Repair Manual F 650 CS BMW Motorrad After Sales
Issued by © BMW Motorrad After Sales UX-VS-2 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.
Introduction This Repair Manual will help you to perform all the main maintenance and repair work correctly and efficiently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and practical knowledge acquired at the BMW Training Centre. It is a contribution toward achieving even higher Service quality. A new issue of this repair manual will be published if amendments or additions (supplements) are needed.
Use Each chapter starts with the list of contents. The list of contents is followed by the technical data table. Key to symbols In this Repair Manual for the F 650 CS model, the following symbols are used; their meanings are explained in the table. Special instructions aimed at improving the work procedures L Note: Special information on operating and inspecting the motorcycle as well as maintenance and adjustment procedures.
Job Order No. Date Mechanic’s signature BMW Annual Service Mileage BMW Inspection every 20,000 km/ 12,000 miles Licence No.
BMW Motorrad Pre-delivery check F 650 CS Customer Licence No. Job Order No.
BMW Motorrad Service data F 650 CS Item Desired value Units / Specifications Oil capacities Litres (Imp. pints/US quarts) Engine (incl. filter) 0.5 (0.88/0.53) Specification: see latest Service Information Litres (Imp. pints/US quarts) Engine (incl. filter) and oil tank Coolant 2.5 (4.4/2.64) Specification: see latest Service Information 50% 50% Water Anti-freeze protection to –25 °C Cooling system 1.3 (2.29/1.37) Litres (Imp. pints/US quarts) Reservoir 0.1 (0.18/0.11) Litres (Imp.
Contents << Back Group / Chapter 00 Tightening torques, Operating fluids 00 Pre-delivery check 00 Maintenance 11 Engine 12 Engine electrics 13 Fuel preparation and control 17 Radiator 18 Exhaust system 21 Clutch 23 Gearbox 27 Chain/belt drive 31 Front forks >> Continuation M B 16 Fuel tank and lines W
>> Continuation Group / Chapter 32 Steering 33 Rear wheel drive 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 61 General electrical equipment 62 Instruments 63 Lights << Back
00 00 Tightening torques, Operating fluids Contents Page Tightening torques ......................................................................................................................3 11 Engine ...........................................................................................................................................3 12 Engine electrics ........................................................................................................................
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00 Tightening torques Model F 650 CS Connection 11 Engine Freewheel housing and freewheel Nm 35 (clean thread + Loctite 648) Engine block Nm 10 Double drive gear on crankshaft Nm 180 (clean thread + Loctite 243) Driver to countershaft Nm 140 (clean thread + Loctite 243) Pressure plate Nm 10 Magnetic hub to crankshaft Nm 180 (clean thread + Loctite 243) Chainwheel to main shaft Nm 140 (clean thread + Loctite 243) Signal transmitter Nm 8 Ignition cover Nm 10 Cylinder base Nm 10
Model F 650 CS Connection 11 Engine Cylinder head cover Nm 10 Machine screw (hole for locating screw) Nm 25 Model F 650 CS Connection 12 Engine electrics Spark plug Nm 20 Magnetic hub to crankshaft Nm 180 (clean thread + Loctite 243) Signal transmitter Nm 8 Engine block cover, left/right Nm 10 Starter to clutch cover Nm 10 Positive lead to starter motor Nm 9 Positive contact to starter motor Nm 4 Necked-down bolt, starter housing Nm 6 Cable cover to engine block Nm 9 Cab
Model F 650 CS Connection 13 Fuel preparation and control Air intake pipe to cylinder head Nm 21 Fuel filter to stowage-compartment frame Nm 9 Injector holder to throttle valve Nm 5 Fuel hose to injection nozzle holder Nm 3 Fuel return hose to pump unit Nm 3 Intake air pipe to intake air silencer Nm 9 Throttle flap to intake stub Nm 1 Throttle-valve potentiometer to throttle valve stub Nm 3 Throttle valve actuator to throttle-valve stub Nm 5 (clean thread + Loctite 243) Model F
Model F 650 CS Connection 18 Exhaust system Oxygen sensor to exhaust elbow Nm 45 Exhaust manifold to cylinder head Nm 20 Silencer to exhaust manifold (Torca clamp) Nm 55 Silencer to rear frame Nm 41 Guards to silencer Nm 5 Model F 650 CS Connection 21 Clutch Driver Nm 140 (clean thread + Loctite 243) Pressure plate Nm 10 Engine block cover, left Nm 10 Release lever to release shaft Nm 10 Model F 650 CS Connection 23 Transmission Gear pedal to frame Nm 21 Shaft lever to se
Model F 650 CS Connection 27 Chain/belt drive Drive sprocket cover to engine Nm 2 Belt cover to swinging arm Nm 9 Eccentric clamp Nm 21 Nm 10 Nm 180 (clean thread + Loctite 638) Initial tightening Belt sprocket to gearbox output shaft Model F 650 CS Connection 31 Front fork Clamp screws, upper fork bridge and steering head clamp Nm 23 Clamp screws at lower fork bridge Nm 23 Bracket to fork leg Nm 5 Damper retaining screw Nm 20 Nm 25 ° 60 Adjusting screw Preload Back off thro
Model F 650 CS Connection 33 Rear wheel drive Suspension strut to frame Wrench angle Nm ° 58 45 ± 15 Suspension strut to angled lever Nm 41 Swinging-fork pivot axle Nm 100 Struts to swinging arm Nm 41 Struts to angled lever Nm 41 Angled lever to frame Nm 58 Wrench angle ° 45 ± 15 Belt pulley to damper housing Nm 28 Damper fastener Nm 160 Eccentric clamp Nm 21 Nm 10 Initial tightening Model F 650 CS Connection 34 Brakes Bleed screw to brake caliper front/rear Nm 7 Brake
Model F 650 CS Connection 34 Brakes Brake lines/hoses Brake hose to brake caliper Nm 18 Brake hose to rear brake caliper Nm 18 Brake hose to brake lever fitting Nm 18 Brake hoses to distributor Nm 18 Brake hose to bracket, rear Nm 18 Brake line to master brake cylinder, rear wheel Nm 18 Banjo bolts, brake line Nm 18 ABS sensor front/rear Nm 9 ABS control unit to holder Nm 21 Brake lines to ABS control unit Nm 18 Brake disc and sensor ring to front wheel Nm 10 (clean thread
Model F 650 CS Connection 46 Frame Covers, right and left, to main frame Nm 2 Covers, right and left, to air guide Nm 3 Cover, front, to covers, right and left Nm 1 Cover, front to main frame Nm 2 Cover, rear, to covers left and right and to stowage-compartment frame Nm 2 Stowage-compartment rail to stowagecompartment frame Nm 9 Stowage-compartment frame to main frame Nm 9 Turn indicators, left and right, to fairing bracket Nm 3 Instrument cover to fairing holder Nm 2 Windscreen
Model F 650 CS Connection 46 Frame Frame Drain plug, on-frame oil tank Nm 21 Oil strainer to frame Nm 80 Oil feed and return lines to main frame Nm 42 Oil tank cover to frame Nm 5 Footrest rubber to rear footrest Nm 5 Fairing bracket to main frame Nm 21 Rear frame to main frame Nm 24 (clean thread + Loctite 2701) Engine shell to bracing tube Nm 25 Side stand to bottom truss Nm 41 Engine shell to engine Nm 55 Engine shell to engine, bottom, with bottom truss Nm 55 Engine to
Model F 650 CS Connection 61 General electrical equipment Cable to idle-indicator switch Nm 1 Idle-indicator switch Nm 3 (clean thread + Loctite 243) Cover for hazard warning flasher switch Nm 5 Clutch switch to handlebar fitting Nm 5 Positive/ground leads, battery Nm 7 Ignition/light switch with cap to ignition/ handlebar lock Nm 1 Voltage regulator to engine shell Nm 9 Horn to fork bridge Nm 18 (clean thread + Loctite 243) Ground terminal, wiring harness to engine block, right N
Table of operating fluids Item Use Order number Quantity Lubricant Staburags NBU 30 PTM High-performance lubricating grease 07 55 9 056 992 75 g tube Optimoly MP 3 High-performance lubricating grease 07 55 9 062 476 100 g tube Optimoly TA High-temperature assembly grease 18 21 9 062 599 100 g tube Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube Retinax EP2 Grease 83 22 9 407 845 100 g tube Contact spray Contact spray 81 22 9 400 208 300 ml spray Chain spray Lubrica
Item Use Order number Quantity Brake cleaner Cleaners 83 11 9 407 848 600 ml spray Normal dilution Cleaners 51 91 9 057 940 1 l bottle Metal Polish Polish for chrome-plated parts 82 14 9 400 890 100 g tube Penetrant MR 68 Crack testing agent for aluminium housings 83 19 9 407 855 500 ml spray Developer MR 70 Crack testing agent for aluminium housings 81 22 9 407 495 500 ml spray Cooling spray 83 19 9 407 762 300 ml spray Cleaners Testing agents Installation aid BMW chilling spray 00.
00 00 Pre-delivery check Contents Page General view of crated motorcycle ...................................................................................17 Checking the shipping crate for damage In case of damage in Germany ...............................................................................................18 In case of damage in importer markets Unpack the motorcycle ......................................................................18 ............................................
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00 General view of crated motorcycle K14009440 00.
Checking the shipping crate for damage • When the motorcycle arrives, check the crate immediately for damage and if necessary examine the contents for consequential damage. In case of damage in Germany • • • Note the damage on the delivery slip. Read the information sheet on damage in transit. Notify the supplier without delay (e.g. freight company or DB) and also Bavaria Wirtschaftsagentur GmbH Abteilung ZW - 12 D-80788 München Tel. +49 89/14327-632 Fax.
00 11 Inspecting motorcycle for dam- age • • • • • – – – Installing remaining items on motorcycle 00 11 Check for damage. Use the “express handling service” to notify BMW Motorrad, UX-VS-1 Fax:+ 49 89-382-33220 Rectify the fault. If parts are needed, order them through the usual channel. Costs are to be processed by the warranty claim system (stage 4).
1 2 3 5 3 4 3 K14000450 61 21 Filling and charging the battery 61 21 010 Removing – – • • • • • • the battery Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove seat. Remove securing screws for stowage-compartment rail (1) and remove left stowage-compartment rail; use wrench from toolkit if necessary. Remove fasteners of rear cover and remove rear cover (2). Disconnect the plug for flashing turn indicator (5). Remove securing screw for flashing turn indicator (4).
- UPPER LEVEL- LOWER LEVEL- K14000460 61 21 Filling and charging the battery d Warning: Battery acid is highly caustic. Protect your eyes, face, hands, clothing and the paintwork. • • • • • Disengage the rubber strap holding the battery. Disconnect the battery breather hose. Remove the battery. Fill all the cells with pure battery acid of density 1.28 to the Upper Level mark. Allow the battery to stand for approximately 30 minutes.
e Attention: Connect the positive battery terminal first, then the negative terminal. • Install the battery. L Note: When connecting the battery lead, always make 00 00 Checking • engine oil level Check whether there is oil in the tank (e.g. dipstick wetted). e Attention: Top up the level if there is no engine oil in the tank. sure that the spring washer is between the screw head and the battery lead. Checking tyre pressures • • • • • • • Apply acid-proof grease to the battery terminal posts.
Final inspection and function check Handover • • • • • This is the ideal opportunity to familiarise the customer with the motorcycle in order to ensure the customer’s satisfaction and safety. – – – – – – – – • • • • • Clutch Check gear shift action.
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00 00 Maintenance Contents Page Key to maintenance intervals ..............................................................................................29 Reading the fault code memory with the MoDiTeC .................................................30 (Inspections I, II, III and IV) .................................................................................................................30 Changing the engine oil [engine only] and oil filter element .............................
Contents Page Adjusting valve clearances ........................................................................................................40 Installing cylinder head cover ............................................................................................................41 Replacing spark plug ...............................................................................................................42 (Inspection III) ..................................................................
Contents Page Replacing toothed belt ............................................................................................................54 (Inspection III) ....................................................................................................................................54 Checking belt tension, adjusting if necessary ...........................................................56 (Inspections I, II and III) .......................................................................
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00 Key to maintenance intervals Maintenance tasks consist of the first Inspection (after the first 1,000 km/600 miles), the BMW Service, BMW Inspection and BMW Annual Service. In this Repair Manual, the individual maintenance intervals are shown by the following codes: Inspection 1,000 km (600 miles) BMW Running-in Check after the first 1,000 km (600 miles). — — — — Inspection at 1,000 km (600 miles)......................I BMW Service at 10,000 km (6,000 miles)...........
00 13 624 Reading the fault code mem- 00 11 209 Changing the engine oil ory with the MoDiTeC [engine only] and oil filter element (Inspections I, II, III and IV) (Inspection I) L Note: If an engine failure occurs, the oil tank and feed line must be flushed with thin oil, and then blown through with compressed air (a 11.17). 00 11 209 – – Preparatory work Remove cover for belt sprocket from engine. Place the motorcycle on the auxiliary stand, BMW No. 00 1 620.
00 11 215 Replacing oil filter element 00 11 215 • • 1 2 3 K14000160 • • • • • • Remove the left-hand screw (3) securing the oilfilter cover (1). Remove the cable for the neutral-indicator switch from its guide. Engage the oil drain guide, BMW No. 11 7 511, on the pins (arrows) on the engine block. Position a drip tray beneath the engine. Remove the screws (2) and remove the oil-filter cover. Remove the filter element. Fully drain the oil and clean the oil-filter housing.
Changing the engine oil [engine and oil tank] and oil filter element e Attention: Do not use synthetic oils. 00 11 215 Operating fluids: Brand-name HD oil, API classification SF, SG or SH; suffix letters CD or CE are permitted; alternatively, brand-name HD oil of CCMC classification G4 or G5; suffix PD2 is permitted. (Inspections II, III and IV) Capacity, engine: with filter replacement ...................................... 0.5 l .............................(0.88 Imp. pints/0.
00 11 215 Replacing oil filter element 00 11 215 • • • 1 2 3 • • • • • d Warning: • • K14000160 • Install the oil drain plug in the frame with a new sealing ring and tighten. Install the oil drain plug in the engine with a new sealing ring and tighten. Fill the oil tank with 2 l (3.52 Imp. pints/2.11 US quarts) of engine oil and install the filler cap. Observe the hazard avoidance instructions for running internal combustion engines in enclosed spaces.
X e Attention: Do not use synthetic oils. Operating fluids: Brand-name HD oil, API classification SF, SG or SH; suffix letters CD or CE are permitted; alternatively, brand-name HD oil of CCMC classification G4 or G5; suffix PD2 is permitted. Capacities, engine and oil tank: with filter replacement ...................................... 2.5 l .............................(4.40 Imp. pints/2.64 US quarts) X Tightening torque: Oil drain plug, engine ...................................
