BMW F 650 CS Repair Manual - PDF DOWNLOAD

BMW F 650 CS Repair Manual - PDF DOWNLOAD

FILE DETAILS:

BMW F 650 CS Repair Manual - PDF DOWNLOAD

Language : English
Pages : 352
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BMW F 650 CS Repair Manual - PDF DOWNLOAD

Repair Manual 1
Introduction 3
Use 4
Key to symbols 4
Contents 4
Activities 4
Maintenance schedule 5
Pre-delivery check 6
Service data 7
Contents 8
00 Tightening torques, Operating fluids 10
Tightening torques 12
Table of operating fluids 22
00 Pre-delivery check 24
General view of crated motorcycle 26
Checking the shipping crate for damage 27
In case of damage in Germany 27
In case of damage in importer markets 27
Unpack the motorcycle 27
Inspecting motorcycle for damage 28
Checking that delivery is complete 28
Installing remaining items on motorcycle 28
Filling and charging the battery 29
Removing the battery 29
Filling and charging the battery 30
Checking engine oil level 31
Checking tyre pressures 31
Final inspection and function check 32
Final cleaning 32
Handover 32
00 Maintenance 34
Key to maintenance intervals 38
Reading the fault code memory with the MoDiTeC 39
(Inspections I, II, III and IV) 39
Changing the engine oil [engine only] and oil filter element 39
(Inspection I) 39
Preparatory work 39
Draining engine oil 39
Replacing oil filter element 40
Filling with engine oil 40
Changing the engine oil [engine and oil tank] and oil filter element 41
(Inspections II, III and IV) 41
Preparatory work 41
Draining engine oil 41
Replacing oil filter element 42
Filling with engine oil 42
Cleaning oil strainer in frame 43
(Inspection II, once only) 43
Greasing rubber grommets for cover insert 43
(Inspections I, II, III and IV) 43
Checking coolant, topping up if necessary 44
(Inspections I, II and III) 44
Checking coolant 44
Adding coolant 44
Changing coolant 45
(Inspection IV, every 2 years) 45
Checking and adjusting valve clearances 47
(Inspections II and III) 47
Checking valve clearances 47
Preparatory work 47
Remove the intake air silencer together with the intake air pipe 47
Exposing the radiator 47
Exposing cylinder head 48
Turning crankshaft to TDC position 48
Checking valve clearance 49
Adjusting valve clearances 49
Installing cylinder head cover 50
Replacing spark plug 51
(Inspection III) 51
Emptying drain from intake air silencer 51
(Inspections I, II and III) 51
Replacing air cleaner element 52
(Inspection III) 52
Replacing fuel filter 53
(Inspection III, every 40,000 km/24,000 miles) 53
Checking clutch play, adjusting ifnecessary 54
(Inspections I, II and III) 54
Checking brake pads and discs for wear, replacing if necessary 54
(Inspections II and III) 54
Checking brake pads for wear 54
Brake pads, front brake 54
Brake pads, rear brake 54
Replacing brake pads 55
Brake pads, front brake 55
Brake pads, rear brake 56
Checking the brake discs 56
Checking brake fluid level at front and rear 57
(Inspections II and III) 57
Brake fluid level (front brake) 57
Checking brake fluid level (front brake) 57
Brake fluid level (rear brake) 57
Checking brake fluid level (rear brake) 57
Checking operation of brake system and checking for leaks; repairing/ replacing as necessary 58
(Inspection III) 58
Changing brake fluid and bleeding brake system 58
(Inspection IV) 58
Changing brake fluid and bleeding brake system (front brakes) 58
Changing brake fluid and bleeding brake system (rear brakes) 59
Replacing primary sealing boot, front brake master cylinder 61
(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) 61
Replacing primary sealing boot, rear brake master cylinder 62
(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) 62
Checking toothed belt pulley and sprocket, replacing if necessary 63
(Inspection III) 63
Replacing toothed belt 63
(Inspection III) 63
Checking belt tension, adjusting if necessary 65
(Inspections I, II and III) 65
Checking belt tension 65
Adjusting belt tension 66
Used belt, new belt 66
Checking battery acid level, adding distilled water if necessary 68
(Inspections II, III and IV) 68
Checking battery acid level 68
Adding distilled water 68
Cleaning and greasing battery terminals, if necessary 68
(Inspection IV) 68
Checking and adjusting steering head bearing play, replacing if necessary 69
(Inspections II and III) 69
Checking steering head bearing play 69
Adjusting steering head bearing play 69
Greasing side stand 70
(Inspections II and III) 70
Side stand 70
Checking specified torque of threaded fasteners with torque wrench 70
(Inspections I, II, III and IV) 70
Final inspection with road safety and functional check 71
(Inspections I, II, III and IV) 71
Road safety check 71
Tyre tread depth (recommended minimum value) 71
Tyre pressures (tyres cold) 71
Roadworthiness check 71
11 Engine 72
Technical Data 76
Cutaway view of engine 82
Engine oil circuit 83
Engine and oil-tank system 84
Valve gear 85
Valves, components 86
Oil pumps, components 87
Removing and installing oil pressure switch with engine installed 88
Removing and installing oil pressure switch 88
Cleaning oil tank and oil lines 88
Removing and installing cylinder head, engine installed 89
Preparatory work 89
Removing camshafts 91
Removing cylinder head 91
Removing cylinder, engine installed 93
Removing engine 94
Preparatory work 94
Removing engine 95
Transferring engine to assembly frame 96
Disassembling engine 97
Removing cylinder head 97
Removing camshafts 97
Checking camshaft for wear 98
Removing and installing timing-chain sprockets 98
Checking centrifugal decompressor lever 98
Disassembling and assembling the centrifugal decompressor 98
Removing cylinder head 99
Checking timing chain for wear 99
Disassembling and assembling cylinder head100
Removing valves100
Bore for bucket tappet100
Checking valve guide for wear101
Removing valve guide101
