BMW AG Motorcycle (F 650 GS). Manual - part 1

Introduction

This repair manual will help you to perform all the main maintenance and repair work correctly and efficient-
ly. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and prac-
tical 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 illus-
trations.

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

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

BMW AG Motorcycle Division
After Sales

Published by:

BMW AG Sparte Motorrad
After Sales
UX-VS-2

D - 80788 München

All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written
permission.
Errors and omissions excepted; subject to technical amendment.

Produced in Germany

Usage

Each chapter starts with the list of contents.

The list of contents is followed by the Technical Data table.

Chapter 00 “Maintenance and general instructions” details the handover checklist and lists all tightening
torques and operating fluids.

Key to symbols

In this Workshop Manual for the F 650 GS model, the following symbols are used; their meanings are ex-
plained in the table.

Special instructions aimed at improving the work procedures

Note:

Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance
procedures.

Caution:

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

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

Tightening torques:

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

Order No. 01 71 0 010 183

UX-VS-2, 10/99

Printed in Germany

Customer

Licence plate no.

Order No.

Mechanic’s signature

BMW

0 km

(

rvi

ever

10,

0 km (6

00 mi

ect

ion

eve

00 km (12

,000 m

ile

)

BMW A

nnu

l Se

ice

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)

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)

20,000

Check clutch play, adjust if necessary

Check wheel spoke tension and tighten if necessary

more frequently if motorcycle is ridden in severe off-road conditions

Examine brake pads and discs for wear, replace if necessary *

)

more frequently if motorcycle is ridden in severe off-road conditions

Check brake fluid level at front and rear and top up if necessary *

)

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

)

Replace the brake fluid at least once a year

Replace the primary front/rear brake master cylinder cup
(every 40,000 km/24,000 miles on a motorcycle with ABS)

40,000

Check wheel bearings and replace if necessary *

)

Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion *

)

more frequently if motorcycle is ridden in severe off-road conditions

Check chain tension and adjust if necessary *

)

Check battery acid level, add distilled water if necessary

more frequently if motorcycle is ridden in severe off-road conditions

Clean and grease the battery terminals, if necessary

Check steering head bearings and adjust *

)

or replace if necessary *

)

Grease the side and main stands

Grease the brake pedal

Check bolts and nuts on engine mountings, frame connections, exhaust system
mountings, swinging fork pivot, suspension levers, brake pedal, main and side
stands and quick-release axles for tightness

Final inspection with road safety and functional check:

–

(Clutch, gearshift)

–

Steering

–

Front and rear brakes

Side stand contact switch

–

Condition of tyres and wheels, tyre pressures

–

Lights and signalling equipment, indicator and warning lights, instruments

–

Test ride, if necessary

)

Associated work invoiced separately, see Flat rates brochure, Motorcycle ’98

BMW AG Motorcycle Division
Maintenance schedule
F 650 GS

Order No. 01 71 0 010 183

UX-VS-2, 10/99

Printed in Germany

Customer

Licence plate no.

Order No.

Mechanic’s signature

BMW
Pre-delivery check

Check the shipping crate for damage

Motorcycle:

–

unpack

–

inspect for damage

–

install remaining items

–

clean

Battery:

–

remove

–

add acid

–

charge

–

grease terminal posts

–

fit (mark with fitting date)

Check that the delivery is complete:

–

Toolkit

–

Documentation

–

Motorcycle keys

–

Optional extras

Read the fault code memory with the BMW MoDiTeC

Check tyre pressures

Fill fuel tank

Final inspection as functional check:

–

Oil inspection

–

Engine idle speed

–

Clutch, gearshift

–

Steering

–

Hand brakes and foot brakes

–

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

–

Test ride, if necessary

BMW AG Motorcycle Division
Pre-delivery Check
F 650 GS

Order No. 01 71 0 010 252

UX-VS-2, 10.99

Printed in Germany

Item

Rated value

Unit of

measurement/

specification

Oil capacities

Engine (with filter)

Telescopic fork – for each post

2.3 (4.05/2.43)

0.60 (1.06/0.63)

Litres (Imp. pints/US quarts)

Specification: see current

Service Information

Litres (Imp. pints/US quarts)

BMW telescopic fork oil

Coolant

Cooling system (entire)
Expansion tank

1.3 (2.29/1.37)
0.1 (0.18/0.11)

Litres (Imp. pints/US quarts)
Litres (Imp. pints/US quarts)

Composition:
Water:

50%

Antifreeze:

50%

Antifreeze protection
to –25 °C ( –13 °F)

Brake fluid

DOT 4

Valve clearances

Measured cold (max. 35 °C/95 °F)

Inlet:

0.10-0.15

(0.004-0.006)

Exhaust: 0.25-0.30

(0.010-0.012)

mm (in)

Spark plugs

Electrode gap

0.6...0.7 (0.02...0.03)

NGK D8 EA

mm (in)

Idle speed

1350 +100

rpm

Clutch cable play

Hand lever cable

1.0 - 2.0

(0.004 - 0.008)

mm (in)

Tyre pressure (on cold tyres)

solo
when fully loaded

front/rear

1.9/2.1 (27/30)
2.1/2.3 (30/33)

bar (psi)
bar (psi)

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

40
10
21
10
10
10
20

25
65
65
21
80
21

100

50
47
71
41

Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm

BMW AG Motorcycle Division
Service data
F 650 GS

F 650 GS

Instructions for
pre-delivery check

BMW AG Sparte Motorrad
After Sales
UX-VS-2
Hufelandstr. 6
D-80937 München

Edition: 11/99

Contents

Page

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

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