BMW F650GS Dakar (R13) 2005 to 2007 service repair manual

BMW AG Motorcycle Division After Sales F 650 GS Repair Manual

Introduction This repair manual will help you to perform all the main maintenance and repair work correctly and efficient- ly. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and prac- tical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even higher Service quality. A new issue of this repair manual will be published if amendments or additions (supplements) are needed. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification. • The repair manual is structured in the logical sequence of the work to be performed: Removal, Disas- sembly, Repair, Assembly, Installation. • The entire contents are divided into individual chapters, corresponding to the Construction Groups. 11 . 10 Chapter Page number within chapter An arrow symbol followed by the chapter and page numbers is a reference to another chapter, e.g. Ób ............................................ See Group 46 • Work to be performed during an Inspection is described in Group “00”. The various inspection routines are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption. • Use of the BMW special tools needed for certain tasks is described in the work instructions. If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the repair manual. We also recommend, as an additional source of information, the Electronic Parts Catalogue (ETC), which contains clear and easy-to-follow illustrations. If the work described here is restricted to a particular equipment specification, for instance if a specific optional extra (OE) is fitted, this is stated in square brackets at the start of the item concerned, e.g. [With heat- ed handlebar grips]. Please refer to the following pages as well for a description of other symbols used and how to work with it. BMW AG Motorcycle Division After Sales Published by: BMW AG Sparte Motorrad After Sales UX-VS-2 D - 80788 München All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Produced in Germany

Usage Each chapter starts with the list of contents. The list of contents is followed by the Technical Data table. Chapter 00 “Maintenance and general instructions” details the handover checklist and lists all tightening torques and operating fluids. Key to symbols In this Workshop Manual for the F 650 GS model, the following symbols are used; their meanings are ex- plained in the table. Special instructions aimed at improving the work procedures L Note: Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance procedures. e Caution: Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply with them could invalidate the warranty. d Warning: This symbol stands for precautions and measures which are essential in order to protect the rider or other persons from possibly severe or fatal injury. Contents Headlines for the work described in the chapter........................................... with the relevant page number Activities • Activities • The bullet symbol means that work steps are described in greater detail under another headline – Preceding activities – A line indicates work steps described in greater detail under another headline or in another chapter If the term “release” or “remove” is used: the fastener (e.g. screw) must be slackened off and taken out or a component (e.g. fuel rail) must be removed to the extent that other components which it conceals (e.g. throttle-valve rail) are accessible If the term “loosen” or “slacken” is used: the fastener (e.g. screw) must only be slackened off but not taken out X Tightening torques: Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.

Order No. 01 71 0 010 183 UX-VS-2, 10/99 Printed in Germany Customer Licence plate no. Order No. Mechanic’s signature BMW Inspection at 1,000 km (600 miles) BMW Service every 10,000 km (6,000 miles) BMW Inspection every 20,000 km (12,000 miles) BMW Annual Service Read the fault code memory with the BMW MoDiTeC Change the engine oil while at regular operating temperature; replace the oil filter element if motorcycle is used only for short journeys or at outside temperatures below 0°C (32°F): every 3 months or at the latest after 3,000 km (1,800 miles) Replace oil in telescopic forks Check the coolant and restore to correct level if necessary * ) Replace the coolant (every 2 years) every 2 years Check valve clearances, adjust if necessary Replace the spark plug Drain the outlet hose from the air filter box Replace intake air filter If motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every 10,000 km (6,000 miles); check every 3,000 km (1,800 miles) Replace fuel filter (every 20,000 km/12,000 miles) 20,000 km Check clutch play, adjust if necessary Check wheel spoke tension and tighten if necessary more frequently if motorcycle is ridden in severe off-road conditions Examine brake pads and discs for wear, replace if necessary * ) more frequently if motorcycle is ridden in severe off-road conditions Check brake fluid level at front and rear and top up if necessary * ) Check for operation of brake system and freedom from leaks; repair/replace if necessary * ) Replace the brake fluid at least once a year Replace the primary front/rear brake master cylinder cup (every 40,000 km/24,000 miles on a motorcycle with ABS) 40,000 km Check wheel bearings and replace if necessary * ) Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion * ) more frequently if motorcycle is ridden in severe off-road conditions Check chain tension and adjust if necessary * ) Check battery acid level, add distilled water if necessary more frequently if motorcycle is ridden in severe off-road conditions Clean and grease the battery terminals, if necessary Check steering head bearings and adjust * ) or replace if necessary * ) Grease the side and main stands Grease the brake pedal Check bolts and nuts on engine mountings, frame connections, exhaust system mountings, swinging fork pivot, suspension levers, brake pedal, main and side stands and quick-release axles for tightness Final inspection with road safety and functional check: – (Clutch, gearshift) – Steering – Front and rear brakes Side stand contact switch – Condition of tyres and wheels, tyre pressures – Lights and signalling equipment, indicator and warning lights, instruments – Test ride, if necessary * ) Associated work invoiced separately, see Flat rates brochure, Motorcycle ’98 BMW AG Motorcycle Division Maintenance schedule F 650 GS

