BMW F 650 CS Betriebsanleitung

BMW Motorrad

After Sales

F 650 CS

Repair Manual

Issued by © BMW Motorrad

After Sales

UX-VS-2

permission.

Errors and omissions excepted; subject to technical amendment.

Printed in Germany 06/01

Introduction

This Repair Manual will help you to perform all the main maintenance and repair work correctly and effi-

ciently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and

practical knowledge acquired at the BMW Training Centre. It is a contribution toward achieving even higher

Service quality.

A new issue of this repair manual will be published if amendments or additions (supplements) are needed.

All information in both text and illustrations refers to motorcycles in standard condition or with genuine

BMW accessories installed, and not to motorcycles which have been modified in any way to depart from

the manufacturer’s specification.

•The Repair Manual is structured in the logical sequence of the work to be performed: Removal, Disas-

sembling, Repair, Assembly, Installation.

•The entire contents are divided into individual chapters, corresponding to the Construction Groups.

11 . 10

Chapter Page number within chapter

If a reference is needed to a different page or chapter, an arrow symbol is shown followed by the chapter

and page numbers, e. g. (a 12.5).

•Work to be performed during an Inspection is described in Group “00”. The various inspection routines

are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that

work can take place without interruption.

•Use of the BMW special tools needed for certain tasks is described in the work instructions.

If the need arises, repair instructions are also issued in the form of Service Information. This information is

of course incorporated into the next issue of the Repair Manual. We also recommend, as an additional

source of information, the Electronic Parts Catalogue (ETK), which contains clear and easy-to-follow illus-

trations.

If the work described here is restricted to a particular equipment specification, for instance if a specific op-

tional extra (OE) is fitted, this is stated in square brackets at the start of the item concerned, e.g. [Heated

handlebar grips].

Please refer to the following pages as well for a description of other symbols used and how to work with

them.

BMW Motorrad

After Sales

Issued by BMW Motorrad

After Sales

UX-VS-2

D-80788 München

permission.

Errors and omissions excepted; subject to technical amendment.

Produced in Germany

Use

Each chapter starts with the list of contents.

The list of contents is followed by the technical data table.

Key to symbols

In this Repair Manual for the F 650 CS model, the following symbols are used; their meanings are explained

in the table.

Special instructions aimed at improving the work procedures

LNote:

Special information on operating and inspecting the motorcycle as well as maintenance and adjustment

procedures.

eAttention:

Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply

with them could invalidate the warranty.

dWarning:

This symbol stands for precautions and measures which are essential in order to protect the rider or other

persons from possibly severe or fatal injury.

Contents

The titles of the tasks described in this chapter............. complete with page numbers

Activities

•Activities

•The bullet symbol indicates work steps that are described in greater detail under another headline

– Preceding activities

– A line indicates work steps that are described in greater detail under another headline or in another

chapter

The term "remove" means that:

the fastener (e.g. screw) must be backed off completely and removed

a component (e.g. injection rail) has to be removed to the extent that components behind it (e.g. throttle

valve rail) are rendered accessible

The term "loosen" or "slacken" means that:

the fastener (e.g. screw) must be backed off, but not removed

X Tightening torque:

Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.

BMW Motorrad

Maintenance schedule

F 650 CS

Customer Licence No. Mileage

Job Order No. Date Mechanic’s signature

BMW Inspection

at 1,000 km/600 miles

BMW Maintenance

Service every

10,000 km/6,000 miles

BMW Inspection

every 20,000 km/

12,000 miles

BMW

Annual Service

Read the fault code memory with the BMW MoDiTeC

Change the engine oil [engine only] while at regular operating temperature

and replace the oil filter element

Change the engine oil [engine and oil tank] while at regular operating temperature

and replace the oil filter element

if motorcycle is used only for short journeys or at outside temperatures below 0°C (32°F): every

3 months or at the latest after 3,000 km (1,800 miles)

Clean oil strainer in frame

once only at 10,000 km/6,000 miles

Check the coolant and restore to correct level if necessary

Grease rubber grommets for cover insert

Replace the coolant *)

every 2 years

Check valve clearances, adjust if necessary *)

Replace the spark plug

Drain the outlet hose from the air filter box

Replace intake air filter

If motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every

10,000 km (6,000 miles); check every 3,000 km (1,800 miles)

Replace fuel filter

every 40,000 km (24,000 miles)

Check clutch play, adjust if necessary

Examine brake pads and discs for wear, replace if necessary *)

Check front/rear circuit brake fluid

Check for operation of brake system and freedom from leaks; repair/replace if necessary *)

Renew brake fluid at least once a year

[ABS] Replace the primary front/rear brake master cylinder cup *)

every 40,000 km (24,000 miles)

Replace toothed belt

Check toothed belt and sprocket, replace if necessary *)

Check belt tension, adjust if necessary *)

Check battery acid level, add distilled water if necessary

Clean and grease the battery terminals, if necessary

Check steering head bearings and adjust *) or replace if necessary *)

Grease the side stand

Using a torque wrench, check that the screws and nuts of the engine mounts, manifold fas-

tener, the frame threaded fasteners, the rear-frame threaded fasteners, and the eccentric

clamp are tightened to specified torque

Final inspection with road safety and functional check:

– Clutch, gearshift

–Steering

– Front and rear brakes

– Side stand contact switch

– Condition of tyres and wheels, tyre pressures

– Lights and signalling equipment, indicator and warning lights, instruments

– Optional equipment

– Test ride, if necessary

*) Write up on separate invoice; Not part of standard service procedure

UX-VS-2, 07.2001 BMW recommends Castrol

BMW Motorrad

Pre-delivery check

F 650 CS

Customer Licence No.

