User manual BMW F 650 GS - REPAIR MANUAL

Repair Manual F 650 GS BMW AG Motorcycle Division After Sales 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 towards achieving even higher Service quality. A new issue of this repair manual will be published if amendments or additions (supplements) are needed. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer's specification. · · The repair manual is structured in the logical sequence of the work to be performed: Removal, Disassembly, Repair, Assembly, Installation. The entire contents are divided into individual chapters, corresponding to the Construction Groups. 11 . 10 Chapter Page number within chapter An arrow symbol followed by the chapter and page numbers is a reference to another chapter, e.g. Ób ............................................See Group 46 · · Work to be performed during an Inspection is described in Group "00". The various inspection routines are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption. Use of the BMW special tools needed for certain tasks is described in the work instructions. If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the repair manual. We also recommend, as an additional source of information, the Electronic Parts Catalogue (ETC), which contains clear and easy-to-follow illustrations. If the work described here is restricted to a particular equipment specification, for instance if a specific optional extra (OE) is fitted, this is stated in square brackets at the start of the item concerned, e.g. [With heated handlebar grips]. Please refer to the following pages as well for a description of other symbols used and how to work with it. BMW AG Motorcycle Division After Sales Published by: BMW AG Sparte Motorrad After Sales UX-VS-2 D - 80788 München All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Produced in Germany Usage Each chapter starts with the list of contents. The list of contents is followed by the Technical Data table. Chapter 00 "Maintenance and general instructions" details the handover checklist and lists all tightening torques and operating fluids. Key to symbols In this Workshop Manual for the F 650 GS model, the following symbols are used; their meanings are explained in the table. Special instructions aimed at improving the work procedures L Note: Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance procedures. e Caution: precautions specifically intended to prevent damage to the motorcycle. Failure to comply Instructions and with them could invalidate the warranty. Warning: This symbol stands for precautions and measures which are essential in order to protect the rider or other persons from possibly severe or fatal injury. d Contents Headlines for the work described in the chapter........................................... with the relevant page number Activities · · ­ ­ Activities The bullet symbol means that work steps are described in greater detail under another headline Preceding activities A line indicates work steps described in greater detail under another headline or in another chapter If the term "release" or "remove" is used: the fastener (e.g. screw) must be slackened off and taken out or a component (e.g. fuel rail) must be removed to the extent that other components which it conceals (e.g. throttle-valve rail) are accessible If the term "loosen" or "slacken" is used: the fastener (e.g. screw) must only be slackened off but not taken out Tightening torques: Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards. X BMW AG Motorcycle Division Maintenance schedule F 650 GS 20,000 km (12,000 miles) 10,000 km (6,000 miles) Customer Licence plate no. BMW Annual Service every 2 years Order No. Mechanic's signature Read the fault code memory with the BMW MoDiTeC Change the engine oil while at regular operating temperature; replace the oil filter element if motorcycle is used only for short journeys or at outside temperatures below 0°C (32°F): every 3 months or at the latest after 3,000 km (1,800 miles) Replace oil in telescopic forks Check the coolant and restore to correct level if necessary *) Replace the coolant (every 2 years) Check valve clearances, adjust if necessary Replace the spark plug Drain the outlet hose from the air filter box Replace intake air filter If motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every 10,000 km (6,000 miles); check every 3,000 km (1,800 miles) Replace fuel filter (every 20,000 km/12,000 miles) Check clutch play, adjust if necessary Check wheel spoke tension and tighten if necessary more frequently if motorcycle is ridden in severe off-road conditions 20,000 km Examine brake pads and discs for wear, replace if necessary *) more frequently if motorcycle is ridden in severe off-road conditions Check brake fluid level at front and rear and top up if necessary *) Check for operation of brake system and freedom from leaks; repair/replace if necessary *) Replace the brake fluid at least once a year Replace the primary front/rear brake master cylinder cup (every 40,000 km/24,000 miles on a motorcycle with ABS) Check wheel bearings and replace if necessary *) Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion *) more frequently if motorcycle is ridden in severe off-road conditions 40,000 km Check chain tension and adjust if necessary *) Check battery acid level, add distilled water if necessary more frequently if motorcycle is ridden in severe off-road conditions Clean and grease the battery terminals, if necessary Check steering head bearings and adjust *) or replace if necessary *) Grease the side and main stands Grease the brake pedal Check bolts and nuts on engine mountings, frame connections, exhaust system mountings, swinging fork pivot, suspension levers, brake pedal, main and side stands and quick-release axles for tightness Final inspection with road safety and functional check: ­ ­ ­ ­ ­ ­ (Clutch, gearshift) Steering Front and rear brakes Side stand contact switch Condition of tyres and wheels, tyre pressures Lights and