Checking coolant, topping up if nec- • essary (Inspections I, II and III) e Attention: Check coolant level only when the engine is cold. Check antifreeze concentration in the expansion tank, top up antifreeze if necessary. L Note: Mix the coolant to a ratio of 50 % antifreeze, 50 % water. Do not refill the coolant expansion tank if valve clearance still has to be checked/adjusted. • • Checking coolant Maximum level ..................................................... A Minimum level ...............
17 00 035 Changing coolant (Inspection IV, every 2 years) – – • Remove left cover (a 46.6). Place motorcycle on side stand. Position a drip tray beneath the engine. 2 K14000130 1 • Remove fastener (2), lift out the expansion tank and drain off all coolant. e K14000110 • • • Remove drain plug (1) from water pump. Hold a funnel below the drain and open the radiator cap. Drain off all the coolant. Attention: Dispose of old coolant in an environmentally compatible manner.
Filling capacity Cooling system ................................................ 1.3 l .............................(2.29 Imp. pints/1.37 US quarts) In expansion tank ............................................. 0.1 l .............................(0.18 Imp. pints/0.11 US quarts) 1 Antifreeze Use only nitrite-free long-term antifreeze and corrosion inhibitor. Concentration Antifreeze .........................................................50% Water ........................................................
00 11 602 Checking and adjusting valve clearances (Inspections II and III) 0011601 Checking valve clearances Preparatory work – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. – Remove the left, right and front covers (a 46.6). Remove the intake air silencer together with the intake air pipe. • Push up the tab to pull the fuse box from the holder. • Remove the fuel filter from the stowage-compartment frame.
Exposing cylinder head 1 2 6 3 4 5 E110410 K14000050 • • • • • • Remove fasteners securing bracket (1) of ignition coil, pull bracket complete with ignition coil (2) forward and lay it down. Remove rubber cap (arrow). Release knurled nut (3). Disengage throttle cable from adapter. Use pliers, BMW No. 17 5 500, to release hose clip (5) and disconnect cylinder-head breather hose (6). Remove spark plug.
Checking valve clearance 1 11 1 810 K14000070 E000160 • • • Remove the fasteners securing the chain guide (arrows) and remove chain guide (1). Use feeler gauges, BMW No. 11 1 810, to measure valve clearances. Make a note of the valve clearances, or adjust them if necessary. Valve clearances: Inlet valve ........ 0.03...0.11 mm (0.0012...0.0043 in) Exhaust valve .. 0.25...0.33 mm (0.0098...0.
• • • Check the TDC positions of the camshaft sprockets. Check valve clearances. Clean the threads of the securing screws for the chain guide, coat threads with Loctite 243 and install the screws. Installing cylinder head cover • E000380 • • • Turn the bucket tappet until the shim (arrow) can be levered out at the groove in the bucket tappet. Before installing new shims, check thickness with a micrometer. Position the shim in the bucket tappet.
00 12 620 Replacing spark plug (Inspection III) Emptying drain from intake air silencer (Inspections I, II and III) – – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove right cover (a 46.6). – – • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove right cover (a 46.6). Have a funnel and drip tray ready. 1 2 K14000180 • • • • Twist rubber ring (1) to release ignition coil from bracket (2). Disconnect the ignition coil from the spark plug.
00 13 630 Replacing air cleaner ele- ment (Inspection III) – – 3 Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove left cover (a 46.6). 1 K1400090 2 L Note: Compressing the front part of the air filter element facilitates removal. K14000080 • • Remove the fasteners securing the intake pipe to intake air silencer (1). Swing intake pipe (2) to the side and lift it up and out of the hook. • • • Remove air filter element (3). Clean the intake air silencer.
0016617 Replacing fuel filter • Installation is the reverse of the removal procedure: pay particular attention to the following. (Inspection III, every 40,000 km/24,000 miles) e d Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. – – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove left cover (a 46.6).
Checking clutch play, adjust- Checking brake pads and discs for wear, replacing if necessary ing if necessary 21 00 004 (Inspections I, II and III) (Inspections II and III) A Checking brake pads for wear Brake pads, front brake 1 E000240 • Release lever (1) on the gearbox must be located on the splines such that when it is pressed forward as far as the release point, distance “A” is as specified. Distance “A” ......... 47...52 mm (1.8504...2.
2 MIN 3 1 C1340370 Minimum lining thickness The brake pads have a clearly visible chamfer (arrow) as wear indicator. K14000230 • • • • Remove keeper (1). Drive out retaining pin (3). Remove the brake pads. Remove fasteners (2) and remove brake caliper. Replacing brake pads e Attention: Do not operate the brake when dismantled. Do not permit the brake pads to wear past the specified minimum thickness. Always replace the brake pads as a complete set.
00 34 633 Brake pads, rear brake • Press the brake caliper against the brake disc in order to force the piston back. Checking the brake discs • Carefully check the brake discs for cracking, damage, deformation and scoring. 1 34 1 571 2 K14000560 K14000250 • • • • Remove keeper (1). Remove retaining pin (2) with press-out tool, BMW No. 34 1 571. Remove brake pads. Installation is the reverse of the removal procedure: pay particular attention to the following.
Checking brake fluid level at front and rear Brake fluid level (rear brake) (Inspections II and III) Checking brake fluid level (rear brake) – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. L Note: The volume of the brake fluid (MIN/MAX) is sufficient for brake-pad thicknesses from new to the wear limit. It is not normally necessary to top up the fluid to accommodate lining wear. A level below MIN indicates the possibility of other faults.
Checking operation of brake system and checking for leaks; repairing/ replacing as necessary 00 34 606 (Inspection III) e Attention: Refer to notes on the hazards involved in handling • • • • Check all brake lines for damage and correct routing. Wipe down all threaded unions on the brake lines and check them. Apply firm pressure to the brake lever and brake pedal and keep this pressure applied for a few moments. Release the brakes and check the brake lines for leaks.
L Note: 1 [ABS] Place rubber diaphragm and reservoir cap in position. Carefully tighten the securing screws. e E000120 – • • • • • Support the motorcycle on its side stand. Move the handlebars to the straight-ahead position. Remove cap (1) with rubber diaphragm, draw off the old brake fluid and clean the reservoir. Top up the brake fluid in the reservoir to the specified level. Connect the brake bleeding device to the bleed screw on the brake caliper. Open the bleed screw by half a turn.
• 1 • • 2 • • Draw off brake fluid until it emerges clear and free from air bubbles. Tighten the bleed screw. Installation is the reverse of the removal procedure: pay particular attention to the following. Before reassembling, carefully wipe the rim of the reservoir, the rubber gaiter and the cover to remove all traces of brake fluid. Top up the brake fluid until the level reaches the “MAX” mark. L Note: K14000590 • • Slacken threaded fasteners at front of brake caliper (2) and swinging arm.
Replacing primary sealing boot, front brake master cylinder 5 6 (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. e Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. • • Drain the front brake system. Remove the hand-brake lever. 7 E340140 • Remove spring (6) with insert (5).
Replacing primary sealing boot, rear brake master cylinder 3 (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. e Attention: Do not allow brake fluid to come into contact with 5 painted parts of the motorcycle, because brake fluid destroys paint. • 4 E340290 Drain the rear brake system. • Remove spring (4) with insert (3). e Attention: Note the washer between the brake piston and the boot.
Checking toothed belt pulley and sprocket, replacing if necessary 3 (Inspection III) – • Remove the sprocket cover. Check toothed belt pulley and sprocket for damaged teeth and indentations caused by hard objects; replace if necessary. 4 Replacing toothed belt (Inspection III) – K14000480 Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. • • • Remove the fastener securing the angled lever to spring strut (3). Remove the fastener securing the strut to the swinging arm (4).
K14000490 • • Use a strap to secure the rear wheel to the rear frame (arrow). Remove the belt from the belt sprocket. K14000500 • Working from the front, pass the new belt between the frame and the belt pulley (arrow). K14000510 K14000580 • • • • • Use a strap to secure the swinging arm at the front (arrow). Remove the swinging arm pivot shaft. Press swinging arm with rear wheel back and to the left, while pressing the brake caliper forward. Pull the belt forward and remove.
Checking belt tension, adjusting if necessary (Inspections I, II and III) Checking belt tension – Place the motorcycle without load on the auxiliary stand, BMW No. 00 1 620. e Attention: Check belt tension at room temperature only. K14000540 • 1 Align the scale of the measuring device flush with the bottom edge of the belt cover (arrow).
Adjusting belt tension Used belt, new belt – Place the motorcycle without load on the auxiliary stand, BMW No. 00 1 620. 2 K14000600 • • 1 The bottom edge of the belt cover must be inside the green section (arrow) of the scale. Adjust belt tension if necessary. 11 1 780 K14000420 e Attention: If the eccentric clamping screws were backed off 0.5 to 1 turns beforehand, do not slacken them any further. • • • Back off screws of eccentric clamp (1) by 0.5 to 1 turn.
1 27 0 501 27 0 502 K14000530 K14000550 – e Suspend weight, BMW No. 27 0 502, from the measuring device. Attention: Coloured mark on belt pulley (1) must point toward the rear when the measuring device is positioned under the corner of the swinging arm. If the coloured mark is no longer visible, vertical runout of the belt pulley must be measured before belt tension can be checked (a 33.15). • • A Mount measuring device, BMW No.
Checking battery acid level, adding distilled water if necessary 61 20 029 (Inspections II, III and IV) Open the battery caps. Use only distilled water to top up the acid level in the battery. Never top up with diluted sulphuric acid. Protect your eyes, face, hands, clothing and the paintwork. – • Adding distilled water e Attention: d Warning: Battery acid is highly caustic. – 61 20 029 Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove left cover.
32 00 454 Checking and adjusting steering head bearing play, replacing if necessary A (Inspections II and III) Checking steering head bearing play • 4 B Relieve load on front wheel. K14310090 • • • • • K14000300 • • • – Move fixed fork tubes forward (arrows). Adjust the steering head bearing if play is perceptible. Swing the fork legs all the way through their full range of travel and check for points of stiffness. Replace the steering head bearings if there are catches in the movement (a 31.17).
Greasing side stand Checking specified torque of threaded fasteners with torque wrench (Inspections II and III) Side stand – (Inspections I, II, III and IV) Place the motorcycle on the auxiliary stand, BMW No. 00 1 620.
Final inspection with road safety and functional check (Inspections I, II, III and IV) Road safety check • Check wheels and tyres. • Check tyre pressures and correct if necessary. Tyre tread depth (recommended minimum value) d Warning: Thread depth must comply with legal regulations concerning minimum tyre tread depth. Front wheel .................................. 2 mm (0.0787 in) Rear wheel ................................... 3 mm (0.1181 in) Tyre pressures (tyres cold) One-up Front wheel ............
11 11 Engine Contents Page Technical Data ................................................................................................................................ 5 Cutaway view of engine Engine oil circuit .......................................................................................................... 11 .........................................................................................................................12 Engine and oil-tank system Valve gear .................
Contents Page Disassembling engine ..............................................................................................................26 Removing cylinder head .............................................................................................................26 Removing camshafts .........................................................................................................................26 Checking camshaft for wear .......................................................
Contents Page Removing crankshaft and balancing shaft .........................................................................40 Checking crankshaft for wear ............................................................................................................41 Removing compensating gear ................................................................................................41 Removing and installing crankshaft gear .......................................................................
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11 Technical Data 11 Engine F 650 CS Engine, general Type Single-cylinder four-stroke, double overhead camshafts driven by roller chain, 4 valves operated by bucket tappets, balancing shaft, liquid-cooled cylinder and cylinder head, integral water pump, 5-speed gearbox and dry sump lubrication. Cylinder bore mm (in) 100 (3.94) Stroke mm (in) 83.0 (3.27) Displacement cc 652 Compression ratio 11.5 : 1 Power output kW 37 at 6800 rpm/25 at 6500 rpm Max.
Technical Data 11 Engine F 650 CS Big end bearing endplay Installed dimension mm (in) 0.30...0.65 (0.012...0.026) Wear limit mm (in) 0.80 (0.031) Small-end bore Installed dimension mm (in) 22.015...22.025 (0.8668...0.8671) Wear limit mm (in) 22.04 (0.868) Balancing shaft Bearing journals Wear limit mm (in) 19.96 (0.79) Cylinder head Camshaft journals, inlet/exhaust Wear limit Camshaft bearing play, inlet/exhaust Wear limit mm (in) 21.967...21.980 (0.8649...0.8654) mm (in) 21.950 (0.
Technical Data 11 Engine F 650 CS Valve seat width Inlet mm (in) 1.05...1.35 (0.041...0.053) Wear limit mm (in) 1.60 (0.063) Exhaust mm (in) 1.25...1.55 (0.049...0.061) Wear limit mm (in) 2.2 (0.087) Valve guide Inlet internal dia. mm (in) 5.006...5.018 (0.1971...0.1976) Wear limit mm (in) 5.080 (0.2) Exhaust internal dia. mm (in) 5.006...5.018 (0.1971...0.1976) Wear limit mm (in) 5.080 (0.2) Bucket tappets (wear limit) Extl. dia. mm (in) 33.400 (1.
Technical Data 11 Engine F 650 CS Piston rings Groove 1: square-section ring Ring thickness mm (in) 1.2 (0.047) Ring height wear limit mm (in) 1.15 (0.045) Ring gap mm (in) 0.2...0.4 (0.008...0.016) Gap wear limit mm (in) 1.0 (0.039) Groove height wear limit mm (in) 1.30 (0.051) Ring groove float mm (in) 0.03...0.065 (0.0012...0.0026) Ring groove float wear limit mm (in) 0.15 (0.006) Groove 2: stepped micro-taper ring Ring thickness mm (in) 1.5 (0.059) Ring height wear limit mm (in) 1.
Technical Data 11 Engine F 650 CS Clutch and gearbox Clutch friction plates (8) Installed dimension of each plate mm (in) 3.45...3.55 (0.136...0.140) Wear limit, height of cluster (total) mm (in) 27.5 (1.083) Clutch springs Wear limit at 190 N mm (in) 27.4 (1.079) Oil pump Oil pumps primary/secondary Housing depth (primary) mm (in) 14 (0.551) Housing depth (secondary) mm (in) 19 (0.748) Wear limit, installed clearance (radial) mm (in) 0.25 (0.
11.
Cutaway view of engine 110054 11.
F 119109 Engine oil circuit 1. Delivery pump 2. Oil tank 3. Check valve 4. Oil filter 5. Control valve 6. Low-pressure line (gearbox) 7. Low-pressure line (clutch) 8. High-pressure line (crankshaft) 9. High-pressure line (big end bearing) 10.High-pressure line (camshafts) 11.Chain tensioner 12.Spray nozzle (for piston) 13.Oil sump 14.Suction pump 11.
Engine and oil-tank system K14110010 11.
Valve gear E110440 11.
Valves, components E110450 11.
Oil pumps, components E110460 11.
11 41 Removing and installing oil pressure switch with engine installed 11 43 Removing and installing oil pressure switch – – – Cleaning oil tank and oil lines Drain the engine oil from the engine and oil tank (a 00.30). Remove the oil strainer (a 00.34). Remove intake air silencer (a 13.7). 1 11 7 671 2 3 K14110100 K14110060 • • • • • Remove rubber cap (1). Disconnect plug (2), without pulling on the cable. Remove oil pressure switch (3).
