BMW F 650 GS Dakar - Service Manual - Manual de Taller - Manuel Reparation

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BMW F 650 GS-GS DAKAR - MANUAL DE TALLER - SERVICE MANUAL - MANUEL REPARATION


- Multilanguage Service Manual (English, Español, Deutsch, Français, Italiano) to motorcycles BMW F 650 GS Dakar


CONTENTS:

SERVICE MANUAL

INTRODUCTION
Structure
Key to symbols
Contents
Activities
MAINTENANCE SCHEDULE
PRE-DELIVERY CHECK
SERVICE DATA
CONTENTS
00 TIGHTENING TORQUES OPERATING FLUIDS
Tightening torques  
Table of operating fluids
00 PRE-DELIVERY CHECK
General view of crated motorcycle
Checking the shipping crate for damage
In case of damage in Germany
In case of damage in importer markets
Unpacking the motorcycle
Inspecting motorcycle for damage
Installing remaining items on motorcycle
Installing the front wheel
Installing windscreen
Installing front mudguard, mirrors and handlebar weights
Filling and charging the battery
Removing right and centre covers
Filling and charging the battery
Checking that delivery is complete
Reading the fault code memory with the BMW MoDiTeC
Checking tyre pressures
Adding fuel to tank
Final inspection and function check
Final cleaning
Handing over the motorcycle
00 MAINTENANCE
Key to maintenance intervals
Reading the fault code memory with the MoDiTeC
(Inspections I, II, III and IV)
Changing the engine oil and oil filter element
(Inspections I, II, III and IV)
Preparatory work
Draining engine oil
Replacing oil filter element
Filling with engine oil
Checking coolant, topping up if necessary
(Inspections I, II and III)
Checking coolant
Adding coolant
Changing coolant
(Inspection IV, every 2 years)
[Dakar] Changing oil in telescopic forks
(Inspection III)
Checking and adjusting valve clearances
(Inspections I, II and III)
Checking valve clearances
Preparatory work
Removing the intake air silencer together with the intake air pipe.
Exposing the radiator
Exposing cylinder head
Turning crankshaft to TDC position
Checking valve clearance
Adjusting valve clearances
Installing cylinder head cover
Replacing spark plugs
(Inspection III)
Emptying drain hose from intake air silencer
(Inspections II and III)
Replacing air cleaner element
(Inspection III)
Replacing fuel filter
(Inspection III, every 20,000 km/12,000 miles)
Checking clutch play, adjusting if necessary
(Inspections I, II and III)
Checking wheel spoke tension, adjusting if necessary
(Inspections II and III)
Checking brake pads and discs for wear, replacing if necessary
(Inspections II and III)
Checking brake pads for wear
Brake pads, front brake
Brake pads, rear brake
Replacing brake pads
Brake pads, front brake
Brake pads, rear brake
Checking the brake discs
Checking the brake fluid level and topping up if necessary
(Inspections II and III)
Brake fluid level (front brake)
Checking brake fluid level (front brake)
Topping up brake fluid level (front brake)
Brake fluid level (rear brake)
Checking brake fluid level (rear brake)
Topping up brake fluid level (rear brake)
Checking operation of brake system and checking for leaks; repairing/replacing as necessary
(Inspection III)
Changing brake fluid and bleeding brake system
(Inspection IV)
Changing brake fluid (front brake)
Changing brake fluid (rear brake)
Replacing primary sealing boot front brake master cylinder
(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS)
Replacing primary sealing boot, rear brake master cylinder
(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS)
Checking chain, chainwheel and chain sprocket, replacing if necessary
(Inspections II and III)
Checking chain tension, adjusting if necessary
(Inspections I, II, III and IV)
Checking chain tension
Adjusting chain tension
Checking battery acid level, adding distilled water if necessary
(Inspections II, III and IV)
Checking battery acid level
Adding distilled water
Cleaning and greasing the battery terminals, if necessary
(Inspection IV)
Checking and adjusting steering head bearing play, renewing if necessary
(Inspections II and III)
Checking steering head bearing play
Adjusting steering head bearing play
Greasing the side and main stands and the brake pedal lever
(Inspections II and III)
Side stand
Main (centre) stand
Brake pedal
Checking security of threaded fasteners
(Inspections I, II, III and IV)
Final inspection with road safety and functional check
(Inspections I, II, III and IV)
Road safety check
Tyre tread depth (recommended minimum value)
Tyre pressures (tyres cold)
Roadworthiness check
11 MOTOR
Cutaway view of engine
Engine oil circuit
Valve gear
Valves, components
Oil pumps, components
Removing and installing cylinder head, engine installed
Preparatory work
Removing camshafts
Removing cylinder head
Removing cylinder, engine installed
Removing engine
Preparatory work
Removing engine
Transferring engine to assembly frame
Disassembling engine
Removing cylinder head
Removing camshafts
Checking camshaft for wear
Removing and installing timing-chain sprockets
Checking centrifugal decompressor lever
Disassembling and assembling the centrifugal decompressor
Removing cylinder head
Checking timing chain for wear
Disassembling and assembling cylinder head
Removing valves
Bore for bucket tappet
Checking valve guide for wear
Removing valve guide
Installing valve guide
Checking valve seat for wear
Installing valve stem seal
Checking valve for wear
Installing valves
Removing cylinder
Checking cylinder
Removing piston
Disassembling piston
Determining clearance of piston in cylinder
Determining piston ring gaps
Determining piston pin clearance
Assembling pistons
Removing ignition magnet
Removing countershaft for starter
Disassembling and assembling freewheel
Disassembling freewheel
Assembling freewheel
Removing clutch
Removing pressure plate
Removing clutch plates
Removing and installing oil pump
Removing oil pump
Inspecting oil pump
Installing oil pump
Removing double drive gear
Removing crankshaft and balancing shaft
Checking crankshaft for wear
Removing compensating gear
Removing and installing crankshaft gear
Removing and installing gearbox mainshaft bearings
Removing and installing gearbox countershaft bearings
Removing and installing grooved ball bearings of balancing shaft
