BMW F 650 CS Scarver - Service Manual - Manual de Taller

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BMW F 650 CS SCARVER - REPAIR MANUAL - MANUAL DE REPARACIONES

- English and Spanish service manual to motorcycles BMW F 650 CS SCARVER


CONTENTS - CONTENIDOS:


REPAIR MANUAL

INTRODUCTION
Use
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
Unpack the motorcycle
Inspecting motorcycle for damage
Checking that delivery is complete
Installing remaining items on motorcycle
Filling and charging the battery
Removing the battery
Filling and charging the battery
Checking engine oil level
Checking tyre pressures
Final inspection and function check
Final cleaning
Handover
00 MAINTENANCE
Key to maintenance intervals
Reading the fault code memory with the MoDiTeC
(Inspections I, II, III and IV)
Changing the engine oil [engine only] and oil filter element
(Inspection I)
Preparatory work
Draining engine oil
Replacing oil filter element
Filling with engine oil
Changing the engine oil [engine and oil tank] and oil filter element
(Inspections II, III and IV)
Preparatory work
Draining engine oil
Replacing oil filter element
Filling with engine oil
Cleaning oil strainer in frame
(Inspection II, once only)
Greasing rubber grommets for cover insert
(Inspections I, II, III and IV)
Checking coolant, topping up if necessary
(Inspections I, II and III)
Checking coolant
Adding coolant
Changing coolant
(Inspection IV, every 2 years)
Checking and adjusting valve clearances
(Inspections II and III)
Checking valve clearances
Preparatory work
Remove 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 plug
(Inspection III)
Emptying drain from intake air silencer
(Inspections I, II and III)
Replacing air cleaner element
(Inspection III)
Replacing fuel filter
(Inspection III, every 40,000 km/24,000 miles)
Checking clutch play, adjusting if necessary
(Inspections I, 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 brake fluid level at front and rear
(Inspections II and III)
Brake fluid level (front brake)
Checking brake fluid level (front brake)
Brake fluid level (rear brake)
Checking 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 and bleeding brake system (front brakes)
Changing brake fluid and bleeding brake system (rear brakes)
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 toothed belt pulley and sprocket, replacing if necessary
(Inspection III)
Replacing toothed belt
(Inspection III)
Checking belt tension, adjusting if necessary
(Inspections I, II and III)
Checking belt tension
Adjusting belt tension
Used belt, new belt
Checking battery acid level, adding distilled water if necessary
(Inspections II, III and IV)
Checking battery acid level
Adding distilled water
Cleaning and greasing battery terminals, if necessary
(Inspection IV)
Checking and adjusting steering head bearing play, replacing if necessary
(Inspections II and III)
Checking steering head bearing play
Adjusting steering head bearing play
Greasing side stand
(Inspections II and III)
Side stand
Checking specified torque of threaded fasteners with torque wrench
(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 ENGINE
Technical Data
Cutaway view of engine
Engine oil circuit
Engine and oil-tank system
Valve gear
Valves, components
Oil pumps, components
Removing and installing oil pressure switch with engine installed
Removing and installing oil pressure switch
Cleaning oil tank and oil lines
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 magneto
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
Technical Data
Ignition magneto
Ignition magneto, components
Removing ignition magneto
Removing right engine block cover
Removing and installing ignition trigger
Removing and installing stator
Installing ignition magneto
Installing magnet rotor
Removing and installing, disassembling starter motor
Removing and installing starter motor
Disassembling and assembling starter motor
Replacing spark plug (a 00.42)
Removing and installing coil
13 FUEL PREPARATION AND CONTROL
Technical Data
Removing and installing BMS control unit
Removing and installing intake air pipe
Removing and installing air temperature sensor
Replacing air filter element (a 00.43)
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 flap stub
Removing and installing intake stub
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
Technical Data
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 00.44)
Removing and installing fuel pump
Removing and installing fuel- evaporation control valve
[USA version]
Removing and installing activated charcoal filter
[USA version]
17 RADIATOR
Technical Data
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 (cylinder head/frame - frame/radiator)
Replacing coolant hose (radiator/water pump)
Replacing coolant hose (filler bowl/expansion tank)
Changing coolant (a 00.36)
Removing and installing fan
Removing and installing radiator
Removing and installing thermostat
18 EXHAUST SYSTEM
Technical Data
Removing and installing exhaust system
Removing and installing silencer (muffler)
Removing and installing exhaust elbow and oxygen sensor
Removing exhaust elbow and oxygen sensor
Installing exhaust elbow and oxygen sensor
Replacing guard for silencer
21 CLUTCH
Technical Data
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
Check clutch discs for wear
Removing and installing release shaft
Installing clutch
23 GEARBOX
Technical Data
Gearbox shafts, components
Gear shift pedal, components
Replacing shaft sealing rings with engine installed
Replacing sealing ring of selector shaft
Replacing shaft sealing ring of belt sprocket
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 CHAIN/BELT DRIVE
Technical Data
Removing and installing belt, belt drive gear and belt sprocket
Removing and installing belt (a 00.54)
Removing and installing belt sprocket (a 33.13)
Removing and installing belt sprocket
Adjust belt tension (a 00.56).
31 FRONT FORKS
Technical Data
Telescopic fork, components
Removing and installing telescopic fork
Removing telescopic fork
Installing telescopic fork
Disassembling telescopic fork
Removing 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
Complete assembly of telescopic fork.
Removing and installing steering head bearing
Upper steering head bearing
Lower steering head bearing
32 STEERING
Technical Data
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 handlebar
Removing and installing clutch cable
Removing and installing throttle cable
Removing and installing left and right handlebar levers
Removing and installing left handlebar lever
Removing and installing right handlebar lever
Checking and adjusting steering head bearing play, replacing if necessary (a 00.60)
33 REAR WHEEL DRIVE
Technical Data
Removing and installing suspension strut
Removing and installing rear swinging arm
Removing and installing needle roller races in rear swinging arm
Removing needle roller races
Installing needle roller races
Removing and installing needle bearings in rear swinging arm
Removing needle roller bearing
Installing needle roller bearing
Removing and installing reaction link
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
Removing and installing drive damper
Removing drive damper
Removing pulley
Disassembling drive damper
Assembling drive damper
Installing pulley
Installing drive damper
Measuring runout of belt pulley
Removing and installing eccentric with drive shaft
Separating eccentric from drive shaft
Removing and installing floating bearing of eccentric
Removing and installing fixed bearing of eccentric
Pressing eccentric onto drive shaft
34 BRAKES
Technical Data
Removing and installing front brake caliper
Removing and installing front brake pads (a 00.46)
Removing and installing front brake pistons
Removing and installing front brake disc
Checking brake disc for wear (a 00.45)
Checking front brake disc for lateral runout
Removing and installing rear brake caliper
Removing and installing rear brake pads (a 00.46)
Removing and installing rear brake pistons
Removing and installing rear brake disc
Checking brake disc for wear (a 00.47)
Checking rear brake disc for lateral runout
Replacing primary sealing boot, front brake master cylinder (a 00.52)
Removing and installing front brake master cylinder

