BMW AG Motorcycle (F 650 GS). Manual - part 3

>> 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

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00.1

Contents

Page

00

Table of operating fluids 

...........................................................................................................5

Tightening torques 

......................................................................................................................6

Key to maintenance intervals 

..............................................................................................15

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

Draining engine oil

 ........................................................................................................................16

Replacing oil filter element

 ........................................................................................................17

Filling with engine oil

 ....................................................................................................................17

Checking coolant, topping up if necessary 

.................................................................18

(Inspections I, II and III) ......................................................................................................................18

Checking coolant

 ..........................................................................................................................18

Adding coolant

 ...............................................................................................................................18

Changing coolant

 .......................................................................................................................18

(Inspection IV, every 2 years)  .............................................................................................................18

Changing oil in telescopic forks 

........................................................................................20

(Inspection III)  ....................................................................................................................................20

Checking and adjusting valve clearances 

....................................................................21

(Inspections I, II and III) ......................................................................................................................21

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 Maintenance and general instructions

00.2

Contents

Page

Adjusting valve clearances

 .......................................................................................................22

Installing cylinder head cover  ............................................................................................................23
Installing fan shroud  ..........................................................................................................................23
Installing intake air silencer ................................................................................................................23
Installing the intake air duct ...............................................................................................................23

Replacing spark plugs

 .............................................................................................................24

(Inspection III)  ....................................................................................................................................24

Emptying drain hose from intake air silencer

 .............................................................24

(Inspections II and III) .........................................................................................................................24

Replacing air cleaner element

 ............................................................................................24

(Inspection III)  ....................................................................................................................................24

Replacing fuel filter

 ...................................................................................................................25

(Inspection III, every 20,000 km/12,000 miles) ...................................................................................25

Checking clutch play, adjusting if necessary

 .............................................................26

(Inspections I, II and III) ......................................................................................................................26

Checking wheel spoke tension, adjusting if necessary 

........................................26

(Inspection II)  .....................................................................................................................................26

Checking brake pads and discs for wear, replacing if necessary 

..................27

(Inspections II and III) .........................................................................................................................27

Checking brake pads for wear

 ................................................................................................27

Brake pads, front brake .....................................................................................................................27
Brake pads, rear brake ......................................................................................................................27

Replacing brake pads

 .................................................................................................................27

Brake pads, front brake .....................................................................................................................27
Brake pads, rear brake ......................................................................................................................28

Checking the brake discs

 .........................................................................................................28

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

00.3

Contents

Page

Replacing primary sealing boot, front brake master cylinder 

...........................31

(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS)  ..........................................31

Replacing primary sealing boot, rear brake master cylinder 

.............................32

(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS)  ..........................................32

Inspecting front and rear wheel bearings, replacing if necessary 

.................33

(Inspection III)  ....................................................................................................................................33

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

 ....................34

(Inspections II, III and IV) ....................................................................................................................34

Checking battery acid level

 ......................................................................................................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 

........................37

(Inspections II and III) .........................................................................................................................37

Side stand

 ........................................................................................................................................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

00.4

00.5

00

Table of operating fluids

Item

Use

Order number

Quantity

Lubricant

Staburags NBU 30 PTM

High-performance lubricating paste

07 55 9 056 992 75 g tube

Optimoly MP 3

High-performance lubricating paste

07 55 9 062 476 100 g tube

Optimoly TA

High-temperature assembly paste

18 21 9 062 599 100 g tube

Silicone grease 300, heavy

Damping grease

07 58 9 058 193 10 g tube

Retinax EP2

Wheel, steering head and taper roller 
bearing grease

83 22 9 407 845 100 g tube

Contact spray

Contact spray

81 22 9 400 208 300 ml spray

Chain spray

Drive chain

72 60 2 316 676
72 60 2 316 667

50 ml spray
300 ml spray

Sealants

3-Bond 1110 B

Surface sealant

07 58 9 056 998 5 g tube

3-Bond 1209

Surface sealant

07 58 9 062 376 30 g tube

omni VISC 1002

Surface sealant (max. 200 °C/392 °F) 07 58 1 465 170 90 g tube

Loctite 574

Surface sealant

81 22 9 407 301 50 ml tube

Curil K 2

Heat-conductive sealant

81 22 9 400 243 250 g can

Hylomar SQ 32 M

Permanently elastic sealant

81 22 9 400 339 100 g tube

Adhesives and retainers

Loctite 648

Joint adhesive (low clearance)

07 58 9 067 732 5 g bottle

Loctite 638

Joint adhesive (greater clearance)

07 58 9 056 030 10 ml bottle

Loctite 243

Thread retainer, medium-strength

07 58 9 056 031 10 ml bottle

Loctite 270

Thread retainer, strong

81 22 9 400 086 10 ml bottle

Loctite 2701

Thread retainer, strong

33 17 2 331 095 10 ml bottle

Loctite 454

Cyanacrylate adhesive (gel)

07 58 9 062 157 20 g tube

Cleaners

Brake cleaner

Brake cleaner

83 11 9 407 848 600 ml spray

Metal Polish

Polish for parts

82 14 9 400 890 100 g tube

Testing agents

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

Installation aid

BMW chilling spray

Chilling components before assembly 83 19 9 407 762 300 ml spray

00

Tightening torques

Model

F 650 GS

Connection

Nm

11 Engine

Freewheel housing and freewheel

35 (clean thread + Loctite 648)

Engine block

10

Double drive gear on crankshaft

180 (clean thread + Loctite 243)

Driver

140 (clean thread + Loctite 243)

Pressure plate

10

Magnet hub

180 (clean thread + Loctite 243)

Signal transmitter

8

Ignition cover

10

Cylinder base

10

Spark plug

20

Threaded connection for chain tensioner

40

Oil circuit

Oil tank to intake air silencer

9

Oil filter cover

10

Oil pressure switch

12 (clean thread + Loctite 243)

Oil tank drain plug

21

Engine oil drain plug

40

Oil supply/oil return lines to engine

35

Oil pump cover

6 (clean thread + Loctite 243)

Oil pressure valve

24

Oil retaining valve

24

00.7

Cylinder head

Collar nuts for cylinder head

60

Collar screws for cylinder head

33

Machine screws (chaincase)

10

Camshaft mount

10

Chain sprockets to camshafts

60 threads oiled

Chain guide to camshaft mount

10 (clean thread + Loctite 243)

Cylinder head cover

10

Machine screw (hole for locating pin)

25

Cylinder head to frame

41

Cylinder head to frame, adjusting sleeve

zero play, max. 5

Cylinder head to frame, locknut

100

12 Engine electrics

Magnet hub

180 (clean thread + Loctite 243)

Signal transmitter

8

Engine block cover, left/right

10

Starter to clutch cover

10

Necked-down bolts, starter housing

6

Cable cover to engine block

4

Ignition coil and holder

9

Model

F 650 GS

Connection

Nm