Removing and installing main bearings
Removal
Installation
Assembling engine
Installing crankshaft and balancing shaft
Shimming crankshaft
Installing double drive gear
Installing oil pump gears
Installing clutch
Installing clutch cage
Installing driver
Installing pressure plate
Installing countershaft for starter motor
Installing magnetic ignition trigger
Installing piston
Installing cylinder
Installing cylinder head
Installing camshaft and adjusting valves
Installing engine
Bleeding engine oil circuit
12 ENGINE ELECTRICS
Ignition magneto
Ignition magneto, components
Removing ignition magneto
Removing right engine housing cover
Removing and installing ignition trigger
Removing and installing stator
Installing magnetic ignition trigger
Installing magnet rotor
Removing and installing or dismantling starter motor
Removing and installing starter motor
Disassembling/assembling starter motor
Replacing spark plug (a 00.36)
Replacing ignition lead
Remove the intake air silencer together with the intake air pipe.
Removing and installing coil
Remove the intake air silencer together with the intake air pipe.
13 FUEL PREPARATION AND CONTROL
Removing and installing BMS control unit
Removing and installing intake air pipe
Removing and installing air temperature sensor
Replacing air filter element (a 00.36)
Removing and installing intake air silencer
Removing and installing intake air pipe
Removing and installing injection nozzle
Removing and installing throttle-valve actuator
Replacing throttle-valve potentiometer
Removing and installing throttle-valve stub pipe
Removing and installing intake pipe
Checking fuel pressure
Removing and installing fuel hoses
Removing and installing feed and return lines
Removing and installing line to fuel injector
Removing and installing throttle cable (a 32.12)
16 FUEL TANK AND LINES
Removing and installing fuel tank
Removing fuel tank
Installing fuel tank
Removing and installing fuel filler cap
Removing and installing roll-over valve
Replacing fuel filter (a 00.37)
Removing and installing fuel pump
Removing and installing fuel pump
Removing and installing fuel strainer
Removing and installing fuel-evaporation control valve
[USA version]
Removing and installing activated charcoal filter
[USA version]
17 RADIATOR
Coolant circuit
Thermostat, components
Removing and installing coolant pump
Removing coolant pump
Installing coolant pump
Adding coolant
Removing and installing coolant-temperature sensor
Checking cooling system for leaks
Removing and installing coolant hoses
Replacing coolant hose (radiator/water pump)
Replacing coolant hose (filler bowl/expansion tank)
Changing coolant (a 00.30)
Removing and installing fan
Removing and installing radiator
Removing and installing thermostat
18 EXHAUST SYSTEM
Removing and installing exhaust system
Removing and installing right- hand silencer
Removing and installing left- hand silencer
Removing and installing exhaust manifold and oxygen sensor
Removing exhaust manifold and oxygen sensor
Installing exhaust manifold and oxygen sensor
Replacing guard for silencer
21 CLUTCH
Clutch, components
Removing and installing clutch
Removing clutch
Removing pressure plate
Disassembling and reassembling pressure plate
Removing clutch plates, driver and clutch cage
Installing clutch cage
Installing driver
Installing pressure plate
Removing and installing releaser shaft
Installing clutch
23 GEARBOX
Gearbox shafts, components
Gear shift pedal, components
Removing and installing gearbox
Removing selector shaft with pawl and index lever
Removing selector forks
Removing selector drum
Removing, disassembling and reassembling gearbox shafts
Removing gearbox shafts
Disassembling and reassembling mainshaft
Checking mainshaft for wear
Disassembling and reassembling countershaft
Checking countershaft for wear
Replacing gearbox mainshaft bearings
Replacing gearbox countershaft bearings
Installing gearbox shafts
Installing selector shaft
Installing selector forks
Installing selector drum
27 DRIVE CHAIN
Removing and installing chain, chainwheel and chain sprocket
Removing and installing chain
Removing and installing chain guide rail
Removing and installing chain takeup roller
Removing chainwheel
Removing chain sprocket
Removing and installing chain guide rail with swinging fork installed
Adjust chain tension (a 00.47)
31 FRONT FORKS
Telescopic fork, components
[Dakar] Changing oil in telescopic forks
Removing and installing telescopic fork
Removing telescopic fork
Installing telescopic fork
Disassembling telescopic fork
Removing fixed tube
Disassembling fixed tube
Measuring telescopic fork
Checking lower fork bridge
Checking parallel alignment of fixed tubes
Checking fixed tube runout
Assembling telescopic fork
Assembling fixed tube
Assembling telescopic fork
Removing and installing steering head bearing
Upper steering head bearing
Lower steering head bearing
32 STEERING
Removing and installing left and right handlebar fittings
Removing and installing left handlebar fitting
Removing and installing clutch switch
Removing and installing right handlebar fitting
Removing and installing handlebars
Removing and installing clutch cable
Removing and installing throttle cable
Checking and adjusting steering head bearing play, renewing if necessary
(Inspections II and III)
Checking steering head bearing play
Adjusting steering head bearing play
Removing and installing left and right handlebar levers
Removing and installing left and right handlebar levers
Removing and installing right handlebar lever
33 REAR WHEEL DRIVE
Removing and installing suspension strut
Removing and installing rear swinging fork
Removing and installing needle roller races in rear swinging fork
Removing needle roller races
Installing needle roller races
Removing and installing reaction links
Removing and installing needle roller bearing in reaction link
Removing needle roller bearing
Installing needle roller bearing
Removing and installing angled lever
Removing and installing needle roller bearings and needle roller races in angled lever
Removing needle roller bearings and needle roller races
Installing needle roller bearings and needle roller races


