BMW AG Motorcycle (F 650 GS). Manual - part 10

11.16

11 12 116 

Removing and installing cyl-

inder head, engine installed

L

 Note:

If an engine failure occurs, the oil tank and oil lines 
must be cleaned with the material used for this pur-
pose in the workshop, and then blown through with 
compressed air.

Preparatory work

–

Remove left, right and centre covers.

a

....................................................See Group 46

–

Remove the battery.

a

....................................................See Group 61

–

Drain coolant.

a

....................................................See Group 00

•

Drain the engine oil from the oil tank.

–

Remove engine guard.

a

....................................................See Group 46

–

Remove the starter motor.

a

....................................................See Group 12

–

Remove exhaust manifold and oxygen sensor.

a

....................................................See Group 18

–

Expose the radiator.

a

....................................................See Group 00

–

Remove the intake air duct.

a

....................................................See Group 13

–

Remove intake air silencer.

a

....................................................See Group 13

•

Remove the battery box.

•

Remove circlip securing throttle cable to throttle 
flap stub and disengage the throttle cable from 
the guide.

•

Disengage throttle cable from adapter.

•

Disconnect plugs at throttle flap stub.

•

Remove the intake pipe from the cylinder head 
and lay it carefully to one side, complete with the 
throttle flap stub.

•

Slacken the fastener securing the lid of the elec-
tronic equipment box.

•

Disengage the cover from the anchorages on the 
main frame on each side and remove.

•

Disconnect the starter coil at the plug.

•

Remove the fastener securing the ignition-coil 
bracket and remove the ignition coil complete 
with bracket.

11.17

•

Remove fastener for oil lines (2) from the cylinder 
head.

•

User pliers, BMW No. 17 5 500, to open the 
clamp securing the breather hose at the valve 
cover.

•

Remove valve cover (1).

•

Remove spark plug.

•

Remove centre screw plug on right in engine 
block.

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 top dead centre position with 
an Allen key.

L

 Note:

Watch out for escaping oil and catch it in a suitable 
container.

•

Remove screw (3) close to the oil feed stub pipe 
and install locking screw, BMW No. 11 6 570, to 
prevent the crankshaft from turning.

E110070

2

3

1

11.18

11 31 022 

Removing camshafts

•

Remove the cable cover from the right-hand side 
of the cylinder.

•

Remove the retainer of the spring-strut adjusting 
knob from the frame.

•

Disconnect plug of oil-pressure switch.

–

Raise the rear frame.

a

....................................................See Group 46

•

Disconnect the oil feed line (arrow) from the en-
gine.

•

Disconnect the oil feed hose from the oil tank.

•

Remove the oil feed line from the ABS modulator 
frame and push it to the right.

•

Remove the chain tensioner.

•

Remove chain guide (1).

•

Remove upper section of camshaft carrier (2).

•

Remove camshafts with chain sprockets.

•

Secure timing chain with retaining wire.

•

Remove front chain guide rail (3).

11 12 116 

Removing cylinder head

•

Remove lower section of camshaft carrier.

•

Remove screws securing cylinder head to 
frame (arrow).

•

Use pin wrench, BMW No. 11 6 661, to slacken 
the locknut.

L

 Note:

Note washers.

•

Back off the adjuster sleeves. 

•

Disconnect the coolant hose from cylinder 
head (4) and drain the last of the coolant from the 
radiator.

•

Disconnect the plug for temperature sensor (5).

E110470

E110420

1

2

3

E110480

E110490

4

5

11.19

•

Remove machine screws for chaincase (1).

•

Disconnect plug of oil-pressure sensor.

•

Remove oil pressure switch.

•

Remove rear collar screw (2) from cylinder head.

•

Remove front collar screws from cylinder head.

•

Remove top collar screws from cylinder head.

•

Remove collar nuts from cylinder head.

•

Raise cylinder head clear of stud bolts, turn the 
cylinder head and lift it toward the rear to re-
move.