11 12 116 Removing and installing cylinder head, engine installed e Attention: If an engine failure occurs, the oil tank and oil lines must be cleaned (a 11.17). Preparatory work – – – – – • – – – • • • • • Remove the left, right, front and rear covers (a 46.6). Remove the stowage-compartment frame (a 46.14). Disconnect battery. Remove exhaust with oxygen sensor (a 18.5). Drain coolant (a 00.42). Drain engine oil. Remove starter (a 12.9). Expose radiator and remove fan (a 17.12).
1 2 K14110030 • • • • Use pliers, BMW No. 17 5 500, to open the clamp securing the breather hose at the cylinder head cover. Remove cylinder head cover (1). Remove spark plug. Remove centre screw plug in engine block cover, right. L Note: TDC position: marks on the timing-chain sprockets are parallel with the cylinder head, the bores in the timing-chain sprockets are at the top. • Turn crankshaft to TDC position with an Allen key.
11 31 022 Removing camshafts 11 12 116 – 2 1 • Removing cylinder head Remove right and left frame trim panels (a 46.14). Remove lower section of camshaft carrier. 3 E110420 • • • • • • Remove chain guide (1). Remove upper section of camshaft carrier (2). Press chain tensioning rail back against chain tensioner. Remove camshafts with chain sprockets. Secure timing chain with retaining wire. Remove front chain guide rail (3). E110480 • • Remove screws securing cylinder head to frame (arrow).
• • • When looping the timing chain over the camshaft sprockets, make sure that the sprockets are at the TDC position. Install chain guide rail. Before installing the cylinder head cover, remove all traces of the gasket and clean the sealing face with degreasing agent. Also clean the groove and the seating faces for the gasket. 2 X 1 E110110 • • • • • • • • • • • Slacken the screw plug for chain tensioner. Remove machine screws for chaincase (1). If applicable, disconnect plug of oil-pressure sensor.
11 11 150 Removing cylinder, engine installed – Remove cylinder head (a 11.20). 11 6 510 E110520 E110500 • Use pliers, BMW No. 17 5 500, to open the clamp securing the coolant hose to the water pump (arrow) and disconnect the hose. • • • • • Space the piston ring gaps at 120°. Oil the piston rings and press the sliding piston ring sleeve, BMW No. 11 6 510, over the piston rings from above so that the piston projects from the sliding sleeve by about 2 mm (0.08 in).
11 00 050 Removing engine e Attention: If an engine failure occurs, the oil tank and oil lines must be cleaned (a 11.17). 11 00 050 – – – – – – – • – • • • • Preparatory work L Note: It is not necessary to remove the belt sprocket if the engine is to be replaced. The belt sprocket is included in the scope of supply of the engine. Note that the belt has to be slackened if the belt sprocket is not removed. – Remove seat. Remove left and right covers (a 46.6). Remove frame trim panels (a 46.14).
11 00 050 • 11 • Removing engine Secure adapter, BMW No. 11 0 591, to the plate for the engine lifter. Place engine lifter, BMW No. 00 1 540, under engine. 1 12 K14110090 2 • • • • • Disengage fuse box (12). Remove fasteners securing intake stub (11) to cylinder head. Disconnect integrated ignition coil from spark plug. Remove the left-hand coolant hose. Remove fasteners for engine shell and remove engine shell with voltage regulator. L Note: When locating pin, BMW No.
Transferring engine to assembly frame 11 0 531 E110530 • • • • • • Secure threaded adapter, BMW No 11 0 531, to engine mount. Detach the engine from the engine lifter, leaving the engine on the lifting platform. Lay the engine on its left side, as viewed in the forward direction of travel. Secure engine adapter, BMW No. 11 0 640, to the right side of the engine without a spacer. Position the assembly stand beside the lifting platform.
1 2 5 4 3 K14110030 11 00 103 Disassembling engine • • e Attention: If there is any mechanical damage, the oil tank and the oil lines must be flushed (a 11.17). Turn crankshaft to TDC position with an Allen key. Remove screws (5) and lock the crankshaft with locating screw, BMW No. 11 6 570. L Note: Check security with Allen key. 11 12 516 Removing – • • • • cylinder head Remove starter (a 12.9) Remove oil lines. Remove cylinder head cover (1). Remove spark plug.
• • Remove camshafts with chain sprockets. Remove the lower camshaft carrier. Checking centrifugal decompressor lever L Note: Never stretch the spring, since this alters the preset Checking camshaft for wear spring force. • When activated, the lever must not project beyond the cam base circle by less than distance “B”. 00 2 590 F110040 • • Measure bearing play with Plastigage type PG-1, BMW No. 00 2 590. Tighten camshaft carrier to specified torque.
1 3 2 E110111 11 12 116 Removing cylinder head • Remove front chain rail (1). • Release the coolant line hose clips with pliers, BMW No. 17 5 500. • Secure timing chain with cable tie. – Remove starter (a 12.9). • Remove collar nuts from cylinder head. Checking timing chain for wear 4 L Note: If the cylinder head does not have to be disassembled, do not separate cylinder head from cylinder. In this case the next six steps can be omitted. • • • • • • A Remove machine screws for chaincase (2).
• • If the wear limit, distance “B”, is exceeded, first inspect the tensioner rail and the two guide rails for score-marks and replace them if necessary. If a part has to be replaced, repeat the measurement procedure described above. If the wear limit has been exceeded, the timing chain must be replaced. Distance “B” ......................max. 9.0 mm (0.0354 in) Disassembling and assembling cylinder head 11 12 528 11 34 020 Removing valves • Use suction cup, BMW No.
Checking valve guide for wear 11 0 571 00 2 510 F110140 F110111 • • Insert new valve from combustion chamber side into valve guide until it reaches the valve stem seal. Using dial gauge, BMW No. 00 2 510, positioned vertically on the valve axis, measure maximum tilt clearance across the camshaft axis. Tilt clearance: Max. tilt clearance ....................... 0.4 mm (0.016 in) Inside diameter of valve guide ..........................max. 5.080 mm (0.
Checking valve seat for wear • Apply engineer’s blue or a similar product to the valve seat rings. • Install correct valve and rotate, applying slight pressure. 11 12 591 Installing valve guide 1 F110151 • • Projection: Inlet ........................... 9.8...10.2 mm (0.39...0.40 in) Exhaust ..................... 9.8...10.2 mm (0.39...0.40 in) L Note: Only use thread-cutting oil to lubricate the reaming tool.
Checking valve for wear 11 34 800 Installing valve stem seal F110190 2 • 1 Check valve stem diameter and valve head seat width. Wear dimensions for valve: Stem diameter Inlet valve ...........................min. 4.89 mm (0.192 in) Exhaust valve .....................min. 4.89 mm (0.192 in) • Check valve for runout. L Note: Remove oil carbon from valve and deburr grooves E110120 • • Install bottom valve spring retainer (1). Use a drift, BMW No. 11 6 650, to insert valve stem seal (2). 11.
11 34 020 Installing valves 11 11 150 • • Install valve with shrink-fit tube. L Note: Removing cylinder Separate the cylinder base from the engine block. e Attention: When removing cylinder, make sure that the piston Remove the shrink-fit tube. does not strike the engine block. 11 5 691 11 5 692 • Remove cylinder. Checking cylinder 11 0 521 11 0 522 11 0 523 • • • • E110130 Install valve spring and valve spring plate. Secure the cylinder head to support plate, BMW No. 11 0 523.
11 25 050 Removing • • piston Remove piston pin circlips. Press out piston pin with drift, BMW No. 11 6 581. Determining clearance of piston in cylinder L Note: Mark exhaust-valve side on piston crown. 11 25 671 Disassembling • • • 1 2 piston 3 Remove piston rings with piston ring pliers. Carefully clean piston. Check piston for signs of damage. E110150 • • Measure cylinder bore at distance of 55...65 mm (2.17...2.
Determining piston ring gaps 12 11 070 • • Install piston ring in cylinder and measure 60 mm (2.36 in) from top edge of cylinder with feeler gauge to determine gap. Removing ignition magneto Unfasten retainer on right engine housing cover. 12 5 500 Wear dimension: Ring gap (all piston rings) ............ 1.0 mm (0.039 in) Determining piston pin clearance • • Measure diameter of piston pin bores in piston stroke direction using an internal micrometer.
12 5 510 5 E110210 • • • Unscrew hex nut. Heat hub to 80 °C (176 °F). L Note: Use temperature measuring device, BMW No. 00 1 900, to check the temperature. • Using puller, BMW No. 12 5 510, pull off magnet rotor. 11 26 500 Removing countershaft for starter 1 2 3 4 E110220 • • • Remove thrust washer (1) and spacer sleeve (2). Remove double gear (4). Pull off idler gear (3). 11.36 E110230 Remove freewheel gear (5).
5 4 6 3 2 1 E110240 Disassembling and assembling freewheel 12 11 077 Assembling freewheel Disassembling freewheel 1. 2. 3. 4. 5. 6. Machine screw Magnet rotor Freewheel Lock ring Freewheel housing Freewheel gear d Warning: Securing screws (1) are secured with Loctite 648 and considerable torque is required to release them. • • • • • Release securing screws (1). Lift off freewheel housing (5). Remove lock ring (4). Remove freewheel gear (3).
• • • Engage the tabs of the lock ring in the recesses in the freewheel gear. Clean the threads of the securing screws and freewheel housing, coat threads with Loctite 648 and install the screws. Check locking function and locking direction of freewheel. 21 4 600 4 3 X Tightening torque: Machine screw (clean threads + Loctite 648) ........................ 35 Nm 21 21 000 Removing • • clutch Turn engine round in assembly fixture. Remove fastener for left engine block cover and remove cover.
11 41 000 Removing and installing oil Installing oil pump pump 7 Removing oil pump 8 9 1 11 2 10 E110270 • • Remove circlip (1) from idler gear. Remove the retaining rings of the oil-pump gears (2) and disengage the oil-pump gears. F110370 7. Inner rotor 8. Outer rotor 9. Cover 10.Markings 11.Needle roller • Installation is the reverse of the removal procedure, pay particular attention to the following. L Note: Markings (5) must be visible. • • 6 5 Oil the inner and outer rotors.
Removing double drive gear 4 2 E110320 1 E110290 • L Note: Swivel assembly fixture so that clutch side is uppermost. Remove knurled nuts (4). e Retaining screw (arrow) must be installed. • • • • Remove hex nut (1). Press chain guide (2) to rear of engine block. Pull off double drive gear with timing chain. 11 21 001 Removing crankshaft and balancing shaft Attention: Do not tilt engine block: this can cause damage to bearing shell.
Removing and installing crankshaft gear L Note: Note shims on crankshaft. • First lift out crankshaft, then balancing shaft. 11 6 502 Checking crankshaft for wear Check bearing journals on crankshaft and conrod for signs of damage and wear. • Bearing journal diameter ..min. 45.97 Radial clearance of main bearing ........................................max. 0.10 Endplay, conrod/crank cheek .........................................max. 0.80 Diameter of small-end bore .....................................
11 11 205 Removing and installing gearbox mainshaft bearings Removing and installing gearbox countershaft bearings 11 11 210 L Note: 11 6 562 To protect the gasket surfaces of the engine block, place the old gasket under the bearing puller. Always replace the mainshaft sealing ring. • • 11 6 561 11 6 564 • E230040 L Note: To protect the gasket surfaces of the engine block, place the old gasket under the bearing puller. Always replace the mainshaft sealing ring.
Removing and installing grooved ball bearings of balancing shaft 11 11 200 L Note: To protect the gasket surfaces of the engine block, place the old gasket under the bearing puller. Always replace the mainshaft sealing ring. • • • • • • • Heat the left of the engine block to 80 — 100 °C (176 — 212 °F). Using bearing puller plate, BMW No. 11 6 561, spindle, BMW No. 11 6 562, and spreader sleeve, BMW No. 11 6 563, pull off the ball bearing. Heat the right of the engine block to 80 - 100 °C (176 - 212 °F).
Installation 11 0 551 F110490 • • • Mark the position of the oil hole in the bearing on the housing. Heat the engine block to 100 °C (212 °F). Align the mark on the drift (arrow) with the mark on the housing. e Attention: The bearing bushing must not project beyond the oil pockets. The end gap of the bearing bushing must always face the balancing shaft. Before driving in, fit both bearing halves with O-ring on mandrel. • Coat bearing bushings with Optimoly TA and drive in with drift, BMW No.
11 00 103 – Assembling engine Shimming crankshaft Install the gearbox (a 23.9). Installing crankshaft and balancing shaft 11 21 511 • Secure right side of engine block in engine bracket with magnet side facing downward. B 2 3 F111041 • Using depth gauge, BMW No. 00 2 550, measure distance from crankshaft web to housing mating face = dimension “B”. 1 E110330 • • • • • Install balancing shaft in engine block; mark (1) must be aligned with mark (3) on block. Coat 1.0 mm (0.
L Note: Allow for the thickness of the compressed Installing double drive gear gasket (approx. 0.4 mm (0.016 in)). On the magnet end, the shim is always 1.0 mm (0.039 in) thick. • Select a suitable shim to ensure that the correct endplay is obtained. 11 6 570 Crankshaft endplay ........................... 0.1...0.3 mm (0.0039...0.0118 in) L Note: Shim the balancing shaft in the same way as the crankshaft. Install shims only on the clutch side. • Fit left engine block half and install fasteners.
11 41 000 Installing oil pump gears 5 1 2 4 3 • • • E110350 Install idler gear (1) with washer and circlip. Install washers (4) of oil pump gears and slide needle rollers (5) into position. Install oil pump gears (3) and install the circlips (2). 11.
6 5 4 2 3 7 8 9 1 E110430 21 21 000 Installing clutch 21 4 600 Installing clutch cage • • • • • Place thrust washer (1) on countershaft. Coat needle sleeves (3, 5) with oil and install, with the small sleeve (5) down. Insert O-ring (2) into groove under splines. Install clutch cage (4); gears must all be in mesh. Install thrust washer (6) and press it against the O-ring until it is firmly seated and does not spring back.
• Installing countershaft for starter motor 11 26 500 Installing pressure plate Insert the plates, starting with a steel plate. Insert steel plates and lined plates alternately. • Turn engine in assembly fixture so that magnet side is uppermost. L Note: Insert the topmost plate (identified by a black spot) in the offset groove of the clutch cage. 10 9 5 4 8 3 2 7 6 E110360 1 F110590 L Note: Oil the bearing bushing for freewheel gear (6) and the straight pins. • Install pressure plate (2).
12 11 070 Installing magnetic ignition trigger 3 e Attention: Tapers on crankshaft, magnet hub and hex nut must be clean and free of grease. • • Apply a thin coat of Loctite 648 to the magnet hub taper. Oil freewheel in freewheel housing. 1 E110380 • • • • 2 • E110370 • • • • Slide magnet wheel (1) onto crankshaft: Woodruff key and keyway must be aligned. Rotate starter double gear (2) counter-clockwise to enable the freewheel to slide on to the collar of the freewheel gear.