34 BRAKES
Removing and installing front brake caliper
Removing and installing front brake pads (a 00.39)
Removing and installing front brake pistons
Removing and installing front brake disc
Checking brake disc for wear (a 00.40)
Checking front brake disc for lateral runout
Removing and installing rear brake caliper
Removing and installing rear brake pads (a 00.40)
Removing and installing rear brake pistons
Removing and installing rear brake disc
Checking brake disc for wear (a 00.40)
Checking rear brake disc for lateral runout
Replacing primary sealing boot, front brake master cylinder (a 00.44)
Removing and installing front brake master cylinder
Removing and installing handbrake lever (a 32.15)
Replacing primary sealing boot, rear brake master cylinder (a 00.45)
Removing and installing rear brake master cylinder
Removing and installing footbrake lever
Checking play at piston thrust rod, adjusting if necessary
Checking play at piston thrust rod
Adjusting play at piston thrust rod
Removing and installing front ABS sensor
Removing and installing front ABS sensor ring
Removing and installing rear ABS sensor
Removing and installing rear ABS sensor ring
Removing and installing ABS control unit
Removing and installing front brake lines/hoses (with ABS)
Removing and installing brake lines
Removing and installing front brake hoses
Removing and installing rear brake lines/hoses (with ABS)
Removing and installing brake lines
Removing and installing brake hose
Checking/adjusting front ABS sensor gap
Adjusting ABS sensor gap
Checking and adjusting gap of speed/rear ABS sensor
Adjusting ABS sensor gap
36 WHEELS AND TYRES
Removing and installing front wheel
Removing front wheel
Installing the front wheel
Removing and installing front wheel bearing
Removing left-hand wheel bearing
Removing right-hand wheel bearing
Installing wheel bearings
Removing and installing rear wheel
Removing and installing rear wheel bearings
Removing left-hand wheel bearing
Removing right-hand wheel bearing
Installing wheel bearings
Removing and installing bearing in chainwheel carrier
Removing and installing spokes
Removing and installing front wheel spokes
Outer left spokes

Inner left spokes
Outer right spokes
Inner right spokes
Removing and installing rear wheel spokes
Outer left and right spokes
Inner left and right spokes
Checking and centering front and rear wheel rims
Checking rims
Centering lateral runout
Centering vertical runout
Static balancing of front/rear wheel
46 FRAME
Removing and installing fairing
Removing and installing covers
Removing and installing left and right covers
Removing and installing centre cover
Removing and installing cockpit fairing
Removing and installing fairing bracket
[Dakar] Removing and installing hand protectors
Removing and installing engine guard
Removing and installing front mudguard
Removing and installing left/right rear trim panel
Removing and installing left/right grip
Removing and installing number- plate panel
Removing and installing base of stowage compartment and partition
Removing and installing seat latch
Removing and installing rear mudguard
Raising, removing and installing rear frame
Raising rear frame
Removing and installing rear frame
Removing frame
Removing and installing right footrest
Removing and installing left footrest
Removing and installing bottom truss
Removing and installing side stand
Removing and installing main (centre) stand
51 EQUIPMENT
Removing and installing ignition switch/steering lock
Removing and installing lock barrel
Removing and installing lock for rear stowage compartment
Removing and installing lock barrel for fuel tank filler cap
Replacing mirrors
61 GENERAL ELECTRICAL EQUIPMENT
Wiring harness
View from left
View from right
[Dakar] General view, left side
[Dakar] General view, right side
Component positions in electronic equipment box
Relay positions in electronic equipment box
Connectors, electronics box
Removing and installing battery

AND MORE....