•

Installation is the reverse of the removal proce-
dure: pay particular attention to the following.

L

 Note:

Replace cylinder head gasket.

•

Initially tighten the collar nuts of the cylinder head 
to 20 Nm (3-6) and then tighten to 60 Nm (7-10).

•

Tighten the fasteners of the cylinder head to cyl-
inder in the sequence as shown (11-16) to spec-
ified torque.

•

When looping the timing chain over the camshaft 
sprockets, make sure that the sprockets are at 
the TDC position.

•

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.

X 

Tightening torques:

Engine guard to frame.................................... 9 Nm
Footrest plate to frame ................................. 30 Nm
Silencer to exhaust manifold ........................ 55 Nm
Exhaust manifold to cylinder head................ 20 Nm
Intake air silencer to frame ............................. 9 Nm
Intake pipe to cylinder head ......................... 21 Nm
Lid of electronic equipment box to frame ....... 4 Nm
Ignition coil holder.......................................... 9 Nm
Oil lines to cylinder head ................................ 8 Nm
Cylinder head cover to cylinder head ........... 10 Nm
Spark plug in cylinder head .......................... 20 Nm
Rear frame to main frame ............................. 21 Nm
Oil line to engine block................................. 35 Nm
Timing-chain tensioner to cylinder head....... 40 Nm
Chain guide to bearing cap
(clean threads + Loctite 243) ........................ 10 Nm
Camshaft bearing cap to cylinder head ........ 10 Nm
Cylinder head to frame ................................. 41 Nm
Cylinder head to frame adjusting sleeve

...............................................zero play max. 5 Nm

Cylinder head to frame locknut................... 100 Nm
Machine screws, chaincase ......................... 10 Nm
Collar screws, cylinder head ........................ 33 Nm
Collar nuts, cylinder head................stage 1: 20 Nm

.......................................................stage 2: 60 Nm

Starter to clutch housing .............................. 10 Nm
Oil-pressure switch in engine block
(clean threads + Loctite 243) ........................ 12 Nm
Cable cover to engine .................................... 5 Nm

E110110

1

2

E110151

7

3

10

6

15

16

14

9

5

11

8

4

16

16

13

12

11.20

11 11 150 

Removing cylinder, engine 

installed

–

Remove cylinder head.

•

Use pliers, BMW No. 17 5 500, to open the 
clamp securing the coolant hose to the water 
pump (arrow) and disconnect the hose.

•

Disconnect ground cable (arrow) from cylinder.

•

Remove cylinder base screws.

•

Push the rear chain guide forward and carefully 
lift the cylinder clear.

•

Installation is the reverse of the removal proce-
dure: pay particular attention to the following.

L

 Note:

When installing, use a new cylinder base gasket.

•

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).

•

Push the timing chain through the chain aperture 
in the cylinder and secure the chain.

•

Slip the cylinder over the piston.

•

Remove sliding sleeve.

X 

Tightening torques:

Cylinder to engine block............................... 10 Nm
Ground cable to cylinder ................................ 8 Nm

E110500

E110510

11 6 510

E110520

11.21

11 00 050 

Removing engine

11 00 050 

Preparatory work 

–

Drain  coolant.

a

....................................................See Group 00

–

Place motorcycle on its centre stand.

–

Secure front wheel in position.

–

Remove seat.

–

Remove intake air silencer.

a

....................................................See Group 13

•

Disconnect battery negative terminal.

–

Remove engine guard.

–

Drain engine oil.

a

....................................................See Group 00

–

Remove rear wheel.

a

....................................................See Group 36

–

Remove exhaust manifold.

a

....................................................See Group 18

•

Disconnect oil feed and return lines from oil tank.

•

Remove cable cover (1) from the engine.

•

Cut the cable tie (arrow) at the voltage regulator.

•

Disconnect the plug of the voltage regulator.

•

Remove voltage regulator (4).