11 25 050 • Installing piston Coat the small end bore in the crankshaft and the piston pin bore in the piston with Optimoly MP 3. 11 6 583 e Attention: Note the mark on the exhaust side of the crown applied on disassembly. • • Install the piston. Press the piston pin in with drift, BMW No. 11 6 581. 11 6 581 E110390 • Position sleeve, BMW No. 11 6 583, with installation arbor, BMW No. 11 6 581, against piston. e Attention: 2 Support side of piston.
11 11 150 Installing • cylinder 11 12 516 Fit cylinder base seal on engine block: oil bore must be clear. Installing cylinder head L Note: Replace cylinder head gasket. • • • • E110400 • • • • Oil the piston rings, turn them so that the gaps are offset by 120°, and press the sliding piston ring sleeve, BMW No. 11 6 510, over the piston rings from above so that the piston projects from the sliding sleeve by about 2 mm (0.08 in).
2 3 9 14 6 7 1 8 11 12 13 14 14 5 4 10 E110151 • • • Initially tighten the collar nuts of the cylinder head to 20 Nm (1- 4) and then tighten to 60 Nm (5-8). Tighten the fasteners of the cylinder head to cylinder in the sequence as shown (9-14) to specified torque. Tighten socket-head screws at base of cylinder. X Tightening torque: Socket-head screws, chaincase .................. 10 Collar screws, cylinder head ........................ 33 Collar nuts to cylinder head.......... first stage 20 ....
1 2 4 3 E110420 11 31 529 Installing camshaft and adjust- ing valves • • • • Oil outside of bucket tappets and install at the correct valves. Measure thickness of shim plates with micrometer and note down thickness. Place lower part of camshaft carrier (1) on cylinder head. Fit camshafts with cam lobes facing upward, press down by hand and measure valve clearance with feeler gauge.
• • • • • Check valve clearances. Install chain tensioner and tighten fastener with sealing ring. Remove all traces of the cylinder head cover gasket and clean the sealing face with degreasing agent. Also clean the groove and the seating faces for the gasket. Install cylinder head cover with gasket. Connect oil lines to engine block, using new copper sealing rings. L Note: Install the oil return line with the tab at the bottom and the oil feed line with the tab at the top.
11 00 050 Installing • • • • • • • • engine Installation is the reverse of the removal procedure, pay particular attention to the following. Working from the right, manoeuvre the engine on the lifter into position below the motorcycle. Slightly raise the engine and connect the crankcase breather. Continue raising the engine and tilt it to the rear. Manoeuvre the bottom engine mount into position. Raise the engine and manoeuvre the fasteners at the cylinder head into position.
Bleeding engine oil circuit • Remove oil filter. 1 E110560 • • • • • • • • Remove check valve (1). Remove spark plug. Turn engine over with the starter motor until oil emerges at the filter chamber. Install check valve. Install oil filter. Turn engine over with starter motor until oil emerges from the oil tank return line. Switch on engine, run for a few minutes, then switch off. Check oil and coolant levels and top up if necessary. X Tightening torque: Check valve...................................
12 12 Engine electrics Contents Page Technical Data ................................................................................................................................ 3 Ignition magneto ...........................................................................................................................5 Ignition magneto, components Removing ignition magneto .............................................................................................6 .............................
12.
12 Technical Data12 Engine electrics F 650 CS Starter motor Type Electric motor with permanent-magnet excitation, driving crankshaft via countershaft and wedgeblock freewheel Gear ratio 1:32 Power rating kW 0.9 Alternator Type Permanently excited generator, mounted on crankshaft stub Gear ratio 1:1 Drive Crankshaft Maximum output rating W/V 400 W at 14 V Maximum current at engine speed 4,000 rpm A 25 Nominal current at engine speed 2,000 rpm A 22 Max.
12.
Ignition magneto E120050 12.
Ignition magneto, components 1 2 3 8 7 6 5 4 E120040 1. 2. 3. 4. 5. 6. 7. 8. Ignition trigger Freewheel housing Lock ring Freewheel gear Starter countershaft Freewheel Magnet rotor Stator winding 12.
12 11 070 Removing ignition magneto e Attention: Never disconnect plug connection on ignition system while engine is running. 11 14 859 Removing right engine block cover • Remove cable cover (4). E110190 1 • Remove the cover, noting the thrust washer (arrow). 12 5 510 2 4 3 K14120020 • • • Disconnect the plug of the stator (3) from connector (2). Disconnect the plug of ignition trigger (1). Remove fastener securing right engine block cover. E110210 • • 12 5 500 Unscrew hex nut.
12 11 060 Removing and installing igni- tion trigger • • • 4 X Tightening torque: Stator to cover (clean thread + Loctite 243).......................... 10 Nm Cable holder to cover..................................... 8 Nm 3 1 2 E110380 • • • • • • Installation is the reverse of the removal procedure, pay particular attention to the following. Coat the rubber grommet of the stator with Three Bond 1209 before inserting it into the cover. Clean the threads of the screws and coat with Loctite 243.
• • • • • • • Fit gasket. Screw assembly handle, BMW No. 12 5 500, into the central hole in the right engine cover. Fit right engine block cover and install securing screws. Remove assembly handle and install cap. Connect the plugs of the ignition trigger and the stator. Clip the stator connector onto the plug. Secure the cable cover to the engine. X Tightening torque: Magnetic hub (clean thread + Loctite 243)........................ 180 Nm Engine block cover, right..............................
1 2 3 4 5 9 8 7 6 E120020 12 41 103 Disassembling and assem- bling starter motor • • Remove tie bolt (9). Remove armature bearing cover (8) complete with brush-holder plate (6). L Note: Note thrust washers (2). • • • • Remove fastener of positive contact (7), lift out brush holder and replace carbon brushes if necessary. Remove front cover (5). Remove armature (3) from housing (1). Using puller, BMW No. 00 8 400, pull the ball bearing (4) off the armature shaft.
Replacing spark plug (a 00.42) 12 12 011 12 13 000 Removing and installing coil 2 1 K14120010 • • • Turn ignition coil (1) counter-clockwise and pull up to remove. Disconnect ignition cable/coil (2) at plug. Installation is the reverse of the removal procedure. 12.
13 13 Fuel preparation and control Contents Page Technical Data ................................................................................................................................ 3 Removing and installing BMS control unit Removing and installing intake air pipe .....................................................................5 ...........................................................................
13.
13 Technical Data 13 Fuel preparation and control F 650 CS Fuel grade Regular unleaded, 91 octane (RON) Mixture preparation Manifold injection Fuel pressure Speed limitation Throttle stub pipe intl. dia. [OE] 34 hp bar (psi) 3.5 ± 0.2 (50.76 ± 2.9) rpm 7500 mm (in) 43 (1.693) mm (in) 43 (1.693) Air filter Paper filter Throttle cable play (engine warm) approx. 1 mm (0.04 in) 13.
13.
Removing and installing BMS control unit 13 61 010 – – • • – • • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove the left, right and front covers (a 46.6). Push up the tab to pull the fuse box from the holder. Remove the fastener securing the fuel filter to the stowage-compartment frame. Remove the stowage-compartment frame (a 46.14). Use pliers, BMW No. 17 5 500, to release clamp for breather hose and pull the hose off intake air silencer.
13 72 120 Removing intake air pipe Removing and installing air temperature sensor – – – • • • and installing Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove left cover (a 46.6). Remove the fasteners securing the intake pipe to the intake air silencer. Swing the intake pipe to the side and lift it up and out of the hook, while disengaging the pin at the front with the rubber sleeve from the fairing bracket.
Removing and installing intake air silencer 13 71 006 – – 13 72 130 – • • – • • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove the left, right and front covers (a 46.6). Push up the tab to pull the fuse box from the holder. Remove the fastener securing the fuel filter to the stowage-compartment frame. Remove the stowage-compartment frame (a 46.14). Use pliers, BMW No. 17 5 500, to release clamp for breather hose and pull the hose off intake air silencer.
13 64 165 Removing injection nozzle and installing Removing and installing throttle-valve actuator – – Remove intake air silencer (a 13.7). 13 54 020 Remove intake air silencer (a 13.7). 1 2 1 3 K14130040 • • • • • • • • Disconnect the plug of fuel injector (1). Use a hose clamp, BMW No. 13 3 010, to close off fuel line (3). Slacken the hose clip securing the fuel line and disconnect the line from the throttle valve stub. Remove spring clip (2).
13 63 005 Replacing throttle-valve potentiometer 13 54 017 – – Remove intake air silencer (a 13.7). Removing and installing throttle flap stub • • Remove intake air silencer (a 13.7). Remove knurled nut securing throttle cable to throttle flap stub and disengage the throttle cable from the guide. Disengage throttle cable from adapter. 1 2 4 K14130040 • • • • Disconnect plug of throttle-valve potentiometer (2). Remove the fasteners (arrows). Remove the throttle-valve potentiometer.
13 71 000 Removing and installing in- 13 60 505 Checking fuel pressure take stub – • • Remove throttle stub pipe (a 13.9). Release the two fasteners securing the intake pipe to the cylinder head and remove the intake pipe. Remember to clean the sealing faces before reinstalling. d Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. – Remove seat. X Tightening torque: Intake stub to cylinder head .........................
Removing and installing fuel hoses 13 31 135 d Warning: – – Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. Removing and installing line to fuel injector • Remove seat. Remove left, right and centre covers (a 46.6). Use a hose clamp, BMW No. 13 3 010, to close off fuel feed line (3). Removing and installing feed and return lines – 4 5 Remove seat.
16 16 Fuel tank and lines Contents Page Technical Data ................................................................................................................................ 3 Removing and installing fuel tank Removing fuel tank Installing fuel tank .......................................................................................5 .........................................................................................................................5 .................................
W B M 16.
16 Technical Data 16 Fuel tank F 650 CS Fuel tank Type Plastic fuel tank Fuel grade Regular unleaded, 91 octane (RON) Tank capacity (usable) including reserve of l (Imp. 15 (26.4/15.855) pints/US quarts) l (Imp. 4 (7.04/4.228) pints/US quarts) Fuel pump Operating voltage Operating pressure Delivery rate Peripheral-gear pump V 7 - 15 bar (psi) 3.5 (50.76) l/h (Imp. 150 (33.015 /39.6 ) at 13.5V, 3.5 bar (50.76 psi) gal/h; US gal/h) M B Type 16.
W B M 16.
16 11 030 Removing and installing fuel tank • e Attention: Comply with safety instructions for handling fuel. Disconnect ground lead from battery and insulate. 16 11 030 – – – • L Note: Do not unplug the BMS control unit. • • • Removing fuel tank Remove the seat and the toolkit. Secure front wheel in position. Remove silencer (a 18.5). Remove brake fluid reservoir from rear frame. Disconnect the plugs for fuel pump (3) and fuellevel sensor (5).
2 1 1 W B M K14160010 • Remove 4 fasteners (1) securing rear frame to main frame. e Attention: Note the brake line (arrow) at the brake master cylinder. Do not allow the weight of the rear frame to pull on the brake line. 16.6 • • • • Carefully remove the rear frame complete with the tank. If applicable, remove the fastener securing the rear section of the rear mudguard to the rear frame. Remove the fasteners securing the fuel tank to rear frame (2). Remove fuel tank.
16 11 030 • Installing fuel tank Installation is the reverse of the removal procedure, pay particular attention to the following. 4 3 e Attention: Note the brake line at the brake master cylinder. Do 5 not allow the weight of the rear frame to pull on the brake line. • When installing the fuel tank and the rear frame, make sure that all lines and hoses are routed at the top of the tank. K14160060 Colours of the wires in the housing for tail light/ brake light 3. blue/black 4. green/red 5.
16 11 211 Removing and installing fuel filler cap Removing and installing rollover valve 16 11 222 – 6 Remove seat. 7 8 1 K14160070 • • • • B M W Remove fasteners (6) holding the fuel filler cap. Remove fuel filler cap together with fuel filler neck (7) and sealing ring (8). Installation is the reverse of the removal procedure, pay particular attention to the following. Check sealing ring (8) for damage, replace if necessary. X Tightening torque: Fuel filler cap to fuel tank................
16 14 011 Removing and installing fuel pump e Attention: Comply with safety instructions for handling fuel. Disconnect ground lead from battery and insulate. – Remove seat. 1 3 2 1 2 4 13 3 010 3 K14160020 • • Disconnect the plugs for fuel-level sensor (1) and fuel pump (4). Close off fuel supply line (3) and the fuel return line (2) with hose clips, BMW No. 13 3 010. Open the hose clips (arrows) and disconnect the fuel lines from the fuel-pump unit.
• Installation is the reverse of the removal procedure, pay particular attention to the following. 16 11 Removing and installing fuelevaporation control valve [USA version] – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. – Remove seat. – Remove the left, right and rear covers (a 46.6). – Remove intake air silencer (a 13.7).
Removing and installing activated charcoal filter 16 13 001 [USA version] – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. 1 2 • • • • • Disconnect the activated charcoal filter from fuelevaporation control valve (2). Disconnect the roll-over valve from activated charcoal filter (1). Remove screws securing the holder to the engine block. Remove the screws securing the holder to the activated charcoal filter. Open the holder and remove the activated charcoal filter.
17 17 Radiator Contents Page Technical Data ................................................................................................................................ 3 Coolant circuit ................................................................................................................................5 Thermostat, components .........................................................................................................
17.
17 Technical Data 17 Radiator F 650 CS Type U-flow pattern with integral thermostat Cooling system capacity Total capacity l (Imp. 1.3 pints/US quarts) Coolant circuit l (Imp. 1.2 pints/US quarts) Coolant expansion tank l (Imp. 0.1 pints/US quarts) Coolant Coolant mixing ratio Protection against freezing down to Use only nitrite-free long-term antifreeze and corrosion inhibitor.
17.
Coolant circuit E170010 17.
Thermostat, components 1 2 4 3 5 6 E170020 1. 2. 3. 4. 5. 6. Coolant-temperature sensor Thermostat housing Thermostat Cover O-ring Spring clip 17.
11 8 10 9 4 3 7 6 5 2 1 E170070 Removing and installing coolant pump 11 51 025 11 51 025 – – – – • • – • Removing coolant pump Drain coolant (a 00.36). Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Drain the engine oil from the engine (a 00.30). Remove complete exhaust system (a 18.5). Mark the position of the shift pedal on its shaft. Remove the gear shift pedal. Remove starter (a 12.9).
11 51 025 Installing coolant pump L Note: Check shaft for score-marks at sealing ring tracks. Always replace shaft and sealing rings as a set. • • • • • • • Coat the sealing lip of the inner sealing ring with Molykote 111. Drive inner sealing ring onto its seat with drift, BMW No. 11 6 541. Drive in the outer sealing ring with drift, BMW No. 11 6 541, and adapter, BMW No. 11 6 542, until flush with the friction face. Coat the sealing lip of the outer sealing ring with Molykote 111.
