BMW AG Motorcycle (F 650 GS). Manual - part 8

00.40

11.1

Contents

Page

............................................................................................................................... 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 Motor

11.2

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

11.3

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

11.4

11.5

Technical Data

F 650 GS

Engine, general

Type

Single-cylinder four-stroke, double overhead
camshafts driven by roller chain, 4 valves operat-
ed by bucket tappets, balancing shaft, liquid-
cooled 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)

11.6

Crank gear

Crankshaft - main bearing play
On installation
Wear limit

mm (in)
mm (in)

0.030...0.070 (0.0012...0.0028)
0.10 (0.004)

Wear limit, main bearing bore diameter
Wear limit

Main bearing journal diameter
Bearing play

Runout at crankpin

Clutch end
Magnet end

mm (in)

mm (in)
mm (in)

46.08 (1.814)

47.97 (1.888)
0.10 (0.004)

0.03 (0.001)
0.05 (0.002)

Connecting rod

Wear limit, connecting rod
Radial play

Big end bore
Small end bore

mm (in)
mm (in)

0.08 (0.003)
0.05 (0.002)

Connecting rod - axial play
On installation
Wear limit

mm (in)
mm (in)

0.30...0.65 (0.012...0.026)
0.80 (0.031)

Small-end bearing - axial play
On installation
Wear limit

mm (in)
mm (in)

22.015...22.025 (0.8668...0.8671)
22.04 (0.868)

Compensating shaft

Bearing journals
Wear limit

19.96 (0.786)

Cylinder head

Camshaft journals I/E

Wear limit

Camshaft bearing play I/E

Wear limit

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)

Valves

Valve clearances with engine cold
(max. 35 °C/95 °F)

Inlet valves
Exhaust valves

mm (in)
mm (in)

0.05...0.10 (0.002...0.004)
0.25...0.30 (0.010...0.012)

Valve timing (at 3 mm/0.12 in valve
clearance)

Inlet opens
Inlet closes
Exhaust opens
Exhaust closes

13° after TDC
25° after BDC
25° before BDC
13° before TDC

Valve head dia.

Inlet
Exhaust

mm (in)
mm (in)

36 (1.41)
31 (1.22)

Stem dia.

Inlet
Wear limit
Exhaust
Wear limit

mm (in)
mm (in)
mm (in)
mm (in)

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

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)

Technical Data

F 650 GS

11.7

Valve seat angle

Inlet
Exhaust

°
°

45
45

Included valve angle

Inlet
Exhaust

°
°

15
18

Valve seat width

Inlet
Wear limit
Exhaust
Wear limit

mm (in)
mm (in)
mm (in)
mm (in)

1.05...1.35 (0.041...0.053)
1.60 (0.063)
1.25...1.55 (0.049...0.061)
2.2 (0.09)

Valve guide

Inlet

Intl. dia.

Wear limit
Exhaust Intl. dia.
Wear limit

mm (in)
mm (in)
mm (in)
mm (in)

5.006...5.018 (0.1971...0.1976)
5.080 (0.2000)
5.006...5.018 (0.1971...0.1976)
5.080 (0.2000)

Bucket tappets (wear limit)

Extl. dia.
Radial clearance in cylinder head
Guide dia. in cylinder head

mm (in)
mm (in)
mm (in)

33.400 (1.3150)

0.200 (0.0079)

33.600 (1.3229)

Valve spring

On installation (free length)

mm (in) min. 40.5 (1.60)

Wear limit

mm (in) 39.0 (1.54)

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

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)

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)

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)

Technical Data

F 650 GS

Content .. 6 7 8 9 ..