
•
in groove.
Wear limit,
ring float in groove................... 0.150 mm (0.006 in)
Remove the cover, noting the thrust
•
washer (arrow).
4
E110190
E110200
If necessary, remove ignition trigger (4).
•
11.35
Page 94
12 5 510
E110210
Unscrew hex nut.
•
Heat hub to 80 °C (176 °F).
•
L Note:
Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.
Using puller, BMW No. 12 5 510, pull off magnet
•
rotor.
11 26 500
starter
Removing countershaft for
1
2
4
5
E110230
Remove freewheel gear (5).
•
3
E110220
Remove thrust washer (1) and spacer sleeve (2).
•
Remove double gear (4).
•
Pull off idler gear (3).
•
11.36
Page 95
5
4
6
3
2
1
E110240
12 11 077
Disassembling and
assembling freewheel
Disassembling freewheel
1 Machine screw
2 Magnet rotor
3 Freewheel
4 Lock ring
5 Freewheel housing
6 Freewheel gear
d Warning:
Securing screws (1) are secured with Loctite 648
and considerable torque is required to release them.
Release retaining screws (1).
•
Lift off freewheel housing (5).
•
Remove circlip (4).
•
Remove freewheel gear (3).
•
Check freewheel housing and freewheel for
•
wear, isolated chatter marks are permissible.
Assembling freewheel
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Install freewheel with arrow mark (arrow) down.
•
E110300
11.37
Page 96
Engage the lugs on the circlip in the recesses in
•
the freewheel gear.
Clean the threads of the securing screws and
•
freewheel housing, coat threads with
Loctite 648 and install the screws.
Check locking function and locking direction of
•
freewheel.
X Tightening torques:
Machine screw
(clean threads + Loctite 648)........................35 Nm
21 21 000 Removing clutch
21 4 600
4
3
Turn engine round in assembly fixture.
•
Remove left retaining for engine housing cover
•
and remove cover.
Removing pressure plate
2
1
Remove hex screws (2) in diagonally opposite
•
sequence.
Lift off complete pressure plate (1).
•
E110250
E110260
Using locating ring, BMW No. 21 4 600, prevent
•
clutch cage (4) and driver (3) from moving and
unscrew hex nut.
Pull off driver.
•
Pull off clutch cage and ring gear.
•
e Caution:
Note the backup washer at the bottom.
Pull off needle cages.
•
Remove the backup washer.
•
Removing clutch plates
e Caution:
The topmost clutch plate is offset. Make sure this
plate is installed in the correct position.
Take plate cluster out of clutch cage.
•
11.38
Page 97
11 41 000
pump
Removing and installing oil
Installing oil pump
Removing oil pump
2
Remove circlip (1) from idler gear.
•
Remove the retaining rings of the oil-pump
•
gears (2) and disengage the oil-pump gears.
1
E110270
7
8
11
10
7 Inner rotor
8 Outer rotor
9Cover
10 Markings
11 Needle roller
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
Markings (5) must be visible.
9
F110370
6
5
3
4
E110280
Remove idler gear (3).
•
Remove needle rollers (4).
•
Remove thrust washers (5).
•
Remove countersunk screws from cover and lift
•
off cover (6).
Inspecting oil pump
Using feeler gauges, measure the clearance be-
•
tween the inner and outer rotors and between
the outer rotor and the housing.
Permissible face runouts between:
Inner and outer rotor .........max. 0.25 mm (0.010 in)
Radial clearance................max. 0.25 mm (0.010 in)
Axial clearance between
rotors and cover................max. 0.25 mm (0.010 in)
Oil the inner and outer rotors.
•
Clean the threads of the countersunk screws
•
and coat with Loctite 243.
X Tightening torque:
Countersunk screws in oil-pump cover
(clean threads + Loctite 243).......................... 6 Nm
11.39
Page 98
Removing double drive gear
2
4
1
L Note:
Retaining screw (arrow) must be installed.
Remove hex nut (1).
•
Press chain guide (2) to rear of engine block.
•
Pull off double drive gear with timing chain.
•
11 21 001
ancing shaft
Removing crankshaft and bal-
3
E110290
E110320
Swivel assembly fixture so that clutch side is up-
•
permost.
Remove knurled nuts (4).
•
e Caution:
Do not tilt engine housing: this can cause damage
to bearing shell.
Raise the engine housing at the left and strike the
•
mainshaft, countershaft and balancing shaft al-
ternately with light blows of a plastic-faced ham-
mer, so that these remain in the magnet side.