17 00 035 – – Adding coolant Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove right cover (a 46.6). Antifreeze Use only nitrite-free long-term antifreeze and corrosion inhibitor. Concentration Antifreeze .........................................................50% Water ...............................................................50% • • • 1 K14000140 • • • • Slacken bleed screw (1) in cylinder head. Connect a hose to the bleed screw.
Removing and installing coolant-temperature sensor 17 00 010 – – – • Drain coolant (a 00.36). Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Checking cooling system for leaks Remove left cover (a 46.6). Open the filler cap on the radiator. 17 5 520 2 17 0 500 1 K14170040 K14170030 • • • Disconnect plug of coolant temperature sensor (2). Remove coolant-temperature sensor (1). Installation is the reverse of the removal procedure. X Tightening torque: Temperature sensor ........
Removing and installing coolant hoses 17 12 068 Replacing coolant hose (cylinder head/frame - frame/radiator) – – • – • • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Drain coolant (a 00.36). Remove the right-hand coolant hose. Remove the left-hand coolant hose between radiator and frame. Installation is the reverse of the removal procedure. 17 12 036 Replacing coolant hose (radiator/water pump) – – – • • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620.
17 40 000 Removing – • • • • • • and installing fan Remove right cover (a 46.6). Unclip the MoDiTeC plug from its holder. Disconnect plug for fan. Disengage the clips at top and bottom and remove the fan. if necessary, remove fan from fan shroud. Installation is the reverse of the removal procedure, pay particular attention to the following. Slide the rubber grommet of the fan onto the pin of the expansion tank and then engage the tabs of the fan on the radiator.
Removing and installing thermostat 17 11 045 – – • Remove left cover (a 46.6). Drain coolant (a 00.36). Do not close the radiator cap. 1 2 E170040 • • Remove spring clip (1). Use a screwdriver to pry cover (2) out of the groove in the housing (arrow). 3 4 E170100 • Remove thermostat insert (4) with thermostat (3) from the housing. L Note: Check O-ring for cracks and replace if necessary. • Installation is the reverse of the removal procedure. 17.
18 18 Exhaust system Contents Page Technical Data ................................................................................................................................ 3 Removing and installing exhaust system Removing and installing silencer (muffler) ........................................................................5 ............................................................................5 Removing and installing exhaust elbow and oxygen sensor .................................
18.
18 Technical Data 18 Exhaust system F 650 CS Type Combination reflection/absorption system Emission control 3-way catalytic converter Silencer (muffler) Reflection/absorption 18.
18.
1 2 K14180010 Removing and installing exhaust system • Removing and installing silencer (muffler) • 18 00 020 18 11 301 – • Extend the side stand and slacken clamp (2) for silencer. Remove the fastener securing the silencer to the rear frame (1). Carefully pull the silencer to the rear and remove, taking care not to scratch the bottom truss and the frame. Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. K14180020 • Use adhesive tape to mask the rim at the silencer (arrow). 18.
• Installation is the reverse of the removal procedure, pay particular attention to the following. L Note: Before installing it on the silencer, coat the inside of the clamp with Optimoly TA. K14180030 • • Make sure that the clamp is correctly positioned (arrow). Slide the silencer onto the exhaust elbow, taking care not to scratch the bottom truss and the frame. X Tightening torque: Clamp for silencer ........................................ 55 Nm Silencer to rear frame ............................
3 4 2 1 K14180010 Removing and installing exhaust elbow and oxygen sensor 18 11 151 • Uniformly tighten the fasteners securing the exhaust elbow to the cylinder head Removing exhaust elbow and oxygen sensor • Loosen clamp (1) for silencer. • Disconnect the plug for oxygen sensor (2). • Extend side stand. • Remove fasteners (3) securing elbow to cylinder head. • Remove the exhaust elbow and remove seal (4). • Remove oxygen sensor (2).
18 12 212 Replacing guard for silencer K14180011 • • Remove the fasteners securing the guard to the silencer and remove the guard. Installation is the reverse of the removal procedure. X Tightening torque: Guard to silencer............................................ 5 Nm 18.
21 21 Clutch Contents Page Technical Data ................................................................................................................................ 3 Clutch, components ....................................................................................................................5 Removing and installing clutch ............................................................................................6 Removing clutch ....................................................
21.
21 Technical Data 21 Clutch F 650 CS Type Pull-action multi-plate clutch in oilbath Clutch plate Ø mm (in) 145 (5.71) Wear limits Lined plate distortion mm (in) 0.25 (0.01) Steel plate distortion mm (in) 0.15 (0.006) Overall height of lined plates mm (in) 27.5 (1.083) Overall height of plate cluster mm (in) 39.1 (1.539) Operation Clutch operating clearance at handlebar lever mechanical mm (in) 1.0 - 2.0 (0.039 - 0.079) 21.
21.
Clutch, components E210010 21.
21 21 000 Removing and installing Removing pressure plate clutch 21 21 000 Removing – – – – • • – • clutch Drain coolant (a 00.36). Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Drain the engine oil from the engine (a 00.30). Remove complete exhaust system (a 18.5). Mark the position of the shift pedal on its shaft. Remove the gear shift pedal. Remove starter (a 12.9). Disengage the clutch cable from the actuating shaft and remove the cable from the guide in the cover.
3 4 5 6 7 8 2 9 1 E210020 Removing clutch plates, driver and clutch cage • L Note: L Note: • • • • • When disassembling the clutch plate cluster, mark the order in which the plates are installed. Lift the plate cluster, lined plates (1) and inner plates (2) out of the clutch cage. 21 4 600 Remove lock washer (8). Hex nut (9) is secured with Loctite 243 and should be heated if necessary before removal. Unscrew hex nut (9). Remove driver (7). Remove clutch cage (5) incl. serrated washer (6).
3 4 5 6 7 8 9 2 10 1 E210020 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. • Install 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 retaining washer (9); it must engage securely.
Removing and installing release shaft 5 4 3 7 2 1 • F110590 6 Install pressure plate (2). L Note: All springs (3) must be replaced after each clutch repair. • • • 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 torque: Thrust plate to driver ....................................
• • • • • Installation is the reverse of the removal procedure, 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 slideon sleeve, BMW No. 21 4 620. Using drift, BMW No. 21 4 630, drive in sealing ring. 21 21 000 Installing • Replace sealing ring on drain plug.
23 23 Gearbox Contents Page Technical Data ................................................................................................................................ 3 Gearbox shafts, components .................................................................................................5 Gear shift pedal, components ...............................................................................................
23.
23 Technical Data 23 Transmission F 650 CS Type 5-speed, integrated into engine block Gearshift type Claw action Gear ratio 1st gear 12/33 = 1 : 2.750 2nd gear 16/28 = 1 : 1.750 3rd gear 16/21 = 1 : 1.313 4th gear 22/23 = 1 : 1.045 5th gear 25/21 = 1 : 0.840 Engine ratio 1st gear 1 : 5.352 2nd gear 1 : 3.406 3rd gear 1 : 2.555 4th gear 1 : 2.034 5th gear 1 : 1.635 Wear limit values for selector fork Selector fork guide journal diameter mm (in) 5.85 (0.
23.
Gearbox shafts, components E230050 23.
Gear shift pedal, components K14230040 23.
21 4 620 21 4 630 00 8 581 00 8 583 00 8 582 K14230020 23 00 Replacing shaft sealing rings with engine installed 23 00 Replacing sealing ring of selector shaft – – – • • • • • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Extend side stand. Remove exhaust system (a 18.5). Remove seal. • • • • 1 • Mark the position of the shaft lever on its shaft. Slacken the screw (arrow) on the shaft lever. Remove the shaft lever and the gear pedal.
23 4 540 23 4 550 00 8 581 00 8 583 00 8 582 K14230030 23 00 Replacing shaft sealing ring of belt sprocket • – • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove the belt sprocket (a 27.5). Pierce the shaft sealing ring with awl, BMW No. 00 8 583. Screw the pull rod, BMW No. 00 8 581, into the pierced hole and use impact weight, BMW No. 00 8 582, to remove the shaft sealing ring. 23.
6 1 5 7 2 4 3 E230010 Removing and installing gearbox 23 00 100 e Attention: If there is any mechanical damage, the oil tank must be flushed (a 11.17). – – • • Swing the selector forks (5) out and remove them. Inspect contact surfaces of selector forks and guide pins for signs of wear. 23 00 651 • Removing selector drum Withdraw selector drum (4). Remove engine (a 11.24). Disassemble the engine (a 11.26).
3 2 1 5 6 7 10 12 13 15 11 9 4 8 14 16 17 18 E230030 23 00 600 Removing, disassembling and reassembling gearbox shafts Removing gearbox shafts • • Pull sliding gears (13, 16) with bearing (15) and washers (14, 17) off the mainshaft. Tap mainshaft (1) and countershaft (18) lightly with a plastic-faced hammer and remove them. 23 00 636 Disassembling and reassem- bling mainshaft • Clamp the mainshaft in a vise fitted with protective jaws.
Checking mainshaft for wear A B F230050 Wear limits: “A” shaft diameter, magnet end. 24.98 mm (0.98 in) “B” shaft diameter, clutch end ... 16.98 mm (0.67 in) Runout .................................. 0.02 mm (0.0008 in) 23.
3 1 2 6 4 5 9 7 8 F230060 23 00 622 Disassembling and reassem- bling countershaft • • • • • • Clamp the countershaft in a vise fitted with protective jaws. Pull off gearwheels (1, 2). Pull off needle roller bearing (3) and washer (4). Pull off gearwheel (5). Remove circlip (6) with special pliers, BMW No. 23 4 500. Pull off washer (7) and gearwheel (8). L Note: Inspect all bearings, bearing points, tooth flanks, keyways and ring grooves for signs of wear.
Replacing gearbox mainshaft bearings Checking countershaft for wear 11 11 205 11 6 562 11 6 561 11 6 564 A B F230070 Wear limits: “A” shaft diameter, magnet end ........................................min. 16.98 mm (0.669 “B” shaft diameter, clutch end ........................................min. 24.97 mm (0.983 Inside diameter, bearing seat Sliding gear, 4th gear ......max. 25.53 mm (1.005 Runout ...................................... 0.02 mm (0.
11 11 210 Replacing gearbox counter- 23 00 600 Installing gearbox shafts shaft bearings L Note: To protect the gasket surfaces of the engine block, place the old gasket under the bearing puller. • • • • • • Heat the left of the engine block to 80 - 100 °C (176 - 212 °F). Using bearing puller plate, BMW No. 11 6 561, spindle, BMW No. 11 6 562, and spreader sleeve, BMW No. 11 6 565, pull off the ball bearing. Heat the right of the engine block to 80 - 100 °C (176 - 212 °F).
23 00 640 Installing selector shaft 23 00 658 Installing selector forks 12 10 2 1 11 F230100 • • Install index lever (2) with index spring (1) in housing. • 5 • 6 7 • 8 F230120 Insert selector fork (10) in shift gear of countershaft. Insert selector rod and swivel together with the selector fork in the direction of the crankshaft. Insert selector forks (11, 12) in the corresponding shift gears of the mainshaft. Insert selector rod and swivel it outward together with the selector forks.
23 00 651 Installing • • • • • selector drum Install the selector drum in the neutral position. The contact pin in the plastic plate is above the neutral-indicator switch in the housing. Press back index lever and selector pawl and install selector drum. Move index lever and selector pawl into mesh. Turn selector forks so that they engage the selector drum. Drive the selector shafts onto their seats with light blows of a plastic-faced hammer.
27 27 Chain/belt drive Contents Page Technical Data ................................................................................................................................ 3 Removing and installing belt, belt drive gear and belt sprocket ........................5 Removing and installing belt (a 00.54) ..................................................................................5 Removing and installing belt sprocket (a 33.
27.
27 Technical Data 27 Chain/belt drive F 650 CS Type Poly Chain GT, 11M-1892-26 Secondary ratio 28/82 = 1:2.929 Number of teeth on belt sprocket 28 Number of teeth on belt drive gear 82 Number of teeth on belt 172 Belt length mm (in) 1892 (74.49) 27.
27.
27 71 Removing and installing belt, belt drive gear and belt sprocket • Removing and installing belt (a 00.54) d Warning: Removing and installing belt sprocket (a 33.13) Removing and installing belt sprocket Do not bend the belt sharply or twist it. Do not bend the belt through a radius of less than 100 mm. • • – • • • 1 Installation is the reverse of the removal procedure.
31 31 Front forks Contents Page Technical Data ................................................................................................................................ 3 Telescopic fork, components ................................................................................................5 Removing and installing telescopic fork Removing telescopic fork Installing telescopic fork .........................................................................6 .................................
31.
31 Technical Data 31 Front suspension F 650 CS Type Telescopic fork Running gear Total travel at wheel mm (in) 125 (4.92) Castor in normal position (full fuel load and 85 kg rider) mm (in) 86 (3.39) Steering lock angle ° 37 Fixed fork tube Fixed tube surface Hard chrome plated Extl. dia. of fixed fork tubes mm (in) 41 (1.61) Fixed fork tube runout limit mm (in) 0,1 (0.004) Installed (test) length of fixed tubes mm (in) 273.5 (10.
31.
Telescopic fork, components K14310010 31.
3142 Removing and installing telescopic fork 3142 5 Removing telescopic fork e Attention: Cover or mask off the instrument cluster and trim to prevent scratches. – 6 Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. K14310110 1 • • 2 • 4 [Hazard warning flashers] Remove fasteners for cover of hazard warning flasher switch (5) and retaining bar from below. Remove retaining bar.
3142 Installing • telescopic fork Fit lower fork bridge into steering head. A e Attention: Check the mating faces of the fork bridge, rub down with an oilstone if necessary and clean. • 1 B Fit upper fork bridge and install adjusting screw. 2 1 K14310090 New photo • 2 • • K14310130 L Note: • • Slacken adjusting screw (1) and tighten to 25 Nm. Turn forks back and forth twice from lock to lock, and leave the forks at the full left lock position.
• – – • – – • Fit caps to fork legs. Install handlebars (a 32.9). Check steering head bearing play (a 00.60). Install cover for hazard warning flashers switch and retaining bar and snap cables on left and right into guides. Install front mudguard (a 46.11). Install the front wheel (a 36.5). Connect the plug for the horn. K14310100 • Install brake caliper and ABS sensor. L Note: Make sure that ABS sensor cable and brake hose are correctly routed. X Tightening torque: Clamp screws for fork bridge ..
1 2 3 4 7 6 5 8 9 K14310020 31 42 503 Disassembling telescopic fork Removing fixed tube • Remove clamp (7). • Remove horn. • Slacken clamping screws (6) at lower fork bridge. • Remove fixed tube together with slider tube from fork bridge. • Clamp slider tube in vise with protective jaws. • Position a drip tray beneath the fixed tube. • Remove sealing caps (1). d Warning: Note that plugs (3) at left and right are spring-loaded. Wear protective goggles when removing and installing.