signalling equipment, indicator and warning lights, instruments Test ride, if necessary *) Associated work invoiced separately, see Flat rates brochure, Motorcycle '98 UX-VS-2, 10/99 Printed in Germany Order No. 01 71 0 010 183 BMW Inspection every 1,000 km (600 miles) BMW Inspection at BMW Service every BMW AG Motorcycle Division Pre-delivery Check F 650 GS Customer Licence plate no. BMW Pre-delivery check Order No. Mechanic's signature Check the shipping crate for damage Motorcycle: ­ ­ ­ ­ unpack inspect for damage install remaining items clean Battery: ­ ­ ­ ­ ­ remove add acid charge grease terminal posts fit (mark with fitting date) Check that the delivery is complete: ­ ­ ­ ­ Toolkit Documentation Motorcycle keys Optional extras Read the fault code memory with the BMW MoDiTeC Check tyre pressures Fill fuel tank Final inspection as functional check: ­ ­ ­ ­ ­ ­ ­ Oil inspection Engine idle speed Clutch, gearshift Steering Hand brakes and foot brakes Check lights and signalling equipment, warning and indicator lights, instruments, ABS Test ride, if necessary Order No. 01 71 0 010 183 UX-VS-2, 10/99 Printed in Germany BMW AG Motorcycle Division Service data F 650 GS Item Rated value Unit of measurement/ specification Litres (Imp. pints/US quarts) Specification: see current Service Information Oil capacities Engine (with filter) 2.3 (4.05/2.43) Telescopic fork ­ for each post 0.60 (1.06/0.63) Litres (Imp. pints/US quarts) BMW telescopic fork oil Coolant Cooling system (entire) Expansion tank 1.3 (2.29/1.37) 0.1 (0.18/0.11) Litres (Imp. pints/US quarts) Litres (Imp. pints/US quarts) Composition: Water: 50% Antifreeze: 50% Antifreeze protection to ­25 °C ( ­13 °F) Brake fluid Valve clearances Measured cold (max. 35 °C/95 °F) 0.10-0.15 (0.004-0.006) Exhaust: 0.25-0.30 (0.010-0.012) Inlet: DOT 4 mm (in) mm (in) Spark plugs Electrode gap Idle speed Clutch cable play Hand lever cable 0.6...0.7 (0.02...0.03) 1350 +100 NGK D8 EA mm (in) rpm 1.0 - 2.0 (0.004 - 0.008) front/rear 1.9/2.1 (27/30) 2.1/2.3 (30/33) mm (in) Tyre pressure (on cold tyres) solo when fully loaded Tightening torques: Engine oil drain plug Engine water drain plug Oil tank drain plug Oil filter cap Valve cap Camshaft bracket Spark plug Telescopic fork oil drain plug Round nut, steering bearing Steering bearing locking tube Flanged nut on locking tube Fork stabilizer clamping screws Front quick-release axle Clamping screws for front quick-release axle Rear quick-release axle Brake caliper at fork slider tube Swinging arm bearings Deflection lever/frame Deflection lever/spring strut Deflection lever/tension strut Swinging fork/tension strut Order No. 01 71 0 010 252 UX-VS-2, 10.99 bar (psi) bar (psi) 40 10 21 10 10 10 20 6 25 65 65 21 80 21 100 41 100 50 47 71 41 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Printed in Germany F 650 GS Instructions for pre-delivery check BMW AG Sparte Motorrad After Sales UX-VS-2 Hufelandstr. 6 D-80937 München Edition: 11/99 62 Contents General view of crated motorcycle Page ....................................................................................3 .............................................................................3 Checking the shipping crate for damage In case of damage in Germany .................................................................................................3 ................................................................................3 In case of damage in importer markets Unpacking the motorcycle ......................................................................................................3 ....................................................................................4 ......................................................................4 Inspecting motorcycle for damage Installing remaining items on motorcycle Installing windscreen .....................................................................................................................4 ...........................................4 Installing front mudguard, mirrors and handlebar weights Filling and charging the battery Removing right and centre covers Filling and charging the battery ...........................................................................................5 ..........................................................................................5 ................................................................................................6 ....................................................................................7 .....................................7 Checking that delivery is complete Reading the fault code memory with the BMW MoDiTeC Checking tyre pressures Adding fuel to tank ..........................................................................................................7 ......................................................................................................................7 .................................................................................7 Final inspection and function check Final cleaning .................................................................................................................................8 ................................................................................................8 Handing over the motorcycle 1 2 E000250 General view of crated motorcycle Checking the shipping crate for damage · Notify the supplier (e.g. freight company) without delay. Unpacking the motorcycle · When the motorcycle arrives, check the crate immediately for damage and if necessary examine the contents for consequential damage. · · · Lever off the cover. Take out the separate pack of items. Force off cross-struts with a suitable lever. 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. 