BMW F650CS Repair Manual sample

Repair ManualF 650 CS BMW Motorrad After Sales Not to be reprinted. Printed in Germany 06/01 . translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted. subject to technical amendment.Issued by © BMW Motorrad After Sales UX-VS-2 All rights reserved. Not to be reprinted.Introduction This Repair Manual will help you to perform all the main maintenance and repair work correctly and efficiently. e. subject to technical amendment. Use of the BMW special tools needed for certain tasks is described in the work instructions. repair instructions are also issued in the form of Service Information. so that work can take place without interruption. Disassembling.g. the Electronic Parts Catalogue (ETK). It is a contribution toward achieving even higher Service quality. BMW Motorrad After Sales Issued by BMW Motorrad After Sales UX-VS-2 D-80788 München All rights reserved. If the need arises. A new issue of this repair manual will be published if amendments or additions (supplements) are needed. [Heated handlebar grips]. and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification. Please refer to the following pages as well for a description of other symbols used and how to work with them.5). All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed. This numbering is repeated in the work descriptions which follow. This information is of course incorporated into the next issue of the Repair Manual. Installation. Assembly. which contains clear and easy-to-follow illustrations. for instance if a specific optional extra (OE) is fitted. g. Errors and omissions excepted. this is stated in square brackets at the start of the item concerned. (a 12. The entire contents are divided into individual chapters. Repair. an arrow symbol is shown followed by the chapter and page numbers. We also recommend. corresponding to the Construction Groups. 11 . If the work described here is restricted to a particular equipment specification. 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. 10 Chapter Page number within chapter If a reference is needed to a different page or chapter. • • The Repair Manual is structured in the logical sequence of the work to be performed: Removal. as an additional source of information. The various inspection routines are numbered I. II. translated or duplicated either wholly or in part without prior written permission. III and IV. Produced in Germany . e. • • Work to be performed during an Inspection is described in Group “00”. screw) must be backed off. X .. the following symbols are used....g. Special instructions aimed at improving the work procedures Note: Special information on operating and inspecting the motorcycle as well as maintenance and adjustment procedures..g. screw) must be backed off completely and removed or a component (e.Use Each chapter starts with the list of contents. throttle valve rail) are rendered accessible The term "loosen" or "slacken" means that: the fastener (e.... 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.. The list of contents is followed by the technical data table.g. their meanings are explained in the table. L Attention: Instructions and precautions specifically intended to prevent damage to the motorcycle. injection rail) has to be removed to the extent that components behind it (e. Failure to comply with them could invalidate the warranty.. Contents The titles of the tasks described in this chapter.g. e d Warning: 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. but not removed Tightening torque: Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards... Key to symbols In this Repair Manual for the F 650 CS model. check that the screws and nuts of the engine mounts.000 miles).000 miles Customer Licence No.000 miles) *) *) *) Replace toothed belt Check toothed belt and sprocket.000 km (6. gearshift – Steering – Front and rear brakes – Side stand contact switch – Condition of tyres and wheels. adjust if necessary Examine brake pads and discs for wear. indicator and warning lights. replace if necessary Check belt tension. the frame threaded fasteners.000 km/ 12. adjust if necessary *) *) Check battery acid level. Not part of standard service procedure BMW recommends Castrol *) or replace if necessary *) UX-VS-2. replace if necessary Check front/rear circuit brake fluid Check for operation of brake system and freedom from leaks. 07.000 miles BMW Inspection at 1. Mileage Job Order No.BMW Motorrad Maintenance schedule F 650 CS BMW Maintenance Service every 10. instruments – Optional equipment – Test ride.000 km (1. 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. and the eccentric clamp are tightened to specified torque Final inspection with road safety and functional check: – Clutch. Date Mechanic’s signature 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. the rear-frame threaded fasteners.800 miles) Clean oil strainer in frame once only at 10.000 km/600 miles BMW Inspection every 20.000 km/6.800 miles) Replace fuel filter every 40. 