1 3 2 4 5 K14310030 • • • • Clamp slider tube in vise with protective jaws. Remove dust cap (1). Lever out circlip (2) with screwdriver. Push fixed tube slightly into slider tube and, pull sharply to remove fixed tube, sealing ring (3), intermediate ring (4) and slide bush (5) from the slider tube. F310040 L Note: Replace damaged slide bushes. • 31.10 Press the slide bush apart with two fingers (arrows) and pull off the fixed tube.
31 42 500 Measuring telescopic fork Checking lower fork bridge e Attention: A After being involved in an accident, the telescopic fork must be examined for cracks and damage. A L Note: When clamping the fork bridge into the vise, use soft jaws. • Clamp the fork bridge at the steering tube. F310050 • Install two new fixed tubes with test length A in the lower fork bridge. L Note: Use fixed tubes with caps installed. Test length A........................................... 273.
Checking parallel alignment of fixed tubes Checking fixed tube runout F310080 F310070 L Note: The fork bridge must slide smoothly over the fixed tubes. • Place both ends of fixed tube in V-blocks. d Warning: Do not attempt to straighten bent fixed tubes. • • • Install upper fork bridge. Check that fixed tubes are parallel with sliding calipers. Check alignment of steering tube with fixed tube. 31.12 • Rotate fixed tube slowly and check with dial gauge.
3 1 4 2 5 6 31 42 503 K14310040 Assembling telescopic fork Assembling fixed tube • Fit damper tube (2) with spring and piston ring (1) into fixed tube. • Fit guide piece (4) onto damper tube (2). L Note: Lightly oil slide bushes with fork oil before assembly. • • Push the fixed tube with the slide bush into the slider tube. Loosely insert retaining screw (6) for damper with new sealing ring (5). 31.
3 8 4 10 1 5 6 7 2 9 K14310050 • 31 3 650 31 1 511 Install intermediate ring (6). L Note: Before assembly, lightly coat outside of radial shaft seal with tyre fitting lubricant. Installed position: wording uppermost. • • Drive in radial shaft seal (5) in the same way. Install retaining ring (4) in groove over the seal. L Note: K14310060 L Note: Lightly oil slide bushes with fork oil before assembly. • • Slide upper slide bush (7) over fixed tube and press lightly into the slider tube.
3 8 4 10 1 5 6 7 2 9 K14310050 • Fill with specified quantity of oil. e Attention: The taper-wound end of coil spring (2) must be at the bottom of the fixed tube. If the coil spring in inserted the wrong way round, it will damage the sliding surface in the fixed tube when the fork is compressed. • • Capacity per fork leg Oil change........................... 0.47 l (0.827 imp.pints) Initial filling .......................... 0.48 l (0.844 imp.pints) Oil grade ...........................
1 2 1 2 4 3 K14310021 L Note: Check O-ring of screw plug for damage and replace if necessary. d Warning: Plugs are spring-loaded. • Push in plug (2) and secure by inserting retaining ring (1) in 2nd groove (arrow). 31.16 Complete assembly of telescopic fork. • Place lower fork bridge in position. Hand-tighten clamping screws (3). • Install clamp (4). • Install horn.
Removing and installing steering head bearing 31 42 721 – Remove telescopic fork (a 31.6). Lower steering head bearing The procedures for removing and installing the lower outer bearing race are the same as those for the upper race. • Upper steering head bearing • Remove upper taper roller bearing. 00 7 500 e Attention: 00 7 521 Always replace bearing and outer bearing race together. 31 3 672 00 8 561 E310140 • • 31 6 500 00 8 562 1 F310130 • • – • Remove lower fork bridge.
32 32 Steering Contents Page Technical Data ................................................................................................................................ 3 Removing and installing left and right handlebar fittings Removing and installing left handlebar fitting ......................................5 .....................................................................5 Removing and installing clutch switch ............................................................................
32.
32 Technical Data 32 Steering F 650 CS Type Tubular steel handlebar Handlebar tube diameter Steering lock angle Handlebar width with weights mm (in) 22 (0.866) ° 37 mm (in) 831 (32.72) 32.
32.
2 3 1 4 5 E320040 Removing and installing left and right handlebar fittings L Note: To avoid damage, use protective apron, BMW No. 16 1 600, to cover the fuel tank. Removing and installing left handlebar fitting – – – – • • • • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove seat. Remove left cover insert. Remove cover of connector, left (a 46.9). Cut the cable tie at the handlebar. Remove cover (3) from housing (2). Remove clutch fitting (1). Remove handlebar weight (5).
61 31 295 Removing and installing clutch switch 2 1 – – • • • • • K14320030 • • • Disconnect plug of left-hand multi-function switch (1). Installation is the reverse of the removal procedure, pay particular attention to the following. Install the rubber grip with Loctite 638 and surface activator. E320080 L Note: The position of the handlebar fittings is indicated by a punch mark (arrow) on the handlebar. X Tightening torque: Clutch fitting to handlebar ..............................
3 1 2 5 4 7 8 6 E320050 Removing and installing right handlebar fitting – – – • • • • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove right cover insert. Remove cover of connector, right (a 46.9). Cut the cable tie at the handlebar. Remove brake microswitch (2). Release cover (6) and leave it dangling on the cable. Remove throttle-cable roller (7) and disengage throttle-cable nipple (8). Remove brake fitting.
1 K14320050 • Disconnect plug of right-hand multi-function switch (1). E320100 L Note: The position of the handlebar fittings is indicated by a punch mark (arrow) on the handlebar. Throttle-cable play .............approx. 1 mm (0.040 in) X Tightening torque: Handlebar fitting to handlebar ...................... 9 Nm Handlebar weight to handlebar ...................... 9 Nm K14320040 • • Disengage the cable ties (arrow) securing the cables at the multi-function switch and the clutch switch.
1 1 2 2 3 E320110 32 71 008 Removing and installing han- dlebar – – • • • Remove left handlebar fitting. Remove right handlebar fitting. Loosen clamping screws (1). Remove handlebar (3) together with clamping blocks (2). Installation is the reverse of the removal procedure, pay particular attention to the following. e Attention: Note the position of the clamping blocks. Wide hole spacing (arrow) to the front.
1 3 2 E320140 32 72 330 Removing and installing clutch cable 5 4 E320160 K14210010 • • • Disengage clutch cable (5) from release lever. Pull cable out of holder (4). Remove rubber grommet (1) from clutch lever. 32.10 • • • • Make sure that slots in adjusting screw, locknut and lever fitting (arrow) are in line. Pull back cable shroud (2). Pull the cable forward through the slot and disengage nipple (3). Pull the cable out to the rear.
• Installation is the reverse of the removal procedure, pay particular attention to the following. e Attention: Make sure that the clutch cable is not kinked when installed. 1 2 A K14320070 • • After installing the cable, adjust clutch clearance by setting distance “A” by turning adjusting screw (1) on the clutch handlebar fitting. Lock adjusting screw (1) with knurled nut (2). Distance “A” ............ 1.0...2.0 mm (0.0394...0.0787) 32.
2 5 3 4 1 E320170 32 72 305 Removing and installing throttle cable – – • • • Remove seat. Remove left cover (a 46.6). • • Remove cover (5). Remove fastener for throttle cable (1) from instrument cluster housing. Disengage throttle-cable adapter (4) and disengage nipple (3). Remove the throttle cable. Installation is the reverse of the removal procedure, pay particular attention to the following. L Note: 6 Make sure that the cable is not kinked when installed.
Removing and installing left and right handlebar levers 1 Removing and installing left handlebar lever 2 32 72 070 2 1 A K14320070 • • K14210010 • • • Disengage clutch cable (1) from release lever. Pull cable out of holder (2). Remove the rubber grommet from the clutch lever. 3 After installing the cable, adjust clutch clearance by setting distance “A” by turning adjusting screw (1) on the clutch handlebar fitting. Lock adjusting screw (1) with knurled nut (2). Distance “A” ........ 1.0...2.
33 33 Rear wheel drive Contents Page Technical Data ................................................................................................................................ 3 Removing and installing suspension strut .....................................................................5 Removing and installing rear swinging arm ..................................................................6 Removing and installing needle roller races in rear swinging arm ............................
33.
33 Technical Data 33 Rear wheel drive F 650 CS Rear wheel drive Type Belt drive with damper in special housing Swinging arm Type Length of swinging arm (toothed belt installed) Single-arm cast aluminium swinging arm with cam-adjustable rear wheel axle mm (in) 556.8 (21.921) Rear suspension Type Total travel at wheel Central suspension strut pivoted to lever system. Extension-stage damping steplessly adjustable mm (in) 140 (5.51) 33.
33.
Removing and installing suspension strut 33 53 000 – 2 Raise rear frame (a 46.15). L Note: Raise the rear frame only far enough to expose the upper eye of the spring strut. K14330100 • • • 1 Remove the fastener securing the spring strut to frame (2). Pull the spring strut to the rear and remove. Installation is the reverse of the removal procedure, pay particular attention to the following.
1 33 1 581 2 3 4 5 K14330010 33 17 350 Removing and installing rear swinging arm – • • • • • • • Remove rear wheel (a 36.7). Release clamp (4). Back off adjusting screw (3). Turn the eccentric to slacken the belt and remove the belt. Apply the rear brake, and slacken nut (1) with socket, BMW No. 33 1 581. Remove fasteners securing belt cover. Remove pulley (2). Remove ABS sensor (5). 6 K14330020 • 33.
1 4 3 2 K14330010 • • • • • • • – – – – Pull the shaft with eccentric to the left and remove. Remove the fasteners securing the struts to swinging arm (3). Remove nut (1) at swinging arm pivot shaft (2). Remove swinging-arm pivot shaft (2). Pull the swinging arm to the rear and remove. Installation is the reverse of the removal procedure, pay particular attention to the following.
1 2 2 1 K14330011 33 17 373 Removing and installing needle roller races in rear swinging arm Installing needle roller races Removing needle roller races Attention: Install needle roller races with sealing ring to the outside. • • Remove protective caps (1). Remove bearing bushings (2) from swinging arm. e 33 6 661 33 1 541 K14330110 e Attention: Protect mating faces (arrow) of the swinging arm from scratches by covering with masking tape or similar.
Removing and installing needle bearings in rear swinging arm 33 1 541 Removing needle roller bearing 33 6 651 33 1 542 B 33 6 652 K14330130 • • • Press in the inner needle roller races with drift, BMW No. 33 1 541, and drift, BMW No. 33 1 542. Fit bearing bushes into swinging arm. Place protective caps in position. 1 K14330012 • • Remove bearing bushing (1) from swinging arm. Lever out the sealing rings with a screwdriver.
Installing needle roller bearing • Heat bearing seats to 100 °C (212 °F). Removing and installing reaction link 33 53 220 33 6 671 1 K14330190 K14330180 • Press in needle roller bearing with drift, BMW No. 33 6 671. • • • • Remove nuts (1). Slightly raise the rear wheel and pull stud to the right to remove. Remove the reaction link. Installation is the reverse of the removal procedure, pay particular attention to the following. L Note: 33 6 671 Grease needle bearings with Shell Retinax EP2.
Removing and installing angled lever 33 53 200 Removing and installing needle roller bearings and needle roller races in angled lever 33 53 610 Removing needle roller bearings and needle roller races – Remove angled lever. 1 2 4 5 6 4 3 K14330180 • • • • • Slacken the nuts of the fastener securing the strut to the angled lever (3). Slightly raise the rear wheel and remove fastener (3). Remove the fastener securing the angled lever to spring strut (2).
3353 Installing needle roller bearings and needle roller races 33 6 631 5 4 6 33 6 632 4 K14330150 K14330210 • Heat bearing seats to 80 °C (212 °F). • 33 6 631 A K14330140 • • Press in needle roller bearing (9) with drift, BMW No. 33 6 631. Offset “A” ..................................... 4 mm (0.1575 in) 33.12 Press in sealing rings (7) with drift, BMW No. 33 6 631, and spacing ring, BMW No. 33 6 632. Install bearing bushings.
33 1 581 5 6 7 8 4 1 2 3 9 10 K14330010 Removing and installing drive damper Removing drive damper • Release eccentric clamp (10). • Back off adjusting screw (9). • Turn the eccentric to slacken the belt. • Remove the belt from the belt pulley. • Slacken the rear fastener securing the belt cover. • Remove the retaining ring. • Apply the rear brake, and slacken nut (1) with socket, BMW No. 33 1 581. • Remove the pressure piece. • Remove damper housing (6). • Remove driver (8).
Assembling drive damper Installing drive damper • Installation is the reverse of the removal procedure, pay particular attention to the following. • Grease the splines of the shaft with Optimoly TA. • Spray long-life lubricant on the splines in the driver.
Measuring runout of belt pulley • – d Warning: If belt pulley and/or drive damper is replaced, runout at the belt pulley has to be measured. • • • • Back off screws of eccentric clamp by 0.5 to 1 turn. Back off the adjusting screw. Turn the eccentric to slacken the belt. Remove the belt from the belt pulley. 00 2 510 Installation is the reverse of the removal procedure, pay particular attention to the following. Adjust belt tension (a 00.56). X Tightening torque: Belt cover to swinging arm ........
Removing and installing eccentric with drive shaft – – Remove rear wheel (a 36.7). Remove drive damper (a 33.13). 1 Removing and installing floating bearing of eccentric • Lever shaft sealing ring out of eccentric with a screwdriver. • Place the eccentric (with bearing stop upward) on 2 wooden supports. • Heat the eccentric to approx. 40 °C (104 °F), lift it slightly and drop it lightly onto the wooden supports. – The bearing drops out. • Lever out the second shaft seal.
Removing and installing fixed bearing of eccentric • Turn the eccentric over onto the other side. • Remove the circlip. • Heat the eccentric to approx. 40 °C (104 °F), lift it slightly and drop it lightly onto the wooden supports. – The bearing drops out. Pressing eccentric onto drive shaft 31 5 692 31 5 696 11 7 601 31 5 611 31 5 691 K14330060 33 1 561 • Mount the eccentric on the drive shaft using M12 threaded rod, BMW No. 31 5 691, plate, BMW No. 23 4 782, threaded bushing, BMW No.
34 34 Brakes Contents Page Technical Data ................................................................................................................................ 3 Removing and installing front brake caliper ..................................................................5 Removing and installing front brake pads (a 00.46) Removing and installing front brake pistons .......................................................5 .....................................................................
Contents Page Removing and installing rear ABS sensor ....................................................................16 Removing and installing ABS control unit ....................................................................17 Removing and installing front brake lines/hoses (with ABS) Removing and installing brake lines .............................18 .....................................................................................18 Removing and installing front brake hoses .........
