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BMW AG Motorcycle (F 650 GS). Manual - part 16

12.8

12 11 060

Removing/installing ignition

trigger

•

Remove fasteners securing ignition trigger (2) in
right cover.

•

Remove cable holder (1).

•

Remove the rubber grommet of ignition
trigger (4) from the cover.

•

Remove ignition trigger (3).

•

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

•

Coat the rubber grommet of the ignition trigger
with 3 Bond 1209 before inserting it into the cov-
er.

Tightening torque:

Ignition trigger in cover................................... 8 Nm

Removing/installing stator

•

Remove cable holder (5).

•

Remove fasteners securing stator (6).

•

Remove the rubber grommet of stator (7) from
the cover.

•

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

•

Coat the rubber grommet of the stator with
3 Bond 1209 before inserting it into the cover.

•

Clean the threads of the screws and coat with
Loctite 243.

Tightening torque:

Stator to cover
(clean threads + Loctite 243)........................ 10 Nm
Cable holder to cover..................................... 8 Nm

12 11 070

Installing magnetic ignition

trigger

12 11 070

Installing magnet wheel

Caution:

Tapers on crankshaft and magnet hub and hex nut
must be clean and free of grease.

•

Apply a thin coat of Loctite 648 to the magnet
hub taper.

•

Oil freewheel in freewheel housing.

•

Slide magnet wheel (8) onto crankshaft: woodruff
key and keyway must be aligned.

•

Rotate starter double gear (9) counter-clockwise
to enable the freewheel to slide on to the collar of
the freewheel gear.

•

Clean the threads on the crankshaft and the
threads of the nut.

•

Install snap ring and coat threads of hex nut with
Loctite 243 and tighten.

E110380

E120060

E110370

12.9

•

Fit gasket.

•

Screw assembly handle, BMW No. 12 5 500,
into the central hole in the right engine cover.

•

Fit right engine housing cover and bolt together.

•

Remove assembly handle and screw in central
plug.

•

Connect the plugs of the ignition trigger and the
stator.

•

Clip the stator connector onto the plug.

•

Secure the cable cover to the engine.

Tightening torque:

Magnetic hub
(clean thread + Loctite 243)........................ 180 Nm
Engine cover, right ....................................... 10 Nm
Cable cover to engine .................................... 5 Nm

12 41 020

Removing/installing or

dismantling starter motor

12 41 020

Removing/installing starter

motor

Caution:

Disconnect the negative battery cable first, then the
positive cable.

•

Disconnect the battery.

•

Disconnect positive cable (1).

•

Remove fastener (2) from engine block and re-
move starter.

•

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

•

Check O-ring for damage and replace if neces-
sary.

Caution:

Connect the positive battery cable first, then the
negative cable.

Tightening torque:

Starter motor to engine block....................... 10 Nm
Positive cable to starter motor........................ 5 Nm

E120010

12.10

12 41 103

Disassembling/assembling

starter motor

•

Remove necked-down bolts (9).

•

Remove armature bearing cover (8) complete
with brush-holder plate (6).

Note:

Note thrust washers (2).

•

Remove fastener of positive contact (7), lift out
brush holder and replace carbon brushes if nec-
essary.

•

Remove front cover (5).

•

Remove armature (3) from housing (1).

•

Using puller, BMW No. 00 8 400, pull the ball
bearing (4) off the armature shaft.

Note:

The insulation should be 0.5 mm (0.02 in) deeper
than the commutator discs: if necessary, remachine
with commutator saw.

•

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

•

Use a suitable tool such as a socket or similar to
press the ball bearing onto the armature shaft.

•

Using protective jaws, clamp the armature in a
vise and slide the brush-holder plate into posi-
tion, pushing the carbon brushes back for clear-
ance.

Note:

Make sure that the mark on the housing (arrow) is
aligned with positive contact point (10).

Tightening torque:

Necked-down bolts, starter housing .............. 5 Nm
Positive contact to starter motor .................... 4 Nm

E120020

E120070

12.11

12 12 011

Replacing spark plug

See Group 00

12 12 085

Replacing ignition lead

–

Remove left, right and centre covers.

–

Remove the battery.

Remove the intake air silencer together with the
intake air pipe.

•

Remove the fastener for the intake air silencer
from the oil tank.

•

Remove the fasteners for the intake air silencer
from the retainer.

•

Remove the starter relay from the holder.

•

Slacken the fasteners for the lid of the electronic
equipment box.

•

Remove the fasteners for the battery tray.

•

Disengage the clamp securing the breather hose
and disconnect the hose from the intake air si-
lencer.

•

Press the oil tank slightly to the left and carefully
disconnect the intake air silencer from the throt-
tle flap stub.

•

Pull the intake air silencer with intake air pipe and
battery carrier to the rear to remove.

•

Cover/seal the throttle flap stub.

•

Disconnect the ignition lead from the ignition coil
and the spark plug and remove.

Tightening torque:

Lid of electronic equipment box. .................... 4 Nm
Oil tank to intake air silencer .......................... 9 Nm
Intake air silencer to frame ............................. 9 Nm
Trim panel/cover ............................................ 3 Nm

12 13 000

Removing/installing coil

–

Remove left, right and centre covers.

–

Remove the battery.

Remove the intake air silencer together with the
intake air pipe.

•

Remove the fastener for the intake air silencer
from the oil tank.

•

Remove the fasteners for the intake air silencer
from the retainer.

•

Remove the starter relay from the holder.

•

Slacken the fasteners for the lid of the electronic
equipment box.

•

Remove the fasteners for the battery tray.

•

Disengage the clamp securing the breather hose
and disconnect the hose from the intake air si-
lencer.

•

Press the oil tank slightly to the left and carefully
disconnect the intake air silencer from the throt-
tle flap stub.

•

Pull the intake air silencer with intake air pipe and
battery carrier to the rear to remove.

•

Cover/seal the throttle flap stub.

•

Disengage cover (1) from the anchorages on
main frame on each side and remove.

•

Disconnect starter coil (2) at plug.

•

Pull spark plug connector (4) off spark plug.

•

Remove screws securing ignition coil (3) to cylin-
der head cover.

Tightening torques:

Ignition coil to cylinder head........................... 9 Nm
Lid of electronic equipment box ..................... 4 Nm
Oil tank to intake air silencer .......................... 9 Nm
Intake air silencer to frame ............................. 9 Nm
Trim panel/cover ............................................ 3 Nm

E000030

12.12

13.1

Contents

Page

Technical Data

............................................................................................................................... 3

Removing and installing BMS control unit

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

Removing and installing intake air pipe

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

Removing/installing air temperature sensor