089/14327-632 Fax. 089/14327-639 e Caution: out the cross-strut panels or the Do not hammer motorcycle may be damaged. · · Remove the end panels. Remove the side panels. e Caution: · Make sure that the motorcycle cannot topple. Remove the straps at front and rear. In case of damage in importer markets · · Note the damage on the delivery slip. Comply with specific national market procedures. In case of doubt, please submit enquiries to: Bavaria Wirtschaftsagentur GmbH Abteilung ZW - 12 D-80788 München Tel. +49 (0)89 14327 632 Fax. (+) 89/14327-639 e Caution:projecting from the base of the crate Remove nails or lying on the base or on the floor. 3 · ­ ­ ­ ­ ­ ­ ­ ­ ­ · Dispose of the packing materials in an environmentally responsible manner as described in Circular 23/91 - Sales. Check the contents of the enclosed package: Front mudguard with fasteners and washers Windshield Mirrors with clamping screws and nuts Handlebar weights with screws Rider's Manual Service and Technical booklet Booklet listing service centres in Europe BMW emergency service sticker Handling instructions for batteries Tightening torques: Windscreen to cockpit fairing ......................... 2 Nm X Installing front mudguard, mirrors and handlebar weights Inspecting motorcycle for damage · · · · · ­ ­ ­ · Check for defects. Use the "express handling service" to notify BMW AG Sparte Motorrad, UX-VS-1 Fax: 00 49 89 382-33220 Rectify the fault. If parts are needed, order them by using the electronic parts list. Costs are to be processed by the warranty claim system (stage 4). Defect codes: Parts missing 10 01 00 00 00 Parts damaged 10 02 00 00 00 Incorrect parts delivered 10 03 00 00 00 If the parts that are needed do not appear in the electronic parts list (e.g. parts for official-user motorcycles), send an order form to: Fax number 030-3396-2262 E000270 · Install front mudguard. 3 2 Installing remaining items on motorcycle Installing windscreen . 1 · Wheel the motorcycle clear of the wooden pallet E000310 · · · Install handlebar weights (1). Tighten clamp screw (2) on handlebar fitting. Install each mirror and secure by tightening nut (3). Tightening torques: Front mudguard to fork bridge ....................... 3 Nm Clamp screw to handlebar fitting.................. 21 Nm Union nut of mirror ....................................... 18 Nm Handlebar weight to handlebar ...................... 9 Nm X E000260 · Tighten the windscreen securing screws. 4 5 6 4 1 2 3 E000280 Filling and charging the battery Removing right and centre covers L Note: · · · · · · · · Do not remove the windscreen after the side panels have been removed, as otherwise the headlight beam setting will have to be checked. Remove the lid of the stowage compartment. Remove the seat. Remove the fasteners securing turn indicator (1). Slacken front securing screw (2). Remove securing screws (5) from side cover. Pull side cover (4) out of the anchorage (arrow) at the bottom and lift it clear of the centre panel at the top. Remove securing screws (6) from centre cover. Remove centre cover (3). 5 E000290 Filling and charging the battery Battery acid is highly caustic. Protect your eyes, face, hands, clothing and the paintwork. d Warning: · · · · · · · · Caution: Connect the positive battery terminal first, then the negative terminal. e · · · · Disengage the rubber strap holding the battery. Disconnect the battery breather hose. Remove the battery. Top up the battery acid to the upper level mark. Allow the battery to stand for at least an hour. Shake the battery slightly to allow the remaining air bubbles to escape. If necessary, top up again to the upper level mark with battery acid. Recharge the battery and allow to stand for 24 hours. Apply acid-proof grease to the battery terminal posts. Install the battery. Install right and centre covers. Install seat. Tightening torques: Right/left covers with centre cover to mounting frame .......................................... 2 Nm Right/left covers to centre cover .................... 2 Nm Centre cover to main frame at front................ 2 Nm X Charge current (amps) .........................10 % of rated battery capacity (Ah) · · Check the acid level and, if necessary, top up with distilled water to the upper level mark. Make a note of the charging date on the battery. 6 Checking that delivery is complete Adding fuel to tank · · ­ ­ ­ ­ ­ ­ ­ ­ · · All optional extras Toolkit: Reversible screwdriver Small star screwdriver 3 open-ended wrenches a/f 8×10, 14×19, 24 Extension for open-ended wrenches Spark plug wrench Wrench for socket-head screws, a/f 8 3 Torx wrenches Torx T25, T30, T45 3 fuses 7.5A, 15A, 20A Documentation Motorcycle keys, 3 · Fill up with fuel. Final inspection and function check L Note: When the motorcycle arrives, the oil level in the tank might be below the sight glass. Reading the fault code memory with the BMW MoDiTeC 2 E000300 1 · · · · · · · · · · · · · · · · E000340 · · · · · Unclip diagnosis plug (1) behind cover on right. Connect the diagnosis unit to the diagnosis plug. Read out the fault memory. Perform all requisite repair work. Clip diagnosis plug into position behind cover on right. Checking tyre pressures · Check/correct tyre pressures. Tyre pressures: Solo ..................................... front 1.9 bar (27.0 psi) ............................................. rear 2.1 bar (29.9 psi) With full load......................... front 2.1 bar (29.9 psi) ............................................. rear 2.3 bar (32.7 psi) · · · Oil check: if oil is not visible in the sight glass, check whether the oil tank (2) contains oil. Clutch Check gear shift action. Steering Front and rear brakes Check lights and signalling equipment: Front and rear parking lights Instrument lighting Low and high headlight beams, headlight flasher Brake light (operate brake at front and rear) Turn signals left/right Horn Telltale and warning lights Instruments As applicable, check function of optional extras: ABS: perform starting test. In the event of a fault in the system, the ABS warning light comes on as soon as the motorcycle is ridden for at least 10 seconds at a speed of 30 km/h (approx. 