34 Technical Data 34 Brakes F 650 CS Brake fluid DOT 4 Front wheel Type Hydraulically actuated 2-piston floating caliper with fixed brake disc Brake pad lining Sintered metal Minimum lining thickness Brake pad surface area mm (in) 1 (0.039) cm2 45.6 (7.068) (sq in) Brake disc dia. mm (in) 300 (11.81) Brake disc thickness mm (in) 5 (0.197) Minimum thickness of brake discs mm (in) 4.5 (0.177) Permissible lateral runout mm (in) 0.14 (0.0055) Piston dia. in brake caliper mm (in) 30/32 (1.
34.
34 11 021 Removing and installing front brake caliper e Attention: Top up brake fluid and bleed brake system. – Operate brake several times until brake pads are bedded. Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. e Attention: Comply with safety instructions for handling brake fluid. X Tightening torque: Brake caliper to slider tube ......................... 41 Nm Brake line to brake caliper............................
6 5 1 4 2 3 K14340020 Removing and installing front brake pistons 34 11 521 – • • • • 1 Remove front brake caliper. Remove the split-pin keeper (2) from retaining pin (1). Drive the retaining pin out toward the wheel side. Pull the brake pads (3) down to remove. Insert a piece of cloth between the brake piston and the caliper. e Attention: Do not insert your fingers between the pistons; risk of injury.
34 11 809 Removing and installing front brake disc Checking brake disc for wear (a 00.45) e Attention: Checking front brake disc for lateral runout – e Attention: Do not operate the brake with the wheel removed. Do not operate the brake with the wheel removed. Remove front wheel (a 36.5). – 3 Remove front wheel (a 36.5). 00 2 510 A 2 K14340010 L Note: Retaining screws (2) are secured with Loctite 2701 F340050 and should be heated if necessary before removal.
34 21 222 Removing and installing rear brake caliper • Installation is the reverse of the removal procedure. L Note: e Attention: Replace sealing rings for brake line. Comply with safety instructions for handling brake fluid. – – • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove rear wheel (a 36.7). Press the brake caliper against the brake disc in order to force the piston back Disconnect brake line from brake caliper, seal the bore and hook it onto the rear frame.
6 4 5 1 3 2 K14340040 Removing and installing rear brake pistons – • • • • Remove rear brake caliper. Remove the split-pin keeper (1) from retaining pin (2). Drive the retaining pin out toward the wheel side. Remove brake pads (6). Insert a piece of cloth between the brake piston and the caliper. e Attention: • • • • • e Attention: Keep the brake pistons parallel with their bores when installing. Do not insert your fingers between the pistons; risk of injury.
34 21 301 Removing brake disc Checking brake disc for wear (a 00.47) e Attention: Do not operate the brake with the wheel removed. Checking rear brake disc for lateral runout – – – and installing rear Remove rear wheel (a 36.7). Remove rear brake caliper. Remove the eccentric (a 33.16). – – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove rear wheel (a 36.7).
Removing and installing front brake master cylinder – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. e Attention: Comply with safety instructions for handling brake fluid. • • Drain the brake system. Remove brake light switch. K14320020 1 e Attention: The position of the handlebar fitting is indicated by a punch mark (arrow). L Note: Replace the sealing rings for the brake hose. 2 E340201 • • • Disconnect brake hose (1) from the brake master cylinder.
3 4 5 2 1 K14340070 Removing and installing rear brake master cylinder 34 31 001 – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. e Attention: Comply with safety instructions for handling brake fluid. Do not operate the brake when disassembled. • • • • • • • • • Drain the brake system. Disengage piston thrust rod (1). Disconnect brake line (3). Open the hose clamp of the expansion tank (4). Remove deflector (5).
5 4 3 1 2 K14340070 Removing and installing brake pedal 35 21 000 • Disengage piston thrust rod (1). e Attention: Note washer (4) between lever and frame. • • • • Remove hexagon fit bolt (3). Remove footbrake lever (2) with torsion spring (5). Installation is the reverse of the removal procedure, pay particular attention to the following. Grease the bearing bushing with Staburags NBU 30 PTM. e Attention: Check/adjust blow-by clearance at piston rod.
Checking blow-by clearance at piston thrust rod, adjusting if necessary • Insert feeler gauge between the brake-light switch lever and the stop on the frame (arrow). Feeler gauge thickness:............ 0.2 mm (0.008 in) Checking blow-by clearance at piston rod 3 2 1 K14000291 K14340090 • • • Press the footbrake lever. Insert feeler gauge between the brake-light switch lever (1) and the stop on the frame (arrow). Slowly release the footbrake lever and check play.
Removing and installing front ABS sensor 34 52 044 – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Removing and installing front ABS sensor ring 34 51 610 e Attention: Do not operate the brake with the wheel removed. – Remove front wheel (a 36.5). 5 1 K14340110 • • • 4 Remove the fastener securing ABS sensor (1) to the front fork. Release ABS sensor cable from clip (arrow). Turn the handlebars to the left.
34 52 111 Removing and installing rear ABS sensor – – • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Slacken the belt (a 00.57). Remove the belt from the belt pulley. 1 2 K14340140 • • • Disconnect ABS plug (2) and push ABS plug out of the holder by pushing back the lug. Remove the ABS sensor cable from the clips and pull it aside. Cut the cable ties at the brake hose. Installation is the reverse of the removal procedure, pay particular attention to the following.
Removing and installing ABS control unit 34 51 050 e Attention: 2 All work on the ABS control unit must be carried out by an authorised BMW workshop. e Attention: If brake fluid escapes, it may damage paint. Line connections must be protected against dirt penetration; seal or cover ends of lines and ports. – – • Remove rear brake lines (a 34.19). Remove front brake lines (a 34.18). Remove the battery breather hose and cable for the brake-light switch out of the holders on the battery holder.
Removing and installing front brake lines/hoses (with ABS) 3 e Attention: If the vehicle is equipped with ABS, the brake system has to be bled using the BMWMoDiTeC, and the Control Units, Toolbox ABS, routine; this procedure is supplementary to that described in the Repair Manual. If the BMWMoDiTeC is not used there is a danger of residual air remaining in the control circuits of the ABS system.
34 32 401 Removing and installing front brake hoses e Attention: Top up brake fluid and bleed brake system. – Operate brake several times until brake pads are bedded. – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove right cover (a 46.6). e Attention: X Tightening torque: Comply with safety instructions for handling brake Brake hose to brake master cylinder ............ 18 Nm fluid. • • Drain the brake system. Disconnect brake hose from brake caliper.
L Note: Install new cable ties before installing the cable guide. 1 e Attention: Top up brake fluid and bleed brake system. Operate brake several times until brake pads are bedded. K14340190 • • • • • • Release ABS sensor cable from holder (arrow). Disconnect brake line (1) from adapter. Release brake line from clip on frame and from retaining clip on battery breather hose. Remove the brake line. Disconnect brake line from brake master cylinder. Release the brake line from both clips on the frame.
2 3 1 11 1 780 • • • K14000420 Back off screws of eccentric clamp (1) by 0.5 to 1 turn. Back off adjusting screw (2) several turns. Relieve tension on belt by backing off eccentric with punch, BMW No. 11 1 780. K14340120 • • Remove ABS sensor (3) from the eccentric. Disconnect brake hose from brake caliper. d Warning: Do not bend the belt sharply or twist it. Do not bend the belt through a radius of less than 100 mm. • Remove the belt from the belt pulley.
• • Hold adapter in position and introduce the brake line. Tighten the fasteners of adapter, brake hose and brake line. 1 5 K14340230 • Unclip brake hose (1) from the belt cover. K14340230 2 3 • Clip brake hose (5) into the belt cover, making sure that the rubber grommet (arrow) is correctly positioned. L Note: 4 Grease the axle of the swinging arm with Optimoly TA before installing. Note the thrust washers when installing the swinging arm.
Checking front ABS sensor ring for runout – Take load off front wheel and lift it clear of ground. K14340240 • • Check gap between ABS sensor and sensor ring by inserting feeler gauge at three points offset 120° around the ring. Replace the sensor ring if the measured gap is greater than the maximum permissible sensor gap at one or more point (a 34.15). ABS sensor gap .................max. 1.5 mm (0.059 in) 34.
36 36 Wheels and tyres Contents Page Technical Data ................................................................................................................................ 3 Removing and installing front wheel .................................................................................5 Removing front wheel ....................................................................................................................5 Installing front wheel .........................................
36.
36 Technical Data 36 Wheels F 650 CS Front wheel Type Cast light-alloy wheel Tyre size 110/70 ZR 17 Tyre pressures (cold) One-up bar (psi) 2.2 (31.91) Two-up bar (psi) 2.2 (31.91) Two-up and luggage bar (psi) 2.2 (31.91) Maximum imbalance Rim size g (oz.) 30 (1.059) 3.00 X 17 Maximum vertical runout (rim) mm (in) 0.3 (0.0118) Maximum lateral runout (rim) mm (in) 0.3 (0.0118) Rear wheel Type Cast light-alloy wheel Tyre size 160/60 ZR 17 Tyre pressures (cold) One-up bar (psi) 2.5 (36.
36.
Removing and installing front wheel 36 30 300 36 30 300 – • Removing front wheel Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Mask off the rim. 36 30 300 e Attention: When installing, avoid damage to ABS sensor, sensor ring, brake disc and brake pads. • • • • • • 1 • • 3 2 K14360080 • Remove ABS sensor (3). Installing front wheel Clean the quick-release axle and the contact face of the shaft sealing ring and grease them with Optimoly TA. Install spacer sleeves.
1 3 4 K14360010 36 31 851 Removing and installing front wheel bearing – Remove front wheel. 00 8 572 31 4 800 K14360020 To simplify removal or installation, heat the bearing seat to 100 °C (212 °F). To avoid damaging the wheel hub, use variable support ring, BMW No. 31 4 800. 36.6 Removing right-hand wheel bearing Lever out the shaft sealing ring with a screwdriver. • Remove bearing (1) with countersupport, BMW No. 00 8 572, internal puller, BMW No. 00 8 574, and variable support ring, BMW No.
36 30 320 36 31 851 Installing wheel bearings • Clean the bearing seats. Removing and installing rear wheel 00 5 500 36 5 512 1 2 3 4 5 6 K14360070 K14360050 • • • Drive in left wheel bearing with handle, BMW No. 00 5 500, and drift, BMW No. 36 5 512. Install the spacer bushing. Drive in right wheel bearing until seated using handle, BMW No. 00 5 500, and drift, BMW No. 36 5 512, making sure that wheel is supported only by the left-hand wheel bearing.
3 36 3 622 36 3 621 00 2 510 1 36 3 641 36 3 600 36 3 6242 36 3 614 2 K14360030 36 32 528 Checking front and rear wheel rims – – • • Apply the dial gauge, BMW No. 00 2 510, only to the machined inner surface of the wheel rim. Remove the wheels. 36 32 528 Checking rims Remove tyre. Level the balancing unit, BMW No. 36 3 600, at bubble gauge (2) in the baseplate. [Front wheel] Pass balancing shaft, BMW No. 36 3 621, through the wheel bearings and secure with nut, BMW No. 36 3 622.
36 3 622 36 3 621 36 3 641 36 3 600 36 3 614 36 3 6242 1 K14360040 36 30 528 Static balancing of front/rear wheel – • • Remove the wheels. Level the balancing unit, BMW No. 36 3 600, at bubble gauge (1) in the baseplate. [Front wheel] Pass balancing shaft, BMW No. 36 3 621, through the wheel bearings and secure with nut, BMW No. 36 3 622. L Note: Lightly oil adapter (cylindrical), BMW No. 36 3 641, prior to installation. • • • • [Rear wheel] Pass balancing shaft, BMW No.
46 46 Frame Contents Page Technical Data ................................................................................................................................ 3 Overview of trim panels ............................................................................................................5 Removing and installing trim panels .................................................................................6 Removing and installing left and right covers ................................
Contents Page Removing and installing side stand truss ...........................................................................21 Removing and installing side stand Measuring wheel track offset ......................................................................................21 ..............................................................................................22 Measurement record, wheel track offset ......................................................................
46 Technical Data 46 Frame F 650 CS Frame Type Bridge-type tubular frame with integrated oil tank and bolted on rear frame Type plate location On main frame, at front right Frame No. location On right of steering head Dimensions Maximum length mm (in) 2143 (84.37) Overall height in normal position (full fuel load and 85 kg rider) mm (in) 1342.5 (52.85) Overall width (across mirrors) mm (in) 893.2 (35.17) Seat height without rider mm (in) 780 (30.
46.
Overview of trim panels 46.
1 2 K14460060 46 63 Removing and installing trim panels 46 63 Removing and installing left and right covers – – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove seat. Removing and installing rear cover • Remove fasteners of rear cover (1) and remove the rear cover. • Installation is the reverse of the removal procedure. X Tightening torque: Stowage-compartment rail to stowage-compartment frame .....................................................
1 3 2 K14460060 Removing and installing left and right covers – Remove rear cover. • Remove securing screws for stowage-compartment rail and remove left/right stowage-compartment rail (1). • Disconnect the plug for flashing turn indicator (3). • Remove securing screw for flashing turn indicator (2). • Remove securing screws for cover. • Installation is the reverse of the removal procedure, pay particular attention to the following.
4 3 5 1 2 K14460070 Removing and installing windscreen and windscreen holder 46 63 021 • – – • • Remove windscreen fasteners (2) and windscreen. Remove left and right covers (a 46.6). Remove fasteners for windscreen holder (1) and remove windscreen holder. Installation is the reverse of the removal procedure. X Tightening torque: Windscreen to windscreen holder .................. 2 Nm Windscreen holder to fairing bracket ..............
Removing and installing left/right connector covers Removing and installing right connector cover – Remove right cover (a 46.6). Removing and installing left connector cover 2 1 2 1 3 K14460320 K14460330 • • • • • • Open cable tie (1). Slightly lift connector cover (2) at the bottom and pull it forward. Remove connector cover. Position the top of the connector cover against the frame. Snap the connector cover into position at the bottom. Secure the cable cover with a cable tie.
46 63 198 Removing and installing fairing bracket – – – – – – – Remove left and right covers. Remove windscreen. Remove windscreen holder. Remove instrument cover. Remove headlight surround. Remove headlight (a 63.5). Remove instrument panel (a 62.6). • • • Cut through cable clip. Press cable holder inward to release it. Turn the handlebars to the left. 4 1 K14460170 • • • K14460150 • Unclip plug of instrument cluster (1) from the fairing bracket and pass the cable through the fairing bracket.
46 61 000 Removing and installing front mudguard 46 63 – – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Removing and installing rear mudguard Remove seat. 2 1 4 3 5 6 K14460100 K14460080 • • – • • • Remove fasteners securing front section of front mudguard (1). Remove front section of front mudguard. Remove front wheel (a 36.5). Remove fastener securing rear section of front mudguard. Remove rear section of front mudguard. Installation is the reverse of the removal procedure.
1 5 2 3 4 6 5 K14460110 46 62 Removing and installing number- plate carrier 46 62 Removing and installing spray guard • Remove 3 fasteners from spray guard (4). • • • Tightening torque: Spray guard to number-plate carrier .............. 3 Nm – • Disconnect plug (6). Release the fastener (2). Remove screws (5) and remove finisher (1). Remove turn indicators and number-plate light (a 63.6). Installation is the reverse of the removal procedure, note that the screws are of different lengths.