Removing and installing handbrake lever (a 32.13)
Replacing primary sealing boot, rear brake master cylinder (a 00.53)
Removing and installing rear brake master cylinder
Removing and installing brake pedal
Checking blow-by clearance at piston thrust rod, adjusting if necessary  
Checking blow-by clearance at piston rod
Adjusting play at piston rod
Removing and installing front ABS sensor
Removing and installing front ABS sensor ring
Removing and installing rear ABS sensor
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 front ABS sensor ring for runout
36 WHEELS AND TYRES
Technical Data
Removing and installing front wheel
Removing front wheel
Installing 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
Checking front and rear wheel rims
Checking rims
Static balancing of front/rear wheel
46 FRAME
Technical Data
Overview of trim panels
Removing and installing trim panels
Removing and installing left and right covers
Removing and installing rear cover
Removing and installing front cover
Removing and installing left and right covers

Removing and installing windscreen and windscreen holder
Removing and installing headlight surround
Removing and installing instrument cover
Removing and installing left/right connector covers
Removing and installing left connector cover
Removing and installing right connector cover
Removing and installing fairing bracket
Removing and installing front mudguard
Removing and installing rear mudguard
Removing and installing number- plate carrier
Removing and installing spray guard
Removing and installing number-plate carrier
Removing and installing left/right rear trim panel
Removing and installing luggage rack
Removing and installing stowage- compartment frame
Removing and installing oil-tank trim panels
Raising, removing and installing rear frame
Raising rear frame
Removing and installing rear frame
Removing frame
Removing and installing left and right footrests
Removing and installing rear footrest
Removing and installing side stand truss
Removing and installing side stand
Measuring wheel track offset
Measurement record, wheel track offset
Key to measurement result:
Checking frame with gauge
Front wheel
Rear wheel
Example
51 EQUIPMENT
Technical Data
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
Technical Data
Wiring harness
View from left
View from right
Component positions in electronic equipment box
Relay positions in electronic equipment box
Connectors, electronics box
Removing and installing battery (a 00.20)
Removing and installing battery carrier (a 34.17)
Replacing fuses
Motorcycle fuses
Fuses
Removing and installing holder for BMS control unit
Removing and installing coolant-temperature sensor (a 17.10)
Removing and installing side stand switch
Removing and installing rear-brake switch for brake light
Removing and installing front-brake switch for brake light
Removing and installing horn
Removing and installing neutral-indicator switch
Removing and installing front/rear ABS sensors (a 34.15)/(a 34.16)
Removing and installing voltage regulator
Removing and installing switch for hazard warning flashers
62 INSTRUMENTS
Technical Data
Telltale/warning lights
Removing and installing instrument panel
Replacing telltale/warning lights
Disassembling and assembling instrument cluster
Removing and installing wiring harness
63 LIGHTS
Technical Data
Removing and installing headlight
Removing and installing rear light
Removing and installing number- plate light
Replacing bulbs
Bulb for low-beam headlight/ high-beam headlight
Bulb, parking light
Flashing turn indicator
Rear lights
Bulb for number-plate light
Checking and adjusting headlight beam throw
Vertical adjustment
Lateral adjustment