20 mph) or more. If necessary, take the motorcycle for a test ride. Confirm pre-delivery check in Service and Technical Booklet. See "Inspecting motorcycle for damage" if defects are detected. 7 Final cleaning Handing over the motorcycle This is the ideal opportunity to familiarise the customer with the motorcycle in order to ensure the customer's satisfaction and safety. · Clean the motorcycle. L Note: L Note: Do not use a steam or high-pressure water jet. The high steam or water pressure could damage seals, the hydraulic system or electrical components. · ­ ­ ­ ­ ­ ­ ­ ­ The number-plate carrier is not pre-drilled so that number plates of any shape can be set to the best possible position. · ­ ­ The following points must be demonstrated and explained to the customer: documentation and stowage space toolkit and stowage space suspension preload adjustment to suit total weight checking brake fluid how to adjust the mirrors controls instruments and telltale lights optional equipment and accessories fitted The user must be given the following information: running-in recommendations and inspection intervals safety check 8 Contents << Back Group / Chapter 00 Maintenance and general instructions ................................................ 00.1 11 Motor ....................................................................................................... 11.1 12 Engine electrics ..................................................................................... 12.1 13 Fuel preparation and control ................................................................ 13.1 16 Fuel tank and lines................................................................................. 16.1 M B W 17 Radiator .................................................................................................. 17.1 18 Exhaust system ...................................................................................... 18.1 21 Clutch...................................................................................................... 21.1 23 Gearbox................................................................................................... 23.1 27 Drive chain............................................................................................... 27.1 >> Continuation >> Continuation Group / Chapter 32 Steering................................................................................................... 32.1 33 Rear wheel drive .................................................................................... 33.1 34 Brakes ..................................................................................................... 34.1 36 Wheels and tyres.................................................................................... 36.1 46 Frame ...................................................................................................... 46.1 51 Equipment............................................................................................... 51.1 61 General electrical equipment ............................................................... 61.1 62 Instruments............................................................................................. 62.1 63 Lights....................................................................................................... 63.1 << Back 00 00 Maintenance and general instructions Contents Table of operating fluids Tightening torques Page ...........................................................................................................5 ......................................................................................................................6 ..............................................................................................15 Key to maintenance intervals Reading the fault code memory with the MoDiTeC ................................................16 (Inspections I, II, III and IV) .................................................................................................................16 Changing the engine oil and oil filter element ............................................................16 (Inspections I, II, III and IV) .................................................................................................................16 Preparatory work ...........................................................................................................................16 ........................................................................................................................16 Draining engine oil Replacing oil filter element ........................................................................................................17 Filling with engine oil ....................................................................................................................17 Checking coolant, topping up if necessary Checking coolant Adding coolant .................................................................18 (Inspections I, II and III) ......................................................................................................................18 ..........................................................................................................................18 ...............................................................................................................................18 Changing coolant .......................................................................................................................18 (Inspection IV, every 2 years) .............................................................................................................18 Changing oil in telescopic forks ........................................................................................20 (Inspection III) ....................................................................................................................................20 ....................................................................21 (Inspections I, II and