Content .. 11 12 13 14 ..

BMW AG Motorcycle (F 650 GS). Manual - part 13

11.40

Removing double drive gear

Note:

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 bal-

ancing shaft

•

Lever out water-pump drive gear (3) with a
screwdriver.

•

Remove needle roller.

•

Swivel engine in assembly fixture so that magnet
side is uppermost.

•

Remove all threaded fasteners for engine hous-
ing.

•

Remove oil filter and unfasten two fasteners on
base plate for engine housing.

•

Swivel assembly fixture so that clutch side is up-
permost.

•

Remove knurled nuts (4).

Caution:

Do not tilt engine housing: this can cause damage
to bearing shell.

•

Raise the engine housing at the left and strike the
mainshaft, countershaft and balancing shaft al-
ternately with light blows of a plastic-faced ham-
mer, so that these remain in the magnet side.

•

Screw knurled nut on to engine support with
spacer.

•

Align marks (7) on balancing shaft and crank-
shaft (5) with mark on housing (6).

E110290

E110310

E110320

E110330

11.41

Note:

Note shims on crankshaft.

•

First lift out crankshaft, then balancing shaft.

Checking crankshaft for wear

•

Check bearing journal on crankshaft and conrod
for signs of damage and wear.

Bearing journal dia. ..........min. 45.97 mm (1.810 in)
Radial play, main bearing .. max. 0.10 mm (0.004 in)
Endplay,
conrod/crankshaft webs.... max. 0.80 mm (0.031 in)
Small end bore dia. ......... max. 22.04 mm (0.868 in)

11 27 020

Removing compensating gear

•

Press off compensating gear with pressure pad,
BMW No. 11 0 561.

•

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

Note:

Coat the bearing seat for the expander gear on the
compensating gear with Optimoly MP 3.

•

Heat the compensating gear to 100 °C (212 °F).

Note:

Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.

•

Use a socket of suitable size or similar adapter to
apply pressure to the thrust face of the gear
when installing the compensating gear.

Removing and installing crankshaft
gear

•

Clamp crankshaft into vise with protective jaws.

•

Use yoke, BMW No. 11 6 501, spindle,
BMW No. 11 6 502, and pressure pad,
BMW No. 11 6 503, to pull off the crankshaft
gear.

•

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

•

When installing, heat the crankshaft gear to
140 °C (284 °F).

Note:

Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.

Caution:

Split pin must not protrude from bore in crankshaft
gear - this is the support face for the thrust washer.

•

Using a suitable adapter, drive the gear onto the
crankshaft.

Projection “A” of split pin ...... max. 18 mm (0.709 in)

F110450

11 6 502

11 6 501

11 6 503

F110460

11.42

11 11 205

Removing and installing gear-

box mainshaft bearings

Note:

To protect the gasket surfaces of the engine block,
place the old gasket under the bearing puller.
Always renew 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 6 564, pull off the ball bear-
ing.

•

Drive out the mainshaft sealing ring from the in-
side.

•

Heat the right of the engine block to 80 - 100 °C
(176 - 212 °F).

•

Use a suitable tool such as a socket or similar to
press the ball bearing through to the other side
from outside.

•

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

Note:

The sealed ends of the cage must point outwards.

•

To install the ball bearing, heat the engine block
to 80 - 100 °C (176 - 212 °F) and spray the ball
bearing with BMW chilling spray.

•

Drive in the shaft sealing ring with sleeve,
BMW No. 23 4 540, and drift,
BMW No. 23 4 550.

11 11 210

Removing and installing gear-

box compensating shaft bearings

Note:

To protect the gasket surfaces of the engine block,
place the old gasket under the bearing puller.
Always renew 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 6 565, pull off the ball bear-
ing.

•

Heat the right 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 6 564, pull off the ball bear-
ing.

•

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

Note:

The sealed ends of the cage must point outwards.

•

To install the ball bearing, heat the engine block
to 80 - 100 °C (176 - 212 °F) and spray the ball
bearing with BMW chilling spray.

