Content .. 9 10 11 12 ..

BMW AG Motorcycle (F 650 GS). Manual - part 11

11.24

•

Disconnect plug of side-stand switch (2).

•

Unscrew connector for idle indicator (3).

•

Disconnect the plug of ignition trigger (4).

•

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 (6).

•

Disconnect the plug for the temperature
sensor (5).

•

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.

•

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.

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

Lowering the 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 (7)
through bottom bore in engine block and secur-
ing stud (8) 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.

E110030

E110040

11.25

•

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.

•

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

•

Raise the engine and tilt it to the rear.

•

Manoeuvre the bottom engine mount into posi-
tion.

•

Raise the engine and manoeuvre the fasteners at
the cylinder head into position.

•

Install the bottom rear engine mount fastener.

•

Install the pivot pin of the swinging arm bearing.

•

Back off the adjusting screws for the cylinder
head mounts until they are seated against the
cylinder head on each side and the cylinder head
itself is centered in the frame.

Tightening torques:

Water pump drain screw .............................. 10 Nm
Intake air silencer to frame ............................. 9 Nm
Engine guard to frame.................................... 9 Nm
Engine oil drain plug..................................... 40 Nm
Rear quick-release axle.............................. 100 Nm
Drive chain tensioning screws ...................... 10 Nm
Exhaust manifold to cylinder head................ 20 Nm
Silencer to exhaust manifold ........................ 55 Nm
Footrest plate to main frame, left/right.......... 30 Nm
Cable cover to engine .................................... 5 Nm
Voltage regulator to bracket ........................... 7 Nm
Chain drive sprocket to mainshaft
(clean threads + Loctite 243) ...................... 140 Nm
Sprocket cover to engine ............................... 2 Nm
Ground terminal to engine block .................... 8 Nm
Connecting cable, idle indicator ..................... 2 Nm
Frame trussing to engine shell...................... 21 Nm
Frame trussing to main frame ....................... 21 Nm
Spring-strut adjusting knob bracket
to frame ......................................................... 9 Nm
Radiator to main frame at top......................... 9 Nm
Swinging-arm pivot .................................... 100 Nm
Frame to engine at rear ................................ 41 Nm
Gearshift pedal to engine ............................. 13 Nm
Brake pedal to frame.................................... 21 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

E110050

11.26

11 00 103

Disassembling engine

Caution:

If there is any mechanical damage, the oil tank and
the oil lines must be cleaned.

11 12 516

Removing cylinder head

–

Remove starter motor

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

•

Remove oil lines.

•

Remove valve cover (1).

•

Remove spark plug.

•

Remove centre screw plug on right in engine
block.

•

Turn crankshaft to top dead centre position with
an Allen key.

•

Remove screw (5) and lock the crankshaft with
locating screw, BMW No. 11 6 570.

Note:

Check for secure seating with Allen key.

11 31 522 Removing camshafts

•

Only unfasten chain sprockets if they need to be
replaced.

•

Remove chain tensioner (3).

•

Remove chain guide (4) from between the chain
sprockets.

•

Remove fasteners securing camshaft carrier (2).

E110070

11.27

•

Remove camshafts with chain sprockets.

•

Take off the lower camshaft carrier.

Checking camshaft for wear

•

Measure bearing play with Plastigage type PG-1,
BMW No. 00 2 590.

•

Tighten camshaft carrier to specified torque.

Tightening torque:

Camshaft carrier........................................... 10 Nm

•

Remove camshaft carrier and determine bearing
clearance using comparative scale.

Wear limits:
Cam height, inlet ..............min. 39.25 mm (1.545 in)
Cam height, exhaust .........min 39.05 mm (1.537 in)
Bearing journal dia. ........min. 21.950 mm (0.864 in)
Bearing dia.
in bearing pedestal........max. 22.040 mm (0.868 in)
Bearing play ..................max. 0.090 mm (0.0035 in)

11 31 671 Removing and installing timing-chain
sprockets

•

Clamp the camshaft in a vise fitted with protec-
tive jaws.

•

Remove the fastener securing the sprocket to
the camshaft and remove the camshaft sprocket.

•

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

•

Before installing, oil the thread of the chain-
sprocket fastener.

Tightening torque:

Sprocket to camshaft
(thread oiled) ................................................ 60 Nm

Checking centrifugal decompressor lever

Note:

Never stretch the spring, since this alters the prede-
termined spring force.

•

When activated, the lever must not project be-
yond the cam base circle by less than
distance “B”.

Distance “B” .................................. 0.6 mm (0.02 in)

11 31 530 Disassembling and assembling the
centrifugal decompressor

Note:

If the centrifugal decompressor is dismantled,
spring (3) must always be renewed.

•

Use a suitable punch to press shaft (1) out of
centrifugal weight (2).

•

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

•

After assembly, check centrifugal weight for ease
of movement.

F110040

00 2 590

E110090

E110100

11.28

11 12 116 Removing cylinder head

•

Remove front chain rail (1).