III) ......................................................................................................................21 Checking and adjusting valve clearances Checking valve clearances .......................................................................................................21 Preparatory work ...............................................................................................................................21 Removing the intake air silencer together with the intake air pipe ......................................................21 Exposing the radiator ........................................................................................................................21 Exposing cylinder head .....................................................................................................................21 Turning crankshaft to TDC position ...................................................................................................21 Checking valve clearance ..................................................................................................................22 00.1 Contents Adjusting valve clearances Installing Installing Installing Installing Page .......................................................................................................22 cylinder head cover ............................................................................................................23 fan shroud ..........................................................................................................................23 intake air silencer ................................................................................................................23 the intake air duct ...............................................................................................................23 Replacing spark plugs .............................................................................................................24 (Inspection III) ....................................................................................................................................24 Emptying drain hose from intake air silencer Replacing air cleaner element Replacing fuel filter .............................................................24 (Inspections II and III) .........................................................................................................................24 ............................................................................................24 (Inspection III) ....................................................................................................................................24 ...................................................................................................................25 (Inspection III, every 20,000 km/12,000 miles) ...................................................................................25 Checking clutch play, adjusting if necessary .............................................................26 (Inspections I, II and III) ......................................................................................................................26 ........................................26 (Inspection II) .....................................................................................................................................26 ..................27 (Inspections II and III) .........................................................................................................................27 Checking wheel spoke tension, adjusting if necessary Checking brake pads and discs for wear, replacing if necessary Checking brake pads for wear ................................................................................................27 Brake pads, front brake .....................................................................................................................27 Brake pads, rear brake ......................................................................................................................27 .................................................................................................................27 Brake pads, front brake .....................................................................................................................27 Brake pads, rear brake ......................................................................................................................28 .........................................................................................................28 Replacing brake pads Checking the brake discs Checking the brake fluid level and topping up if necessary ..............................28 (Inspection II) .....................................................................................................................................28 Brake fluid level (front brake) ....................................................................................................28 Checking brake fluid level (front brake) ..............................................................................................28 Topping up brake fluid level (front brake) ...........................................................................................28 Brake fluid level (rear brake) .....................................................................................................29 Checking brake fluid level (rear brake) ...............................................................................................29 Topping up brake fluid level (rear brake) ............................................................................................29 Checking operation of brake system and freedom from leaks, repairing/ replacing if necessary ..............................................................................................................29 (Inspection III) ....................................................................................................................................29 