BMW F 650 GS - Repair, Service Manual - Reparaturanleitung

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BMW F 650 GS - SERVICE MANUAL - REPARATURANLEITUNG

English & Deutsch service manual to motorcycles BMW F 650 GS



CONTENTS:
    
REPAIR MANUAL

INTRODUCTION
Usage
Key to symbols
Contents
Activities

MAINTENANCE SCHEDULE

PRE-DELIVERY CHECK

SERVICE DATA

INSTRUCTIONS FOR 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 windscreen
Installing front mudguard, mirrors and handlebar w...
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

CONTENTS
00 MAINTENANCE AND GENERAL INSTRUCTIONS
Table of operating fluids
Tightening torques
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)
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...
Exposing the radiator
Exposing cylinder head
Turning crankshaft to TDC position
Checking valve clearance
Adjusting valve clearances
Installing cylinder head cover
Installing fan shroud
Installing intake air silencer
Installing the intake air duct
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 necess...
(Inspection II)
Checking brake pads and discs for wear, replacing ...
(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 n...
(Inspection II)
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 freedom fro...
(Inspection III)
Changing brake fluid
(Inspection IV)
Changing brake fluid (front brake)
Changing brake fluid (rear brake)
Replacing primary sealing boot, front brake master...
(Inspection III, every 40,000 km/24,000 miles for ...
Replacing primary sealing boot, rear brake master ...
(Inspection III, every 40,000 km/24,000 miles for ...
Inspecting front and rear wheel bearings, replacin...
(Inspection III)
Checking chain, chainwheel and chain sprocket, rep...
(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 wate...
(Inspections II, III and IV)
Checking battery acid level
Adding distilled water
Cleaning and greasing the battery terminals, if ne...
(Inspections III and IV)
Checking and adjusting steering head bearing play,...
(Inspections II and III)
Checking steering head bearing play
Checking and adjusting steering head bearing play,...
(Inspections II and III)
Adjusting steering head bearing play
Greasing the side and main stands and the brake pe...
(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 c...
(Inspections I, II, III and IV)
Road safety check
Tyre tread depth (recommended minimum value)
Tyre pressures (tyres cold)
Roadworthiness check
11 MOTOR
Sectional view of engine
Engine oil circuit
Valve gear
Valves, components
Oil pumps, components
Removing and installing cylinder head, engine inst...
Preparatory work
Removing camshafts
Removing cylinder head
Removing cylinder, engine installed
Removing engine
Preparatory work
Removing engine
Transferring engine to assembly frame
Lowering engine
Preparatory work
Lowering the engine
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 deco...
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 compensating shaft...
Removing and installing grooved ball bearings of g...
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 magnet
Removing right engine housing cover
Removing/installing ignition trigger
Removing/installing stator
Installing magnetic ignition trigger
Installing magnet wheel
Removing/installing or dismantling starter motor
Removing/installing starter motor
Disassembling/assembling starter motor
Replacing spark plug
See Group 00
Replacing ignition lead
Remove the intake air silencer together with the i...
Removing/installing coil
Remove the intake air silencer together with the i...
13 FUEL PREPARATION AND CONTROL
Removing and installing BMS control unit
Removing and installing intake air pipe
Removing/installing air temperature sensor
Replacing air filter element
See Group 00
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
See Group 32
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
See Group 00
Removing and installing fuel pump
Removing and installing fuel pump
Removing and installing fuel strainer
Removing and installing warning-contact switch for...
Removing and installing fuel-evaporation control v...
[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...
Replacing coolant
See Group 00
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 oxyge...
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/installing gearbox
Removing selector shaft with pawl and index lever
Removing selector forks
Removing selector drum
Removing, disassembling and reassembling gearbox s...
Removing gearbox shafts
Disassembling and reassembling mainshaft
Checking mainshaft for wear
Disassembling and reassembling compensating shaft...
Checking countershaft for wear
Replacing gearbox mainshaft bearings
Replacing gearbox compensating shaft bearings
Installing gearbox shafts
Installing selector shaft
Installing selector forks
Installing selector drum
27 DRIVE CHAIN
Removing and installing chain, chainwheel and chai...
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 swin...
Adjusting chain tension
See Group 00
32 STEERING
Removing and installing left and right handlebar f...
Removing and installing left handlebar fitting
Removing and installing clutch switch
Removing and installing right handlebar fitting
Removing and installing handlebar
Removing and installing clutch cable
Removing and installing throttle cable
Checking and adjusting steering head bearing play,...
(Inspections II and III)
Checking steering head bearing play
Checking and adjusting steering head bearing play,...
(Inspections II and III)
Adjusting steering head bearing play
Removing and installing left and right handlebar l...
Removing and installing left handlebar lever
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 re...
Removing needle roller races
Installing needle roller races
Removing and installing struts
Removing and installing needle roller bearing in ...
Removing needle roller bearing
Installing needle roller bearing
Removing and installing angled lever
Removing and installing needle roller bearings an...
Removing needle roller bearings and needle roller...
Installing needle roller bearings and needle rolle...
34 BRAKES
Removing and installing front brake calliper
Removing and installing front brake pads
See Group 00
Removing and installing front brake pistons
Removing and installing front brake disc
Checking brake disc for wear
See Group 00
Checking front brake disc for lateral runout
Removing and installing rear brake calliper
Removing and installing rear brake pads
See Group 00
Removing and installing rear brake piston
Removing and installing rear brake disc
Checking brake disc for wear
See Group 00
Checking rear brake disc for lateral runout
Replacing primary sealing boot front brake master ...
See Group 00
Removing and installing front brake master cylinde...
Removing and installing handbrake lever
See Group 32
Replacing primary sealing boot, rear brake master ...
See Group 00
Removing and installing rear brake master cylinder...
Removing and installing footbrake lever
Checking play at piston thrust rod, adjusting if n...
Checking play at piston thrust rod
Adjusting play at piston thrust rod
Removing and installing front ABS sensor
Removing 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 (w...
Removing and installing brake lines
Removing and installing front brake hoses
Removing and installing rear brake lines/hoses (wi...
Removing and installing brake lines
Removing and installing brake hose
Checking/adjusting front ABS sensor gap
Adjusting ABS sensor gap
Checking/adjusting rear speed/ABS sensor gap
Adjusting ABS sensor gap
36 WHEELS AND TYRES
Removing/installing front wheel
Removing front wheel
Installing the front wheel
Removing/installing front wheel bearing
Removing left-hand wheel bearing
Removing right-hand wheel bearing
Installing wheel bearings
Removing/installing rear wheel
Removing/installing rear wheel bearings
Removing left-hand wheel bearing
Removing right-hand wheel bearing
Installing wheel bearings
Removing/installing bearing in chainwheel carrier
Removing/installing wheel spokes
Removing/installing front wheel spokes
Outer left spokes
Inner left spokes
Outer right spokes
Inner right spokes
Removing/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 covers
Removing and installing left/right cover
Removing and installing centre cover
Removing and installing cockpit fairing
Removing and installing fairing bracket
Raising rear frame
Removing and installing front mudguard
Removing and installing rear frame
51 EQUIPMENT
Removing and installing ignition switch/steering l...
Removing and installing lock barrel
Removing and installing lock for rear stowage comp...
Removing and installing lock barrel for fuel tank ...
Replacing mirrors
61 GENERAL ELECTRICAL EQUIPMENT
Wiring harness
View from left
View from right
Component positions in electronic equipment box
Relay positions in electronic equipment box
Connectors, electronic equipment box
Removing and installing battery

AND MORE.....