•

Straighten tab (2) and release breather line (3).

L

 Note:

The chain drive sprocket has to be removed at this 
point before engine disassembly can proceed.

•

Remove the chain sprocket.

a

....................................................See Group 27

•

Remove ground terminal (5) from the engine.

•

Disconnect plug of side-stand switch (6).

•

Unscrew connector for idle indicator (7).

•

Disconnect the plug of ignition trigger (8).

•

Disconnect plug of oil pressure sensor in oil filter 
housing.

•

Disconnect positive lead from starter motor.

•

Remove frame trussing.

•

Remove the chain from the drive sprocket.

•

Cut the cable tie at the adjusting-knob bracket 
(arrow).

•

Remove the fastener securing the adjusting-
knob bracket (10).

•

Disconnect the plug for the temperature 
sensor (9).

•

Slacken the hose clip at the throttle flap stub
and disconnect the throttle flap stub from the in-
take pipe.

•

Disconnect the starter coil at the plug.

•

Pull spark plug connector off spark plug.

E110010

1

2

3

4

E110020

8

6

7

5

E110030

10

9

11.22

•

Remove the ignition-coil bracket complete with 
ignition coil from the cylinder head cover.

•

Disconnect clutch cable from release lever.

•

Disconnect breather hose for oil tank from the 
cylinder head cover.

•

Remove radiator.

a

.................................................... see Group 27

•

Remove the right-hand coolant hose.

•

Remove fasteners for engine shell and remove 
engine shell with the bracket for the voltage reg-
ulator.

•

Remove swinging fork pivot pin.

•

Remove bottom rear engine mount fastener.

•

Secure the motorcycle by attaching two straps to 
the front forks.

•

Remove the brake pedal.

•

Remove the gear shift pedal.

11 00 050 

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.

•

Secure the engine lifter by installing stud bolt (1) 
through bottom bore in engine block and secur-
ing stud (2) in top bore in engine block.

•

Remove screws securing cylinder head to frame 
on left and right. Use pin wrench, 
BMW No. 11 6 661, to slacken the locknuts and 
back off the adjusting sleeves.

•

Lower the engine until the cylinder head is rest-
ing on the radiator fastening lug (arrow).

•

Continue lowering the engine; the engine tilts to-
ward the rear.

•

Continue lowering the engine until the fastening 
lug is above the cylinder head cover.

•

Turn the engine toward the right and push it clear 
of the motorcycle.

Transferring engine to assembly frame

•

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.

E110040

1

2

E110050

E110530

11 0 531

11.23

•

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.

•

Manoeuvre the engine so that the engine adapter 
is level with the flange of the assembly stand.

•

Secure engine adapter (1) to the flange of the as-
sembly stand (2).

•

Turn engine adapter.

11 00 050 

Lowering engine

11 00 050 

Preparatory work 

–

Drain coolant.

a

....................................................See Group 00

–

Place motorcycle on its centre stand.

–

Secure front wheel in position.

–

Remove seat.

–

Remove intake air silencer.

a

....................................................See Group 13

•

Disconnect battery negative terminal.

–

Remove engine guard.

–

Drain engine oil.

a

....................................................See Group 00

–

Remove rear wheel.

a

....................................................See Group 36

–

Remove exhaust manifold.

a

....................................................See Group 18

•

Disconnect oil feed and return lines from oil tank.

•

Remove cable cover (3) from the engine.

•

Cut the cable tie (arrow) at the voltage regulator.

•

Disconnect the plug of the voltage regulator.

•

Remove voltage regulator (6).

•

Straighten tab (4) and release breather line (5).

L

 Note:

The chain drive sprocket has to be removed at this 
point before engine disassembly can proceed.

•

Remove the chain sprocket.

a

....................................................See Group 27

•

Remove ground terminal (1) from the engine.

E110060

1

2

E110010

3

4

5

6

E110020

4

2

3

1