BMW AG Motorcycle (F 650 GS). Manual - part 22

21.4

21.5

Clutch, components

E210010

21.6

21 21 000 

Removing and installing 

clutch

21 21 000 

Removing clutch

–

Remove seat.

–

Remove left cover.

a

....................................................See Group 46

–

Drain engine oil.

a

....................................................See Group 00

–

Place motorcycle on side stand.

–

Position a drip tray beneath the engine.

•

Remove drain plug (1) from water pump.

•

Hold a funnel below the drain and open the radi-
ator cap.

•

Drain off all the coolant.

–

Place motorcycle on its centre stand.

•

Remove the gear shift pedal.

–

Remove the starter motor.

a

....................................................See Group 12

•

Disconnect clutch cable at release shaft.

•

Disconnect the oil return line from the engine and 
the oil tank.

•

Disconnect the oil line from the cylinder head.

•

Using hose clip pliers, BMW No. 17 5 500, re-
move hose clips (1).

•

Remove left engine housing cover.

Removing pressure plate

•

Remove hex screws (3) in diagonally opposite 
sequence.

•

Lift off complete pressure plate (2).

•

Check length of compression springs.

Disassembling and reassembling pressure plate

•

Remove circlip (7) with circlip pliers.

•

Check splines on release head (4).

•

Heat pressure plate (6) to 80 °C (176 °F) and 
drive in grooved ball bearing (5), using a suitable 
drift (such as a socket, for example).

L

 Note:

Use temperature measuring device, 
BMW No. 00 1 900, to check the temperature.

•

Grooved ball bearing (5) must turn easily.

•

Installation is the reverse of the removal proce-
dure.

E170060

1

E110251

3

2

E210030

7

4

5

6

21.7

Removing clutch plates, driver and clutch cage

L

 Note:

When dismantling the clutch plate cluster, mark the 
order in which the plates are installed.

•

Take the plate cluster, lined plates (1) and inner 
plates (2) out of the clutch cage.

•

Using locating ring, BMW No. 21 4 600, secure 
clutch cage (5) and driver (7) in position. 

•

Remove lock washer (8).

L

 Note:

Hex nut (9) is secured with Loctite 243 and should 
be heated if necessary before unscrewing.

•

Unscrew hex nut (9).

•

Remove driver (7).

•

Remove clutch cage (5) incl. serrated washer (6).

•

Remove needle cages (3, 4).

E210020

1

2

8

9

6

5

3

7

4

E110260

21 4 600

21.8

Installing clutch cage

•

Coat needle sleeves (3, 4) with oil and install, 
with the small sleeve (3) down.

•

Insert O-ring (6) into groove under splines.

•

Install clutch cage (5); gears must all be in mesh.

•

Attach thrust washer (7) and press it against the 
O-ring until it is firmly seated and does not spring 
back.

Installing driver

•

Insert driver (8) and coat internal splines with 
Optimoly MP 3.

•

Fit serrated washer (9); it must engage securely.

•

Clean threads of compensating shaft and hexa-
gon nut (10), coat threads with Loctite 243 and 
install nut.

•

Insert locating ring, BMW No. 21 4 600.

•

Tighten hex nut and tilt up retaining plate (8).

X 

Tightening torques:

Driver to compensating shaft
(clean thread + Loctite 243)........................ 140 Nm

Installing pressure plate

•

Insert the plates, starting with a steel plate. Install 
steel plates (2) and lined plates (1) alternately; 
with marked lined plate always at the top.

L

 Note:

Insert the topmost plate in the offset groove of the 
clutch cage.

Check clutch plates for wear

•

Measure the height of the 8 lined plates when 
pressed together.

•

Height of complete compressed plate cluster.

Height of lined plate 
cluster ..................................min. 27.5 mm (1.08 in)
Height of complete plate 
cluster ..................................min. 39.1 mm (1.54 in)
Lined plate distortion................. 0.25 mm (0.010 in)
Steel plate distortion ................. 0.15 mm (0.006 in)

E210020

1

2

8

9

6

5

3

7

4

10

21.9

•

Install pressure plate (2).

L

 Note:

All springs (3) must be renewed after each clutch re-
pair.

•

Install springs (3).

•

Uniformly tighten screws (4) with washers (5) in 
diagonally opposite sequence.

•

Position thrust head (1) correctly in relation to the 
release shaft and hold temporarily in position 
with grease.

X 

Tightening torques:

Pressure plate to driver ................................ 10 Nm

Removing and installing releaser shaft

•

Remove keeper (6) for release shaft (7).

•

Withdraw release shaft from cover.

•

Using puller, BMW No. 21 4 610, pull out both 
needle roller bearings and the sealing ring to-
gether.

F110590

1

2

3

4

5

E210040

6

7

E210050

21 4 610

21.10

•

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

•

Drive the lower and upper needle roller bearings 
in together with drift, BMW No. 21 4 640.

•

Insert release shaft.

•

Cover the splines on the release shaft with slide-
on sleeve, BMW No. 21 4 620.

•

Using drift, BMW No. 21 4 630, drive in sealing 
ring.

21 21 000 

Installing clutch

•

Lower the engine.

a

....................................................See Group 11

•

Remove oil return line.

•

Align splines on water pump driven gear with 
driving gear on compensating shaft.

•

Fit gasket.

L

 Note:

Always replace selector shaft seal in clutch cover.

•

Install selector shaft sealing ring in clutch cover 
with sliding sleeve, BMW No. 21 4 620, and drift, 
BMW No. 21 4 630.

•

Fit left engine cover and install securing screws.

•

Connect the oil return line to the engine.

•

Install the engine.

a

....................................................See Group 11

X 

Tightening torques:

Engine block cover, left ................................ 10 Nm
Drain plug for water pump ...........................  10 Nm
Oil line to cylinder head .................................. 8 Nm
Oil line to engine block ................................. 35 Nm

23.1

Contents

Page

23

Technical Data

............................................................................................................................... 3

Gearbox shafts, components 

.................................................................................................5

Gear shift pedal, components 

...............................................................................................6

Removing/installing gearbox

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

Removing selector shaft with pawl and index lever

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

Removing selector forks

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

Removing selector drum

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

Removing, disassembling and reassembling gearbox shafts 

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

Removing gearbox shafts

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

Disassembling and reassembling mainshaft

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

Checking mainshaft for wear  ...............................................................................................................9

Disassembling and reassembling compensating shaft

 ................................................10

Checking countershaft for wear .........................................................................................................11

Replacing gearbox mainshaft bearings

 ...............................................................................11

Replacing gearbox compensating shaft bearings

 ..........................................................12

Installing gearbox shafts

 ............................................................................................................12

Installing selector shaft

 ...............................................................................................................13

Installing selector forks

 ...............................................................................................................13

Installing selector drum

 ..............................................................................................................13

23 Gearbox