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.000 km/6.000 km (24.000 km (1. clean or replace the intake air filter every 10. if necessary Check steering head bearings and adjust Grease the side stand Using a torque wrench. tyre pressures – Lights and signalling equipment. if necessary *) Write up on separate invoice.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. check every 3. manifold fastener.2001 BMW Annual Service .000 miles) Check clutch play. add distilled water if necessary Clean and grease the battery terminals. BMW Pre-delivery check Job Order No. warning and indicator lights. if necessary Confirm delivery inspection in “Maintenance Booklet“ Final cleaning Vehicle delivered on: UX-VS-2. ABS – Test ride. Mechanic’s signature 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. 07. instruments. gearshift – Steering – Hand brakes and foot brakes – Check lights and signalling equipment.2001 BMW recommends Castrol .BMW Motorrad Pre-delivery check F 650 CS Customer Licence No. 88/0.0.26) 2.010-0. pints/US quarts) DOT 4 measured cold (max.02.5 (31..1 (0.3 (2.0 (0. on-frame oil tank Oil lines to frame Oil strainer to frame Water pump drain screw Vent screw Expansion tank to radiator Cylinder head cover Spark plugs Camshaft bearing cap Chain guide Fuel filter to stowage-compartment frame Intake air pipe to intake air silencer Suspension strut to angled lever Eccentric clamp Brake caliper to swinging arm Struts to swinging arm Swinging-fork pivot axle Adjusting screw steering head bearing 40 10 21 42 80 10 12 9 10 20 10 10 9 9 41 Initial tightening 10 21 21 41 100 25 Back off through angle of rotation 60 23 50 41 100 55 55 24 24 20 55 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm (Loctite 243) Nm Nm Nm Nm Nm Nm Nm Nm Nm ° Nm Nm Nm Nm Nm Nm Nm Nm (Loctite 2701) Nm Nm BMW recommends Castrol 2.53) Specification: see latest Service Information Desired value Units / Specifications Litres (Imp.25-0.11 (0.2/2.2.400 1. pints/US quarts) Litres (Imp. locknut Engine shell to engine Engine shell to engine.4/2.5 (0.5 (31.0. filter) 0.004) 0.0 . 07. pints/US quarts) Engine (incl. with bottom truss Engine shell to bracing tube Rear frame to main frame Exhaust manifold to cylinder head Silencer to exhaust manifold UX-VS-2. filter) and oil tank Coolant Cooling system Reservoir Brake Fluid Valve clearance Inlet Exhaust Spark plugs Electrode gap Engine idle speed Clutch cable play Cable at grip Tyre pressure Solo front/rear fully loaded front/rear Tightening torques Engine oil drain plug Oil filter cover Drain plug.0012-0.5 (4. pints/US quarts) Engine (incl.11) Specification: see latest Service Information Water Anti-freeze protection to –25 °C Litres (Imp.91/36.7 (0.91/36.03) 1... bottom.37) 0.008) 2.2001 .03-0..6.2/2.013) NGK DR8 EB 0.0.26) mm (in) mm (in) mm (in) rpm mm (in) tyres cold bar (psi) bar (psi) Clamp screw for fork bridge steering head Engine to frame at rear Cylinder head to frame Cylinder head to frame.64) 50% 50% 1.BMW Motorrad Service data F 650 CS Item Oil capacities Litres (Imp.004 . 35 °C/95 °F) 0.33 (0.18/0.29/1. Contents << Back Group / Chapter 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 M B W 17 Radiator 18 Exhaust system 21 Clutch 23 Gearbox 27 Chain/belt drive 31 Front forks >> Continuation . >> Continuation 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 . ....3 11 Engine ..........................................................................................................................................................................................3 12 Engine electrics ............................................................................................................................................................................................................................................................................................................... Operating fluids Contents Page Tightening torques .........................................................................................................................................................13 00..................................................................................................................................7 33 Rear wheel drive .........................8 36 Wheels and tyres ...................................................................................................................................................................................................................................................................7 31 Front fork ................8 34 Brakes ...................................................................................................6 27 Chain/belt drive ...........6 21 Clutch .................................................................................................9 46 Frame .................... 