Changing brake fluid .................................................................................................................30 (Inspection IV) ....................................................................................................................................30 Changing brake fluid (front brake) .........................................................................................30 Changing brake fluid (rear brake) ...........................................................................................30 00.2 Contents Replacing primary sealing boot, front brake master cylinder Replacing primary sealing boot, rear brake master cylinder Page ...........................31 (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ..........................................31 .............................32 (Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ..........................................32 .................33 (Inspection III) ....................................................................................................................................33 Inspecting front and rear wheel bearings, replacing if necessary Checking chain, chainwheel and chain sprocket, replacing if necessary .33 (Inspections II and III) .........................................................................................................................33 Checking chain tension, adjusting if necessary ........................................................33 (Inspections I, II, III and IV) .................................................................................................................33 Checking chain tension ..............................................................................................................33 Adjusting chain tension ..............................................................................................................34 Checking battery acid level, adding distilled water if necessary Checking battery acid level ....................34 (Inspections II, III and IV) ....................................................................................................................34 ......................................................................................................34 Adding distilled water ..................................................................................................................34 Cleaning and greasing the battery terminals, if necessary .................................35 (Inspections III and IV) .......................................................................................................................35 Checking and adjusting steering head bearing play, replacing if necessary ..............................................................................................................35 (Inspections II and III) .........................................................................................................................35 Checking steering head bearing play ..................................................................................35 Checking and adjusting steering head bearing play, replacing if necessary ..............................................................................................................36 (Inspections II and III) .........................................................................................................................36 Adjusting steering head bearing play ...................................................................................36 Greasing the side and main stands and the brake pedal lever Side stand ........................37 (Inspections II and III) .........................................................................................................................37 ........................................................................................................................................37 Main (centre) stand .......................................................................................................................37 Brake pedal .....................................................................................................................................38 Checking security of threaded fasteners ......................................................................38 (Inspections I, II, III and IV) .................................................................................................................38 Final inspection with road safety and functional check .......................................39 (Inspections I, II, III and IV) .................................................................................................................39 Road safety check ............................................................................................................................39 Tyre tread depth (recommended minimum value) ..............................................................................39 Tyre pressures (tyres cold) ................................................................................................................39 Roadworthiness check ......................................................................................................................39 00.3 00.4 00 Table of operating fluids Item Lubricant Use Order number Quantity Staburags NBU 30 PTM Optimoly MP 3 Optimoly TA Silicone grease 300, heavy Retinax EP2 Contact spray Chain spray Sealants High-performance lubricating paste High-performance lubricating paste High-temperature assembly paste Damping grease 07 55 9 056 992 75 g tube 07 55 9 062 476 100 g tube 18 21 9 062 599 100 g tube 07 58 9 058 193 10 g tube Wheel, steering head and taper roller 83 22 9 407 845 100 g tube bearing grease Contact spray Drive chain 81 22 9 400 208 300 ml spray 72 60 2 316 676 50 ml spray 72 60 2 316 667 300 ml spray 3-Bond 1110 B 3-Bond 1209 omni