•

Release the coolant line hose clips with pliers,
BMW No. 17 5 500.

•

Allow the timing chain to slide into its cavity.

•

Remove the starter motor.

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

•

Remove collar nuts from cylinder head.

Note:

If the cylinder head does not have to be dismantled,
do not separate cylinder head from cylinder.
In this case the next six work steps can be omitted.

•

Remove machine screws for chaincase (2).

•

Remove rear collar screw (3) from cylinder head.

•

Remove front collar screws from cylinder head.

•

Remove top collar screws from cylinder head.

•

Separate the cylinder head from the cylinder.

•

Remove cylinder head.

Checking timing chain for wear

•

Push hydraulic chain tensioner (4) in the direc-
tion of the tensioner rail in the guide on the cylin-
der, until resistance to movement is felt.

•

Measure distance (A) from the sealing face to the
chain tensioner piston.

E110111

F111060

11.29

•

If the wear limit, distance “B”, is exceeded, first
inspect the tensioner rail and the two guide rails
for score-marks and renew them if necessary.

•

If a part has to be renewed, repeat the measure-
ment procedure described above.
If the wear limit has been exceeded, the timing
chain must be renewed.

Distance “B” ........................max. 9.0 mm (0.354 in)

11 12 528

Disassembling and

assembling cylinder head

1 Valve
2 Lower valve spring plate
3 Valve stem seal
4 Valve spring
5 Upper valve spring plate
6 Valve collets

11 34 020 Removing valves

•

Use suction device, BMW No. 11 3 251, to pull
out the bucket-type tappets.

•

Check that bucket tappets and guides are in per-
fect condition.

Bore for bucket tappet
In cylinder head........... max. 33.600 mm (1.3229 in)
Radial clearance of
bucket tappet.............. max. 0.200 mm (0.0079 in)

Caution:

Mark the bucket tappets to ensure that they are re-
installed in their original positions (risk of jamming).

Note:

To simplify removal of the valve collets, tap the
valves sharply with a plastic-faced hammer.

•

Secure the cylinder head to support plate,
BMW No. 11 0 523.

•

Secure adapter plate, BMW No. 11 0 521, sup-
port, BMW No. 11 5 691, spindle,
BMW No. 11 5 692, nut, BMW No. 11 5 693,
and thrust plate, BMW No. 11 0 522.

•

Press down the valves with the thrust plate.

•

Use a screwdriver to press apart and remove the
valve collets.

•

Pull the valves down to remove.

E110120

E110130

11 0 523

11 0 521

11 5 692

11 0 522

11 5 691

11.30

Checking valve guide for wear

•

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, posi-
tioned vertically on the valve axis, measure max-
imum play at right angles to the camshaft axis.

Play:
Max. play..................................... 0.4 mm (0.016 in)
Intl. dia. of
valve guide ....................max. 5.080 mm (0.2000 in)

11 12 591 Removing valve guide

Caution:

Do not damage sliding surfaces on bucket tappets:
risk of jamming.

•

Pull off valve stem seal (1) with pliers,
BMW No. 11 1 250.

•

Remove valve spring support (2) from cylinder
head.

Note:

To facilitate removal, heat the cylinder head to
100 °C (212 °F).
Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.

•

Use drift, BMW No. 11 0 571, to drive out the
valve guide toward the combustion chamber.

Caution:

The cylinder head has to be replaced if the bore for
the valve guide is worn.

F110111

00 2 510

F110121

F110140

11 0 571

11.31

11 12 591 Installing valve guide

•

Heat the cylinder head to 100 °C (212 °F).

•

Using driving-in tool, BMW No. 11 0 571, drive
valve guide (1) into the cylinder head until valve
guide projection is as specified.

Projection:
Inlet ........................... 9.8...10.2 mm (0.39...0.40 in)
Exhaust ..................... 9.8...10.2 mm (0.39...0.40 in)

Note:

Only use thread-cutting oil to lubricate the reaming
tool.
Only rotate reaming tool in the cutting direction -
never in the opposite direction.
Withdraw reaming tool at regular intervals for clean-
ing: always rotate the tool in cutting direction while
removing.

•

Ream out valve guide with 5H7 reaming tool.

Checking valve seat for wear

•

Apply engineer’s blue or a similar product to the
valve seat rings.

•

Install relevant valve and rotate, applying slight
pressure.

•

Check valve seat width “A” and contact pattern
for wear.

Wear limits for valve seat width “A”:
Inlet valve .................................... 1.6 mm (0.063 in)
Exhaust valve .............................. 2.2 mm (0.087 in)

•

Once the wear limit of the seat width has been
reached, or if the contact pattern is no longer
perfect, the seat can be remachined.

•

If necessary, remachine valve seat with valve
seat turning tool (2).

Valve seat width “B”:
Inlet valve .................................... 1.2 mm (0.047 in)
Exhaust valve .............................. 1.4 mm (0.055 in)

F110151

F110160

E110540

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