Order No. 01 71 0 010 183 UX-VS-2, 10/99 Printed in Germany Customer Licence plate no. Order No. Mechanic’s signature BMW Pre-delivery check Check the shipping crate for damage Motorcycle: – unpack – inspect for damage – install remaining items – clean Battery: – remove – add acid – charge – grease terminal posts – fit (mark with fitting date) Check that the delivery is complete: – Toolkit – Documentation – Motorcycle keys – Optional extras Read the fault code memory with the BMW MoDiTeC Check tyre pressures Fill fuel tank Final inspection as functional check: – Oil inspection – Engine idle speed – Clutch, gearshift – Steering – Hand brakes and foot brakes – Check lights and signalling equipment, warning and indicator lights, instruments, ABS – Test ride, if necessary BMW AG Motorcycle Division Pre-delivery Check F 650 GS

Order No. 01 71 0 010 252 UX-VS-2, 10.99 Printed in Germany Item Rated value Unit of measurement/ specification Oil capacities Engine (with filter) Telescopic fork – for each post 2.3 (4.05/2.43) 0.60 (1.06/0.63) Litres (Imp. pints/US quarts) Specification: see current Service Information Litres (Imp. pints/US quarts) BMW telescopic fork oil Coolant Cooling system (entire) Expansion tank 1.3 (2.29/1.37) 0.1 (0.18/0.11) Litres (Imp. pints/US quarts) Litres (Imp. pints/US quarts) Composition: Water: 50% Antifreeze: 50% Antifreeze protection to –25 °C ( –13 °F) Brake fluid DOT 4 Valve clearances Measured cold (max. 35 °C/95 °F) Inlet: 0.10-0.15 (0.004-0.006) Exhaust: 0.25-0.30 (0.010-0.012) mm (in) mm (in) Spark plugs Electrode gap 0.6...0.7 (0.02...0.03) NGK D8 EA mm (in) Idle speed 1350 +100 rpm Clutch cable play Hand lever cable 1.0 - 2.0 (0.004 - 0.008) mm (in) Tyre pressure (on cold tyres) solo when fully loaded front/rear 1.9/2.1 (27/30) 2.1/2.3 (30/33) bar (psi) bar (psi) Tightening torques: Engine oil drain plug Engine water drain plug Oil tank drain plug Oil filter cap Valve cap Camshaft bracket Spark plug Telescopic fork oil drain plug Round nut, steering bearing Steering bearing locking tube Flanged nut on locking tube Fork stabilizer clamping screws Front quick-release axle Clamping screws for front quick-release axle Rear quick-release axle Brake caliper at fork slider tube Swinging arm bearings Deflection lever/frame Deflection lever/spring strut Deflection lever/tension strut Swinging fork/tension strut 40 10 21 10 10 10 20 6 25 65 65 21 80 21 100 41 100 50 47 71 41 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm BMW AG Motorcycle Division Service data F 650 GS

F 650 GS Instructions for pre-delivery check BMW AG Sparte Motorrad After Sales UX-VS-2 Hufelandstr. 6 D-80937 München Edition: 11/99

1 Contents Page 62 General view of crated motorcycle ....................................................................................3 Checking the shipping crate for damage .............................................................................3 In case of damage in Germany .................................................................................................3 In case of damage in importer markets ................................................................................3 Unpacking the motorcycle ......................................................................................................3 Inspecting motorcycle for damage ....................................................................................4 Installing remaining items on motorcycle ......................................................................4 Installing windscreen .....................................................................................................................4 Installing front mudguard, mirrors and handlebar weights ...........................................4 Filling and charging the battery ...........................................................................................5 Removing right and centre covers ..........................................................................................5 Filling and charging the battery ................................................................................................6 Checking that delivery is complete ....................................................................................7 Reading the fault code memory with the BMW MoDiTeC .....................................7 Checking tyre pressures ..........................................................................................................7 Adding fuel to tank ......................................................................................................................7 Final inspection and function check .................................................................................7 Final cleaning .................................................................................................................................8 Handing over the motorcycle ................................................................................................8

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BMW F650GS Dakar (R13) 2005 to 2007 service repair manual

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