Screw knurled nut on to engine support with
•
spacer.
5
6
E110310
Lever out water-pump drive gear (3) with a
•
screwdriver.
Remove needle roller.
•
Swivel engine in assembly fixture so that magnet
•
side is uppermost.
Remove all threaded fasteners for engine hous-
•
ing.
Remove oil filter and unfasten two fasteners on
•
base plate for engine housing.
11.40
7
Align marks (7) on balancing shaft and crank-
•
shaft (5) with mark on housing (6).
E110330
Page 99
L Note:
Note shims on crankshaft.
First lift out crankshaft, then balancing shaft.
•
Checking crankshaft for wear
Removing and installing crankshaft gear
11 6 502
Check bearing journal on crankshaft and conrod
•
for signs of damage and wear.
Bearing journal dia. ..........min. 45.97 mm (1.810 in)
Radial play, main bearing ..max. 0.10 mm (0.004 in)
Endplay,
conrod/crankshaft webs....max. 0.80 mm (0.031 in)
Small end bore dia. .........max. 22.04 mm (0.868 in)
11 27 020
Press off compensating gear with pressure pad,
•
BMW No. 11 0 561.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Removing compensating gear
L Note:
Coat the bearing seat for the expander gear on the
compensating gear with Optimoly MP 3.
Heat the compensating gear to 100 °C (212 °F).
•
L Note:
Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.
11 6 501
11 6 503
F110450
Clamp crankshaft into vise with protective jaws.
•
Use yoke, BMW No. 11 6 501, spindle,
•
BMWNo.116502, and pressure pad,
BMWNo.116503, to pull off the crankshaft
gear.
A
Use a socket of suitable size or similar adapter to
•
apply pressure to the thrust face of the gear
when installing the compensating gear.
F110460
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
When installing, heat the crankshaft gear to
•
140 °C (284 °F).
L Note:
Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.
e Caution:
Split pin must not protrude from bore in crankshaft
gear - this is the support face for the thrust washer.
Using a suitable adapter, drive the gear onto the
•
crankshaft.
Projection “A” of split pin......max. 18 mm (0.709 in)
11.41
Page 100
11 11 205 Removing and installing gear-
box mainshaft bearings
11 11 210
Removing and installing gear-
box compensating shaft bearings
11 6 562
11 6 561
11 6 564
E230040
L Note:
To protect the gasket surfaces of the engine block,
place the old gasket under the bearing puller.
Always renew the mainshaft sealing ring.
Heat the left of the engine block to 80 — 100 °C
•
(176 — 212 °F).
Using bearing puller plate, BMWNo.116561,
•
spindle, BMW No. 11 6 562, and spreader
sleeve, BMW No. 11 6 564, pull off the ball bearing.
Drive out the mainshaft sealing ring from the in-
•
side.
Heat the right of the engine block to 80 - 100 °C
•
(176 - 212 °F).
Use a suitable tool such as a socket or similar to
•
press the ball bearing through to the other side
from outside.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
To protect the gasket surfaces of the engine block,
place the old gasket under the bearing puller.
Always renew the mainshaft sealing ring.
Heat the left of the engine block to 80 — 100 °C
•
(176 — 212 °F).
Using bearing puller plate, BMW No. 11 6 561,
•
spindle, BMW No. 11 6 562, and spreader
sleeve, BMW No. 11 6 565, pull off the ball bear-
ing.
Heat the right of the engine block to 80 - 100 °C
•
(176 - 212 °F).
Using bearing puller plate, BMW No. 11 6 561,
•
spindle, BMW No. 11 6 562, and spreader
sleeve, BMW No. 11 6 564, pull off the ball bear-
ing.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
The sealed ends of the cage must point outwards.
To install the ball bearing, heat the engine block
•
to 80 - 100 °C (176 - 212 °F) and spray the ball
bearing with BMW chilling spray.
Wear limit values for bearing seats in housing:
Magneto side:
Countershaft ............... max. Ø 46.99 mm (1.850 in)
Mainshaft .................... max. Ø 62.02 mm (2.442 in)
Clutch side:
Countershaft ............... max. Ø 51.99 mm (2.047 in)
Mainshaft .................... max. Ø 46.99 mm (1.850 in)
L Note:
The sealed ends of the cage must point outwards.
To install the ball bearing, heat the engine block
•
to 80 - 100 °C (176 - 212 °F) and spray the ball
bearing with BMW chilling spray.
Drive in the shaft sealing ring with sleeve,
•
BMWNo.234540, and drift,
BMWNo.234550.
11.42
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