11 61 General electrical equipment .........................................7 32 Steering .................................................6 23 Transmission ...........................................................................................................................................................4 13 Fuel preparation and control .............................................................................................................5 17 Radiator ...............12 62 Instruments ..................................................................................................................................................................................................................................................................................................................................12 Table of operating fluids .......................................12 63 Lights ..............................5 16 Fuel tank and lines ...........................................................................................................................................................................................................................................................................1 .........................................................................5 18 Exhaust system ................................................................................... 10 51 Equipment ........................................................................................00 00 Tightening torques.................................... 00.2 . 3 .00 Tightening torques Model Connection 11 Engine Freewheel housing and freewheel Engine block Double drive gear on crankshaft Driver to countershaft Pressure plate Magnetic hub to crankshaft Chainwheel to main shaft Signal transmitter Ignition cover Cylinder base Fastener for chain tensioner Oil circuit Oil filter cover Oil pressure switch Strainer cover to housing half Drain plug. on-frame oil tank Engine oil drain plug Oil supply/oil return lines to engine Oil pump cover Oil pressure valve Oil retaining valve Cylinder head Collar nuts for cylinder head Collar screws for cylinder head Machine screws (chaincase) Camshaft bearing cap Chain sprockets to camshafts Chain guide to camshaft bearing cap Nm Nm Nm Nm Nm Nm 60 33 10 10 60 threads oiled 10 (clean thread + Loctite 243) Nm Nm Nm Nm Nm Nm Nm Nm Nm 10 12 (clean thread + Loctite 243) 8 21 40 42 6 (clean thread + Loctite 243) 24 24 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm 35 (clean thread + Loctite 648) 10 180 (clean thread + Loctite 243) 140 (clean thread + Loctite 243) 10 180 (clean thread + Loctite 243) 140 (clean thread + Loctite 243) 8 10 10 40 F 650 CS 00. left/right Starter to clutch cover Positive lead to starter motor Positive contact to starter motor Necked-down bolt.Model Connection 11 Engine Cylinder head cover Machine screw (hole for locating screw) Model Connection 12 Engine electrics Spark plug Magnetic hub to crankshaft Signal transmitter Engine block cover. starter housing Cable cover to engine block Cable holder to ignition cover Stator to ignition cover Ignition coil bracket to cylinder head cover Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm F 650 CS 10 25 F 650 CS 20 180 (clean thread + Loctite 243) 8 10 10 9 4 6 9 8 10 (clean thread + Loctite 243) 9 00.4 . 5 .Model Connection 13 Fuel preparation and control Air intake pipe to cylinder head Fuel filter to stowage-compartment frame Injector holder to throttle valve Fuel hose to injection nozzle holder Fuel return hose to pump unit Intake air pipe to intake air silencer Throttle flap to intake stub Throttle-valve potentiometer to throttle valve stub Throttle valve actuator to throttle-valve stub Model Connection 16 Fuel tank and lines Fuel tank to rear frame (M 8 stud) Fuel filler cap to fuel tank Roll-over valve to fuel tank Clamps. activated charcoal filter bracket Fuel pump to fuel tank Model Connection 17 Radiator Expansion tank to radiator Radiator to main frame at top Fan to fan shroud Water pump drain screw Coolant hoses to radiator/engine/frame Breather hose to expansion tank Left engine block cover to engine block Water pump cover Temperature sensor in cylinder head Vent screw Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm F 650 CS 21 9 5 3 3 9 1 3 5 (clean thread + Loctite 243) F 650 CS 21 3 2 9 30 F 650 CS 9 9 3 10 3 2 10 10 15 12 00. Model Connection 18 Exhaust system Oxygen sensor to exhaust elbow Exhaust manifold to cylinder head Silencer to exhaust manifold (Torca clamp) Silencer to rear frame Guards to silencer Model Connection 21 Clutch Driver Pressure plate Engine block cover.6 . left Release lever to release shaft Model Connection 23 Transmission Gear pedal to frame Shaft lever to selector shaft Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm F 650 CS 45 20 55 41 5 F 650 CS 140 (clean thread + Loctite 243) 10 10 10 F 650 CS 21 9 00.