Wear limit values for bearing seats in housing:
Magneto side:
Countershaft ............... max. Ø 46.99 mm (1.850 in)
Mainshaft .................... max. Ø 62.02 mm (2.442 in)
Clutch side:
Countershaft ............... max. Ø 51.99 mm (2.047 in)
Mainshaft .................... max. Ø 46.99 mm (1.850 in)

E230040

11 6 564

11 6 561

11 6 562

11.43

11 11 200

Removing and installing

grooved ball bearings of gearbox
compensating shaft

Note:

To protect the gasket surfaces of the engine block,
place the old gasket under the bearing puller.
Always renew 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 bear-
ing.

•

Heat the right 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 bear-
ing.

•

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

Note:

The sealed ends of the cage must point outwards.

•

To install the ball bearing, heat the engine block
to 80 - 100 °C (176 - 212 °F) and spray the ball
bearing with BMW chilling spray.

11 21 001

Removing and installing main

bearings

•

Check main bearings for signs of damage and
wear.

Removal

•

Heat the engine housing to 100 °C (212 °F).

•

Drive out the bearing bushings with drift,
BMW No. 11 0 541, and drift,
BMW No. 00 5 500.

F110480

00 5 500

11 0 541

11.44

Installation

•

Mark the position of the oil hole in the bearing on
the housing.

•

Heat the engine housing to 100 °C (212 °F).

•

Align the mark on the drift (arrow) with the mark
on the housing.

Caution:

The bearing bushing must not project beyond the oil
pockets.
The end gap of the bearing bushing must always
face the balancing shaft.

•

Coat bearing bushings with Optimoly TA

and

drive in with drift, BMW No. 11 0 551, working
from the inside.

F110490

11 0 551

11.45

11 00 103

Assembling engine

–

Install the gearbox.

...................................................See Group 23.

11 21 511

Installing crankshaft and

balancing shaft

•

Secure right side of engine housing in engine
bracket with magnet side facing downwards.

•

Install balancing shaft in engine housing;
marking (1) must be aligned with marking (3) on
housing.

•

Coat 1.0 mm (0.04 in) thrust washer with oil and
install on crankshaft.

•

Rotate crankshaft before installing, so that
marking (2) is aligned with marking (3).

•

Fit gasket.

•

Oil thrust washers and install on crankshaft and
balancing shaft.

Note:

Oil shaft bearing points.
Re-shim the crankshaft and balancing shaft if the
housing or either of the shafts was renewed.

•

Coat the balancing shaft bearing journals with
Optimoly MP 3.

Shimming crankshaft

•

Using depth gauge, BMW No. 00 2 550, meas-
ure distance from crankshaft web to housing
joint line = dimension “B”.

•

Measure distance from left engine housing joint
face to spacing washer contact face = dimension
“A”.

–

Dimension “A” minus dimension “B” = crankshaft
endplay.

E110330

F111041

F111050

11.46

Note:

Allow for the thickness of the compressed
gasket (approx. 0.4 mm/0.016 in).
On the magnet side, the spacing washer is always
1.0 mm (0.04 in) thick.

•

Select a suitable spacing washer to ensure that
the correct endplay is obtained.

Crankshaft
endplay ................... 0.1...0.3 mm (0.004...0.012 in)

Note:

Shim the balancing shaft in the same way as the
crankshaft.
Install spacing washers only on the clutch side.

•

Fit left engine housing and screw down.

Note:

Note the two fasteners in the oil filter housing.

•

Cut off protruding gasket.

Tightening torque:

Threaded fasteners of engine housing ......... 10 Nm

Installing double drive gear

•

Lock the crankshaft in the TDC position with lo-
cating screw, BMW No. 11 6 570.

•

Insert chain through chain aperture and loop it
around crankshaft.

•

Slide double drive gear (2) on to crankshaft.

•

Engage chain.

•

Install snap ring.

•

Clean threads of crankshaft and hexagon nut (1),
coat threads with Loctite 243 and install nut.

•

Engage needle roller of water-pump drive gear
on stub of compensating shaft and push drive
gear (3) into position.

Tightening torque:

Double drive gear on crankshaft
(clean thread + Loctite 243)........................ 180 Nm

E110340

11 6 570

E110290

11.47

11 41 000

Installing oil pump gears

•

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).

E110350

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