VISC 1002 Loctite 574 Curil K 2 Hylomar SQ 32 M Adhesives and retainers Surface sealant Surface sealant 07 58 9 056 998 5 g tube 07 58 9 062 376 30 g tube Surface sealant (max. 200 °C/392 °F) 07 58 1 465 170 90 g tube Surface sealant Heat-conductive sealant Permanently elastic sealant 81 22 9 407 301 50 ml tube 81 22 9 400 243 250 g can 81 22 9 400 339 100 g tube Loctite 648 Loctite 638 Loctite 243 Loctite 270 Loctite 2701 Loctite 454 Cleaners Joint adhesive (low clearance) Joint adhesive (greater clearance) Thread retainer, medium-strength Thread retainer, strong Thread retainer, strong Cyanacrylate adhesive (gel) 07 58 9 067 732 5 g bottle 07 58 9 056 030 10 ml bottle 07 58 9 056 031 10 ml bottle 81 22 9 400 086 10 ml bottle 33 17 2 331 095 10 ml bottle 07 58 9 062 157 20 g tube Brake cleaner Metal Polish Testing agents Brake cleaner Polish for parts 83 11 9 407 848 600 ml spray 82 14 9 400 890 100 g tube Penetrant MR 68 Developer MR 70 Installation aid Crack testing agent for aluminium housings Crack testing agent for aluminium housings 83 19 9 407 855 500 ml spray 81 22 9 407 495 500 ml spray BMW chilling spray Chilling components before assembly 83 19 9 407 762 300 ml spray 00.5 Tightening torques Model Connection 11 Engine Freewheel housing and freewheel Engine block Double drive gear on crankshaft Driver Pressure plate Magnet hub Signal transmitter Ignition cover Cylinder base Spark plug Threaded connection for chain tensioner Oil circuit Oil tank to intake air silencer Oil filter cover Oil pressure switch Oil tank drain plug Engine oil drain plug Oil supply/oil return lines to engine Oil pump cover Oil pressure valve Oil retaining valve 9 10 12 (clean thread + Loctite 243) 21 40 35 6 (clean thread + Loctite 243) 24 24 35 (clean thread + Loctite 648) 10 180 (clean thread + Loctite 243) 140 (clean thread + Loctite 243) 10 180 (clean thread + Loctite 243) 8 10 10 20 40 F 650 GS Nm 00 Model Connection Cylinder head Collar nuts for cylinder head Collar screws for cylinder head Machine screws (chaincase) Camshaft mount Chain sprockets to camshafts Chain guide to camshaft mount Cylinder head cover Machine screw (hole for locating pin) Cylinder head to frame Cylinder head to frame, adjusting sleeve Cylinder head to frame, locknut 12 Engine electrics Magnet hub Signal transmitter Engine block cover, left/right Starter to clutch cover Necked-down bolts, starter housing Cable cover to engine block Ignition coil and holder F 650 GS Nm 60 33 10 10 60 threads oiled 10 (clean thread + Loctite 243) 10 25 41 zero play, max. 5 100 180 (clean thread + Loctite 243) 8 10 10 6 4 9 00.7 Model Connection 13 Fuel preparation and control Air intake connection to cylinder head Fuel filter to frame Injector holder to throttle valve Connecting flange, air filter box to battery carrier Intake air silencer to retainer Oil tank to intake air silencer Throttle-valve potentiometer to throttle flap stub Throttle lifter to throttle flap stub 16 Fuel tank and lines Fuel tank to rear frame (M 8 stud) Tank cover to fuel tank Roll-over valve to fuel tank Bracket, activated charcoal filter to fuel tank Fuel pump to fuel tank 17 Radiator Air duct to frame trussing Expansion tank to radiator Radiator to main frame Water pump drain screw Left engine block cover to engine block Water pump cover Temperature sensor in cylinder head Bleed screw F 650 GS Nm 25 9 5 5 9 9 3 5 (clean thread + Loctite 243) 21 3 2 3 36 3 9 9 10 10 10 15 12 00 Model Connection 18 Exhaust system Oxygen sensor to exhaust Exhaust manifold to cylinder head Silencer to exhaust manifold (Torca clamp) Silencer to rear frame Guard to silencer 21 Clutch Driver Pressure plate Engine block cover, left 23 Transmission Selector lever to selector shaft 27 Drive chain Drive pinion cover to engine Chain takeup roller to frame Chain sprocket to chain sprocket carrier Quick-release shaft nut Drive chain tensioning screws Central nut to main shaft F 650 GS Nm 45 20 55 21 9 140 (clean thread + Loctite 243) 10 10 13 2 21 21 100 10 140 (clean thread + Loctite 243) 00.9 Model Connection 31 Front forks Fork stabiliser to fork leg Clamp screws for fork bridges, top/bottom Plate for bottom fork bridge to fork bridge Oil drain plug Damper retaining screw Knurled nut/bearing preload Locknut at upper fork bridge 32 Steering Handlebar to fork bridge Handlebar weight to handlebar Clutch fitting to handlebar, M 6 Clutch switch to handlebar fitting Pivot pin for brake lever Locknut for pivot pin, clutch lever 33 Rear wheel drive Suspension strut to frame Suspension strut to angled lever F 650 GS Nm 21 21 9 6 20 25 65 21 9 9 5 6 8 50 47 Knob for adjusting suspension-strut damping to holder 21 Holder, suspension-strut damping to frame Swinging fork pivot shaft Tension strut to swinging fork Tension strut to angled lever Angled lever to frame 9 100 41 71 50 00 Model Connection 34 Brakes Bleed screw in front/rear brake calliper Brake calliper to fork slider tube Brake disc and sensor ring to front wheel Brake disc to rear wheel Brake fluid reservoir for rear brake to rear frame Brake pedal to frame Brake lines/hoses Brake hose to brake calliper Brake hose to brake lever fitting Brake hose/brake line interfaces Brake line to master brake cylinder, rear wheel ABS ABS sensor front/rear ABS pressure modulator to holder Holder for ABS pressure modulator to frame transverse tube Brake line to ABS pressure modulator Sensor ring to rear wheel Brake disc and sensor ring to front wheel 36 Wheels and tyres Clamp nut, front quick-release axle Front quick-release axle to fork leg Rear quick-release axle to swinging arm Chain sprocket to chain sprocket carrier F 650 GS Nm 7 41 9 (clean thread + Loctite 243) 9 (clean thread + Loctite 243) 1.5 21 18 18 18 18 9 21 9 18 5 (clean thread + Loctite 243) 9 (clean thread + Loctite 243) 21 80 100 21 00.11 Model Connection 46 Frame Body Fairing sections/covers Fairing support bracket to frame Grip to rear frame End trimmer to rear frame Tail to rear frame Seat lock to rear frame F 650 GS Nm