Job Order No. Mechanic’s signature

BMW

Pre-delivery check

Check the shipping pallet for damage

Unpack the motorcycle

Inspect motorcycle for damage

Check complete specification delivery:

– tools

– handbooks and documents

–keys

– optional extras

Motorcycle complete

Battery:

–remove

– add battery acid

– charge

– grease the terminal posts

– re-install (mark date)

Check tyre pressure

Fuel the motorcycle

Safety/operating check as final inspection:

– Oil inspection

– Clutch, gearshift

– Steering

– Hand brakes and foot brakes

– Check lights and signalling equipment, warning and indicator lights, instruments, ABS

– Test ride, if necessary

Confirm delivery inspection in “Maintenance Booklet“

Final cleaning

Vehicle delivered on:

UX-VS-2, 07.2001 BMW recommends Castrol

BMW Motorrad

Service data

F 650 CS

Item Desired value Units / Specifications

Oil capacities

Engine (incl. filter) 0.5 (0.88/0.53)

Litres (Imp. pints/US quarts)

Specification: see latest

Service Information

Engine (incl. filter) and oil tank 2.5 (4.4/2.64)

Litres (Imp. pints/US quarts)

Specification: see latest

Service Information

Coolant 50%

50%

Water

Anti-freeze

protection to –25 °C

Cooling system 1.3 (2.29/1.37) Litres (Imp. pints/US quarts)

Reservoir 0.1 (0.18/0.11) Litres (Imp. pints/US quarts)

Brake Fluid DOT 4

Valve clearance measured cold (max. 35 °C/95 °F)

Inlet 0.03-0.11 (0.0012-0.004) mm (in)

Exhaust 0.25-0.33 (0.010-0.013) mm (in)

Spark plugs NGK DR8 EB

Electrode gap 0.6...0.7 (0.02...0.03) mm (in)

Engine idle speed 1,400 rpm

Clutch cable play

Cable at grip 1.0 - 2.0 (0.004 - 0.008) mm (in)

Tyre pressure tyres cold

Solo front/rear 2.2/2.5 (31.91/36.26) bar (psi)

fully loaded front/rear 2.2/2.5 (31.91/36.26) bar (psi)

Tightening torques

Engine oil drain plug 40 Nm

Oil filter cover 10 Nm

Drain plug, on-frame oil tank 21 Nm

Oil lines to frame 42 Nm

Oil strainer to frame 80 Nm

Water pump drain screw 10 Nm

Vent screw 12 Nm

Expansion tank to radiator 9Nm

Cylinder head cover 10 Nm

Spark plugs 20 Nm

Camshaft bearing cap 10 Nm

Chain guide 10 Nm (Loctite 243)

Fuel filter to stowage-compartment frame 9Nm

Intake air pipe to intake air silencer 9Nm

Suspension strut to angled lever 41 Nm

Eccentric clamp Initial tightening 10

Brake caliper to swinging arm 21 Nm

Struts to swinging arm 41 Nm

Swinging-fork pivot axle 100 Nm

Adjusting screw steering head bearing 25

Back off through

angle of rotation 60

Clamp screw for fork bridge steering head 23 Nm

Engine to frame at rear 50 Nm

Cylinder head to frame 41 Nm

Cylinder head to frame, locknut 100 Nm

Engine shell to engine 55 Nm

Engine shell to engine, bottom, with bottom truss 55 Nm

Engine shell to bracing tube 24 Nm

Rear frame to main frame 24 Nm (Loctite 2701)

Exhaust manifold to cylinder head 20 Nm

Silencer to exhaust manifold 55 Nm

UX-VS-2, 07.2001 BMW recommends Castrol

00 Tightening torques, Operating fluids

00 Pre-delivery check

00 Maintenance

11 Engine

12 Engine electrics

13 Fuel preparation and control

16 Fuel tank and lines

17 Radiator

18 Exhaust system

21 Clutch

23 Gearbox

27 Chain/belt drive

31 Front forks

>> Continuation

Contents

<< Back

Group / Chapter

32 Steering

33 Rear wheel drive

34 Brakes

36 Wheels and tyres

46 Frame

51 Equipment

61 General electrical equipment

62 Instruments

63 Lights

<< Back

>> Continuation

Group / Chapter

00.1

Contents Page

Tightening torques ......................................................................................................................3

11 Engine ...........................................................................................................................................3

12 Engine electrics ........................................................................................................................4

13 Fuel preparation and control ...............................................................................................5

16 Fuel tank and lines ...................................................................................................................5

17 Radiator ........................................................................................................................................5

18 Exhaust system .........................................................................................................................6

21 Clutch ............................................................................................................................................6

23 Transmission ..............................................................................................................................6

27 Chain/belt drive .........................................................................................................................7

31 Front fork ......................................................................................................................................7

32 Steering ........................................................................................................................................7

33 Rear wheel drive .......................................................................................................................8

34 Brakes ...........................................................................................................................................8

36 Wheels and tyres ......................................................................................................................9

46 Frame ..........................................................................................................................................10

51 Equipment ................................................................................................................................. 11

61 General electrical equipment ............................................................................................12

62 Instruments ...............................................................................................................................12

63 Lights ...........................................................................................................................................12

Table of operating fluids .........................................................................................................13

00 Tightening torques,

Operating fluids

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