BMW AG Motorcycle (F 650 GS). Manual - part 26

32.4

32.5

Removing and installing left and 
right handlebar fittings

L

 Note:

To avoid damage, use a protective apron for the 
tank, BMW No. 16 1 600.

Removing and installing left handlebar 
fitting

–

Place motorcycle on its centre stand.

–

Remove seat.

–

Remove left, right and centre covers.

•

Cut the cable tie at the handlebar.

•

Remove cover (3) from housing (2).

•

Remove clutch fitting (1).

•

Remove handlebar weight (5).

•

Remove rubber grip (4).

•

Cut through cable ties (arrows).

•

Disconnect the expansion tank and pull it to one 
side.

•

Remove the fasteners securing the oil tank and 
allow the oil tank to dangle to one side on the 
hoses.

•

Remove the starter relay from the holder.

•

Remove the lid of the electronic equipment box.

•

Cut through the cable tie holding the wiring har-
ness at the electronic equipment box.

•

Disengage cover from the anchorage on main 
frame on left.

E320040

2

3

5

4

1

E320060

32.6

•

Disconnect plug of left-hand multi-function 
switch (1).

•

Push the cover over the cylinder head slightly to 
one side and remove the connector.

•

Cut through the cable ties securing the cables at 
the multi-function switch and the clutch switch.

•

Slide the housing off the handlebar.

•

Remove the mirrors, if necessary.

•

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

•

Install the rubber grip with Loctite 638 and sur-
face activator.

L

 Note:

The position of the handlebar fittings is indicated by 
a punch mark (arrow) on the handlebar.

X 

Tightening torques:

Clutch-lever fitting to handlebar ....................  9 Nm
Handlebar weight to handlebar......................  9 Nm
Oil tank to intake air silencer .......................... 9 Nm
Lid of electronic equipment box ..................... 4 Nm
Expansion tank to radiator.............................. 9 Nm

61 31 295 

Removing and installing clutch 

switch

–

Place motorcycle on its centre stand.

–

Remove seat.

–

Remove left, right and centre covers.

•

Release clutch switch on handlebar fitting.

•

Cut through the cable ties securing the cables at 
the handlebar and the multi-function switch.

•

Cut through the cable tie at the frame head.

•

Disconnect the expansion tank and pull it to one 
side.

•

Remove the fasteners securing the oil tank and 
allow the oil tank to dangle to one side on the 
hoses.

•

Remove the starter relay from the holder.

•

Remove the lid of the electronic equipment box.

•

Cut through the cable tie holding the wiring har-
ness at the electronic equipment box.

•

Disengage cover from the anchorage on main 
frame on left.

•

Separate plug connector at clutch switch (2).

•

Push the cover over the cylinder head slightly to 
one side and remove the connector.

•

Installation is the reverse of the removal proce-
dure.

X 

Tightening torques:

Oil tank to intake air silencer .......................... 9 Nm
Lid of electronic equipment box ..................... 4 Nm
Expansion tank to radiator ............................. 9 Nm
Clutch switch to handlebar fitting ................... 5 Nm

E610030

1

E320080

E610030

2

32.7

Removing and installing right 
handlebar fitting

–

Place motorcycle on its centre stand.

–

Remove seat.

–

Remove left, right and centre covers.

•

Cut the cable tie at the handlebar.

e

 Caution:

Refer to notes on the hazards involved in handling 
brake fluid.

•

Disconnect and seal brake hose (1).

•

Remove brake microswitch (2).

•

Release cover (6) and leave it dangling on the ca-
ble.

•

Remove throttle-cable roller (7) and disengage 
throttle-cable nipple (8).

•

Remove brake fitting.

•

Remove fastener for throttle cable (arrow) and 
pull out the throttle cable.

•

Remove handlebar weight (4).

•

Remove housing (3) together with twist-grip 
tube (5).

E320050

1

2

4

5

6

3

7

8

E320090

32.8

•

Disconnect the expansion tank and pull it to one 
side.

•

Remove the fasteners securing the oil tank and 
allow the oil tank to dangle to one side on the 
hoses.

•

Remove the starter relay from the holder.

•

Remove the lid of the electronic equipment box.

•

Cut through the cable tie holding the wiring har-
ness at the electronic equipment box.

•

Disengage cover from the anchorage on main 
frame on left.

•

Disconnect plug of right-hand multi-function 
switch (1).

•

Push the cover over the cylinder head slightly to 
one side and remove the connector.

•

Cut through the cable ties securing the cables at 
the multi-function switch and the clutch switch.

•

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

e

 Caution:

Top up brake fluid and bleed brake system.

L

 Note:

Before assembling, grease the handlebar end and 
nipple mount (arrow) lightly with Shell Retinax EP2. 

•

Position the twist-grip tube in the groove before 
mounting it on the handlebar.

L

 Note:

The position of the handlebar fittings is indicated by 
a punch mark (arrow) on the handlebar.

Throttle cable play............... approx. 1 mm (0.04 in)

X 

Tightening torques:

Handlebar fitting to handlebar ...................... 9 Nm
Handlebar weight to handlebar ...................... 9 Nm
Brake hose to brake master cylinder ............ 18 Nm
Oil tank to intake air silencer .......................... 9 Nm
Lid of electronic equipment box ..................... 4 Nm
Expansion tank to radiator ............................. 9 Nm

E610030

1

E320100

32.9

32 71 008 

Removing and installing 

handlebar

–

Remove left handlebar fitting.

–

Remove right handlebar fitting.

•

Remove impact pad (1).

•

Loosen clamping screws (2).

•

Remove handlebar (4) together with clamping 
blocks (3).

•

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

e

 

Caution:

Note the position of the clamping blocks. Wide hole 
spacing (arrow) to the front.

L

 Note:

The position of the handlebar is indicated by a 
punch mark (arrow) on the handlebar. 

•

Begin by tightening the front securing screws (as 
viewed in the forward direction of travel), then 
tighten the rear securing screws.

X 

Tightening torques:

Handlebar to fork bridge .............................. 21 Nm

E320110

1

2

3

4

E320120

E320130

32.10

32 72 330 

Removing and installing 

clutch cable

•

Disengage clutch cable (5) from release lever.

•

Pull cable out of holder (4).

•

Remove rubber grommet (1) from clutch lever.

•

Make sure that slots in adjusting screw, locknut 
and lever fitting (arrow) are in line.

•

Pull back cable shroud (2).

•

Pull the cable forward through the slot and disen-
gage nipple (3).

•

Pull the cable out to the rear.

•

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

E320140

1

3

2

E320150

5

4

E320160

32.11

e

 

Caution:

Make sure that the clutch cable is not kinked when 
installed.

•

After installing the cable, adjust clutch clearance 
by setting distance “B” by turning adjusting 
screw (2) on the clutch handlebar fitting.

•

Lock adjusting screw (2) with knurled nut (3).

Distance “B” ................ 1.0...2.0 mm (0.04...0.08 in)

E000200

B

3

2