Content .. 10 11 12 13 ..

BMW AG Motorcycle (F 650 GS). Manual - part 12

11.32

11 34 800 Installing valve stem seal

•

Install bottom valve spring retainer (1).

•

Use a drift, BMW No. 11 6 650, to insert valve
stem seal (2).

Checking valve for wear

•

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.

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.

E110120

F110190

11.33

11 34 020 Installing valves

•

Install valve with shrink-fit tube.

Note:

Remove the shrink-fit tube.

•

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, BMW No. 11 5 691, 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.

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.

11 11 150

Removing cylinder

•

Separate the cylinder base from the engine
block.

Caution:

When removing cylinder, make sure that the piston
does not strike the engine block.

•

Remove cylinder.

Checking cylinder

•

Check cylinder face and sealing faces for dam-
age and blow out oil ducts for chain tensioner.

•

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).

Wear limits for cylinder bore:
Cylinder A ................... max. 100.03 mm (3.9382 in)
Cylinder B ................... max. 100.04 mm (3.9387 in)

E110130

11 0 523

11 0 521

11 5 692

11 0 522

11 5 691

E110140

E110150

11.34

11 25 050

Removing piston

•

Remove piston pin circlips.

•

Press out piston pin with drift,
BMW No. 11 6 581.

Note:

Mark exhaust-valve side on piston crown.

11 25 671

Disassembling piston

•

Remove piston rings with piston ring pliers.

•

Carefully clean piston.

•

Check piston for signs of damage.

Determining clearance of piston in
cylinder

•

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”.

•

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.

Note:

Determine piston clearance:
Dimension “A” minus dimension “B” = piston clear-
ance

Piston clearance:
When new ... 0.024...0.040 mm (0.0009...0.0016 in)
Wear limit ...................... max. 0.100 mm (0.0039 in)

E110150

E110160

11.35

Determining piston ring gaps

•

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

Note:

The “Top” must face towards the piston crown.
Install the piston rings with their gaps offset
by 120 °.

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)

12 11 070

Removing ignition magnet

•

Remove retainer on right engine housing cover.

•

Remove the central plug and install handle,
BMW No. 12 5 500.

•

Remove the cover, noting the thrust
washer (arrow).

•

If necessary, remove ignition trigger (4).

E110170

E110180

12 5 500

E110190

E110200

11.36

•

Unscrew hex nut.

•

Heat hub to 80 °C (176 °F).

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

Removing countershaft for

starter

•

Remove thrust washer (1) and spacer sleeve (2).

•

Remove double gear (4).

•

Pull off idler gear (3).

•

Remove freewheel gear (5).

E110210

12 5 510

E110220

E110230

11.37

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

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.

E110240

E110300

11.38

•

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.

Tightening torques:

Machine screw
(clean threads + Loctite 648) ........................ 35 Nm

21 21 000

Removing clutch

•

Turn engine round in assembly fixture.

•

Remove left retaining for engine housing cover
and remove cover.

Removing pressure plate

•

Remove hex screws (2) in diagonally opposite
sequence.

•

Lift off complete pressure plate (1).

Removing clutch plates

Caution:

The topmost clutch plate is offset. Make sure this
plate is installed in the correct position.

•

Take plate cluster out of clutch cage.

•

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.

Caution:

Note the backup washer at the bottom.

•

Pull off needle cages.

•

Remove the backup washer.

E110250

E110260

21 4 600

11.39

11 41 000

Removing and installing oil

pump

Removing oil pump

•

Remove circlip (1) from idler gear.

•

Remove the retaining rings of the oil-pump
gears (2) and disengage the oil-pump gears.

•

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)

Installing oil pump

7 Inner rotor
8 Outer rotor
9 Cover
10 Markings
11 Needle roller

•

Installation is the reverse of the removal proce-
dure: pay particular attention to the following.

Note:

Markings (5) must be visible.

•

Oil the inner and outer rotors.

•

Clean the threads of the countersunk screws
and coat with Loctite 243.

Tightening torque:

Countersunk screws in oil-pump cover
(clean threads + Loctite 243) .......................... 6 Nm

E110270

E110280

F110370

Content .. 10 11 12 13 ..