3 1 2 3 1 1 K14460090 46 63 Removing and installing left/right 46 54 rear trim panel rack – • – • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove seat. Remove luggage rack. • e Attention: Note washers. • • • Removing and installing luggage Remove screws (3) and remove the luggage rack. Installation is the reverse of the removal procedure, note that the screws are of different lengths. X Tightening torque: Handle to rear frame ......................................
2 2 K14460120 Removing and installing stowagecompartment frame Removing and installing oil-tank trim panels – – • • • 1 Remove seat. Remove left and right covers. Remove screws (2). Remove the trim panel. Installation is the reverse of the removal procedure, note the washers and the spacer on the right-hand side. X 1 K14460040 • • • Release fasteners (1). Remove the stowage-compartment frame. Installation is the reverse of the removal procedure.
Raising, removing and installing rear frame Raising rear frame – – • Remove left and right covers (a 46.6). Remove silencer (a 18.5). Secure front wheel in position. K14460270 e Attention: Do not raise the rear frame all the way, as it is seated against the lock of the seat (arrow). • K14460290 • • • • Use strap to suspend the rear frame to crane, BMW No. 46 5 640. Remove brake fluid reservoir from rear frame. Remove lower fasteners securing rear frame to main frame.
46 51 050 Removing and installing rear frame – – – – – – • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Secure front wheel in position. Remove seat. Remove left and right covers (a 46.6). Disconnect battery. Remove silencer (a 18.5). Remove brake fluid reservoir from rear frame. 3 K14160040 5 • 4 2 Disconnect the breather hose from the roll-over valve. 6 1 13 3 010 K14160020 • • • • Close off fuel supply line (2) and the fuel return line (1) with hose clips, BMW No. 13 3 010.
• • • Installation is the reverse of the removal procedure, pay particular attention to the following. When installing the rear frame, make sure that all lines and hoses are routed at the top of the tank. Clean the tapped bore in the frame and the threads of the bottom rear frame securing screw, coat threads with Loctite 2701 and install the screw. L Note: Make sure that the rear light and brake light are correctly connected.
1 2 K14460130 46 51 120 Removing – – – – – – – – – frame Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove the battery (a 00.20). Remove throttle stub pipe (a 13.9). Remove covers of connectors, left and right (a 46.9). Remove radiator (a 17.12). Remove engine (a 11.23). Remove the rear frame (a 46.16). Remove fuel filter. Remove rear brake lines (a 34.19). 46.18 • • • • • Remove fastener securing shock absorber at top. Remove the fastener (1) securing the angled lever.
• • – • Remove Remove Remove Remove cable ties at pressure modulator. brake cylinder with footbrake lever. pressure modulator (a 34.17). the battery holder. 4 5 6 1 K14610090 • Disconnect plugs for ignition switch (4), brakelight switch (5) and right multi-function switch (6). K14160190 • Remove brake-light switch (1). 7 2 8 3 K14320030 • K14160210 • • • – Disconnect front brake lines from distributor (3). Remove fastener (2) for distributor.
X K14160230 7 K14160200 • • • • – – • Disconnect crankcase breather (7) from the frame. Disconnect all cable ties for the wiring harness from the frame and the fairing bracket. Remove wiring harness, control-unit holder and relay carrier. Suspend frame from crane, BMW No. 46 5 640. Remove telescopic fork (a 31.6). Remove the auxiliary stand. Installation is the reverse of the removal procedure, pay particular attention to the following.
Removing and installing left and right footrests 46 71 46 71 176 Removing and installing rear footrest 1 2 1 2 3 4 3 5 K14460260 K14460240 • Remove keeper (3). e Attention: Note spring loading. • • Remove pin (1), remove spring (2) and footrest. Installation is the reverse of the removal procedure. • • Remove keeper (2). Release pin (1). e Attention: Note that ball is spring-loaded. • • Remove footrest with locking plate (5), ball (4) and spring (3).
46 51 125 Removing and installing side stand truss 46 53 000 Removing and installing side stand 1 2 1 3 4 6 2 5 K14460250 – – • • • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove exhaust system (a 18.5). Remove cable cover on left-hand side of engine block. Disconnect plug of side-stand switch. Release fasteners (1, 2). Installation is the reverse of the removal procedure. X Tightening torque: Side-stand truss to frame .............................
2 3 46 51 040 1 Measuring wheel track off- set • • Place the motorcycle on a level surface on auxiliary stand, BMW No. 00 1 620. Place track alignment gauge, BMW No. 36 3 920, against the left or right side of the motorcycle. L Note: In order to use the track alignment gauge on either the left or right side, simply screw the supports in on the other side. • • • • • K14460280 • Calculate wheel track offset “S”.
Measurement record, wheel track offset Front wheel Example Distance A _______ mm Distance A 98.5 mm (3.858 in) + ½ rim _______ mm + ½ rim 41.4 mm (1.63 in) = Front _______ mm = Front 139.9 mm (5.508 in) Rear _______ mm Rear 139.3 mm (5.484 in) - Front _______ mm - Front 139.9 mm (5.508 in) =S _______ mm =S - 0.6 mm (-0.024 in) Distance 90.0 mm (3.543 in) Distance 90.0 mm (3.543 in) + ½ rim _______ mm + ½ rim 49.3 mm (1.941 in) = Rear _______ mm = Rear 139.3 mm (5.
46 5 614 46 5 616 46 5 613 46 5 608 46 5 615 46 5 605 K14460050 Checking frame with gauge 2 L Note: In the event of an accident or fall, the frame can be subjected to much higher forces than are ever encountered during normal operation. If this situation has occurred, and no changes to the frame can be detected with the naked eye, the frame can be checked with frame alignment test gauge, BMW No. 46 5 600, and adapters suitable for the specific motorcycle model.
F460270 • Lightly grease the measuring pins, BMW No. 46 5 602, and insert them into the holes in the adapters. L Note: Refer to the latest BMW Motorcycle Service Information for information on tolerances. • Align gauge in such a way that, when measuring tips make gentle contact with the measuring discs, the same value appears on the left and right sides of the measuring drift scale. e Attention: The frame will have to be replaced if the difference is out of tolerance. 46.
51 51 Equipment Contents Page Technical Data ................................................................................................................................ 3 Removing and installing ignition switch/steering lock Removing and installing lock barrel ...........................................5 ........................................................................................
51.
51 Technical Data 51 Equipment F 650 CS 51.
51.
Removing and installing ignition switch/steering lock 51 25 040 – – – 4 Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove right cover insert. Remove cover of connector, right (a 46.9). e Attention: Cover or mask off the instrument cluster and trim to prevent scratches. K14610090 1 • • • Disconnect plug for ignition lock (4). Remove the cable complete with the plug. Remove the upper fork bridge complete with the ignition lock.
Removing and installing lock barrel 8 5 – 6 • • • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove cover for hazard warning flasher switch. Turn the handlebars to the left. Turn the ignition key to the ON position. 7 8 K14510090 • • • • • • • • Remove securing screws (5) and remove ignition switch (8). Using a 5 mm bit, drill at least 6 mm (0.236 in) into the non-removable screws (9). Using an 8 mm bit, drill at least 5 mm (0,197 in) into the non-removable screws.
Removing and installing lock for rear stowage compartment 51 25 030 – L Note: – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove rear mudguard (a 46.11). Removing and installing lock barrel for fuel tank filler cap Make sure that screws do not fall into fuel tank: cover fuel tank filler neck with cloth. • • 1 Open the fuel filler cap. Remove the bottom part of the filler cap. 1 2 1 K14510100 • • Release 4 fasteners (1). Disengage throttle cable.
51 16 042 Replacing mirrors 4 K14510020 • • • Slacken nut (4). Remove the mirror. Installation is the reverse of the removal procedure. X Tightening torque: Mirror to handlebar fitting ............................. 18 Nm 51.
61 61 General electrical equipment Contents Page Technical Data ................................................................................................................................ 3 Wiring harness View from left ...............................................................................................................................5 ....................................................................................................................................
61.
61 Technical Data 61 Electrical equipment F 650 CS Battery Voltage Rated capacity V 12 A/h 12 Cold-test current A 80 Fuses A 7.5; 10; 15; 20 61.
61.
Wiring harness View from left K14619010 61.
View from right K14619020 61.
Component positions in electronic equipment box Relay positions in electronic equipment box Removing and installing battery (a 00.20) 61 21 010 Removing and installing battery carrier (a 34.17) 61 21 100 Replacing fuses 1 2 3 – 4 • • 5 6 K14610110 Starter relay Hazard warning flasher relay Flasher relay Diode Relief relay BMS relay Flasher unit 1 3 2 4 Connectors, electronics box 8 12 13 Remove seat. Open the cover of the fuse box. Replace the defective fuse. Fuses 7 1. 2. 3. 4. 5. 6. 7.
61 13 011 Removing and installing holder for BMS control unit 61 31 302 – – – • Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove the BMS control unit. Disconnect the plug. Removing and installing side stand switch Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. 1 2 K14120020 K14610060 • • • • • • Push the holder up and out of its front mounting points. Pull the electronic equipment box toward the rear and off the pin on the frame. Open the cable ties.
61 31 310 Removing and installing rear-brake switch for brake light 61 31 300 – – Remove seat. Removing and installing front-brake switch for brake light – – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove insert from right cover. Remove cover of connector, right (a 46.9). 3 1 K14160030 • • – • • Disconnect the brake light switch plug (3) for the rear brake. Disengage cable from ABS holder. Raise rear frame (a 46.15). Remove the cable from the holders on the frame.
61 33 000 Removing – and installing horn Remove front mudguard (a 46.11). Removing and installing neutral-indicator switch 61 31 227 – New photo Remove cover for belt drive sprocket. 3 4 Lift the horn up to remove!!! 3 K14610100 K14610050 • • • Disconnect plug for horn (4). Remove fastener securing horn (3). Installation is the reverse of the removal procedure. X Tightening torque: Horn to fork bridge, bottom (clean thread + Loctite 243)..........................
Removing and installing voltage regulator 12 32 000 • • • • • • • • • Remove cable cover on right-hand side of engine block. Disconnect the plug of the ignition trigger. Disconnect the plug of the stator. Open two cable ties. Unclip plug of oxygen sensor from holder on engine shell. Remove lead for oxygen sensor and cable for side-stand switch from clip at bottom left of engine shell. Remove fasteners securing engine shell to top tube and engine. Remove voltage regulator from engine shell.
62 62 Instruments Contents Page Technical Data ................................................................................................................................ 3 Telltale/warning lights ...............................................................................................................5 Removing and installing instrument panel Replacing telltale/warning lights .....................................................................6 ...........................................
62.
62 Technical Data 62 Instruments F 650 CS Instrument cluster Speedometer type Electronic Rev. counter type Electronic Turn-indicator cancellation Manual Instrument lighting W 5/1.2 - 12 V 1.2 W Telltale and warning lights Flashing turn indicator W 5/1.2 - 12 V 1.2 W High (main) beam headlight W 5/1.2 - 12 V 1.2 W Neutral W 5/1.2 - 12 V 1.2 W Oil pressure W 5/1.2 - 12 V 1.2 W Water temperature W 5/1.2 - 12 V 1.2 W Fuel gauge W 5/1.2 - 12 V 1.2 W ABS warning lights W 5/1.2 - 12 V 1.
62.
4 1 2 3 7 6 5 8 9 E620050 Telltale/warning lights 1. 2. 3. 4. 5. 6. 7. 8. 9. Water temperature Oil pressure Neutral High (main) beam headlight Fuel gauge ABS Flashing turn indicator Speedometer lighting Revolution counter lighting 62.
62 11 200 Removing and installing in- Replacing telltale/warning lights strument panel – – – Remove instrument panel. Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove instrument cover (a 46.8). 3 2 E620040 1 K14620010 • • • • Disconnect the plug for the warning lights (1). Pull off the rubber boot (2) and disconnect the plug. Remove the latches (arrows) and remove the instrument cluster.
1 E620030 • • • Remove the 3 securing screws (1) from the rear of the housing. Press back the 4 snap locks (arrows) on the plug housing and press out the instrument panel. Installation is the reverse of the removal procedure. Removing and installing wiring harness – Remove instrument panel (a 62.6). 2 3 E620051 • • • Pull out the warning lights (2) with the rubber grommets. Disconnect the wiring harness (3). Installation is the reverse of the removal procedure. 62.
63 63 Lights Contents Page Technical Data ................................................................................................................................ 3 Removing and installing headlight .....................................................................................5 Removing and installing rear light ......................................................................................6 Removing and installing number-plate light Replacing bulbs ...........................
63.
63 Technical Data 63 Lights F 650 CS Headlight type Twin ellipsoid headlights Bulbs Low (dipped) beam headlight H3 halogen bulb 12 V 55 W High (main) beam headlight H1 halogen bulb 12 V 55 W Parking light 12 V 5 W Rear/brake light 12 V 5/21 W Standard designation P 21/5 W Flashing turn indicator 12 V 10 W Type P 25-1 Number plate light Halogen bulb 12 V/6 W 63.
63.
Removing and installing headlight 63 12 090 – – Place the motorcycle on the auxiliary stand, BMW No. 00 1 620. Remove instrument cover (a 46.8). 4 2 3 5 K14630030 1 K14630010 • Remove fasteners of headlight surround (1) and remove the headlight surround from the clip fittings (arrows). Cable colours of the contacts for low-beam and high-beam headlights 2. brown 3. yellow 4. brown 5. white e Attention: Route the cables as shown (arrows).
63 21 380 Removing and installing rear light – • Removing and installing numberplate light Remove right and left rear trim panels (a 46.13). Disconnect the plugs of the rear light. 1 K14630090 K14630040 • • • Remove retaining washer (1). Remove the fasteners for the rear light (arrows) and remove the rear light. Installation is the reverse of the removal procedure, pay particular attention to the following. • • • Remove fasteners for number-plate light (arrows) and lift out number-plate light.
Replacing bulbs Cable colours of the contacts for low-beam and high-beam headlights (a 63.5) e Attention: Always switch off the ignition before changing bulbs. L Note: Do not touch inside of reflector and glass of bulbs with bare hands. Bulb for low-beam headlight/ high-beam headlight 63 12 241 • Remove caps. K14630080 e Attention: Cable penetrations in the caps (arrows) must point down. 63 99 161 1 – Bulb, parking light Place motorcycle on its centre stand.
63 99 271 Flashing • • • Remove turn-indicator cover. Press the bulb to the rear and turn it counterclockwise to release. Installation is the reverse of the removal procedure. 63 99 381 Rear • • • • lights Remove rear-light lens. Press the bulb to the rear and turn it counterclockwise to release. Installation is the reverse of the removal procedure. 63 99 399 Bulb – turn indicator for number-plate light Remove the number plate light.