Installing valve guide102
Checking valve seat for wear102
Installing valve stem seal103
Checking valve for wear103
Installing valves104
Removing cylinder104
Checking cylinder104
Removing piston105
Disassembling piston105
Determining clearance of piston in cylinder105
Determining piston ring gaps106
Determining piston pin clearance106
Assembling pistons106
Removing ignition magneto106
Removing countershaft for starter107
Disassembling and assembling freewheel108
Disassembling freewheel108
Assembling freewheel108
Removing clutch109
Removing pressure plate109
Removing clutch plates109
Removing and installing oil pump110
Removing oil pump110
Inspecting oil pump110
Installing oil pump110
Removing double drive gear111
Removing crankshaft and balancing shaft111
Checking crankshaft for wear112
Removing compensating gear112
Removing and installing crankshaft gear112
Removing and installing gearbox mainshaft bearings113
Removing and installing gearbox countershaft bearings113
Removing and installing grooved ball bearings of balancing shaft114
Removing and installing main bearings114
Removal114
Installation115
Assembling engine116
Installing crankshaft and balancing shaft116
Shimming crankshaft116
Installing double drive gear117
Installing oil pump gears118
Installing clutch119
Installing clutch cage119
Installing driver119
Installing pressure plate120
Installing countershaft for starter motor120
Installing magnetic ignition trigger121
Installing piston122
Installing cylinder123
Installing cylinder head123
Installing camshaft and adjusting valves125
Installing engine127
Bleeding engine oil circuit128
12 Engine electrics129
Technical Data131
Ignition magneto133
Ignition magneto, components134
Removing ignition magneto135
Removing right engine block cover135
Removing and installing ignition trigger136
Removing and installing stator136
Installing ignition magneto136
Installing magnet rotor136
Removing and installing, disassembling starter motor137
Removing and installing starter motor137
Disassembling and assembling starter motor138
Replacing spark plug (a0042)139
Removing and installing coil139
13 Fuel preparation and control140
Technical Data142
Removing and installing BMS control unit144
Removing and installing intake air pipe145
Removing and installing air temperature sensor145
Replacing air filter element (a0043)145
Removing and installing intake air silencer146
Removing and installing intake air pipe146
Removing and installing injection nozzle147
Removing and installing throttle-valve actuator147
Replacing throttle-valve potentiometer148
Removing and installing throttle flap stub148
Removing and installing intake stub149
Checking fuel pressure149
Removing and installing fuel hoses150
Removing and installing feed and return lines150
Removing and installing line to fuel injector150
Removing and installing throttle cable (a3212)150
16 Fuel tank and lines151
Technical Data153
Removing and installing fuel tank155
Removing fuel tank155
Installing fuel tank157
Removing and installing fuel filler cap158
Removing and installing roll- over valve158
Replacing fuel filter (a0044)158
Removing and installing fuel pump159
Removing and installing fuel- evaporation control valve160
[USA version]160
Removing and installing activated charcoal filter161
[USA version]161
17 Radiator162
Technical Data164
Coolant circuit166
Thermostat, components167
Removing and installing coolant pump168
Removing coolant pump168
Installing coolant pump169
Adding coolant170
Removing and installing coolant-temperature sensor171
Checking cooling system for leaks171
Removing and installing coolant hoses172
Replacing coolant hose (cylinder head/frame - frame/radiator)172
Replacing coolant hose (radiator/water pump)172
Replacing coolant hose (filler bowl/expansion tank)172
Changing coolant (a0036)172
Removing and installing fan173
Removing and installing radiator173
Removing and installing thermostat174
18 Exhaust system175
Technical Data177
Removing and installing exhaust system179
Removing and installing silencer (muffler)179
Removing and installing exhaust elbow and oxygen sensor181
Removing exhaust elbow and oxygen sensor181
Installing exhaust elbow and oxygen sensor181
Replacing guard for silencer182
21 Clutch183
Technical Data185
Clutch, components187
Removing and installing clutch188
Removing clutch188
Removing pressure plate188
Disassembling and reassembling pressure plate188
Removing clutch plates, driver and clutch cage189
Installing clutch cage190
Installing driver190
Installing pressure plate190
Check clutch discs for wear190
Removing and installing release shaft191
Installing clutch192
23 Gearbox193
Technical Data195
Gearbox shafts, components197
Gear shift pedal, components198
Replacing shaft sealing rings with engine installed199
Replacing sealing ring of selector shaft199
Replacing shaft sealing ring of belt sprocket200
Removing and installing gearbox201
Removing selector shaft with pawl and index lever201
Removing selector forks201
Removing selector drum201
Removing, disassembling and reassembling gearbox shafts202
Removing gearbox shafts202
Disassembling and reassembling mainshaft202
Checking mainshaft for wear203
Disassembling and reassembling countershaft204
Checking countershaft for wear205
Replacing gearbox mainshaft bearings205
Replacing gearbox countershaft bearings206
Installing gearbox shafts206
Installing selector shaft207
Installing selector forks207
Installing selector drum208
27 Chain/belt drive209
Technical Data211
Removing and installing belt, belt drive gear and belt sprocket213
Removing and installing belt (a0054)213
Removing and installing belt sprocket (a3313)213
Removing and installing belt sprocket213
Adjust belt tension (a0056)213
31 Front forks214
Technical Data216
Telescopic fork, components218
Removing and installing telescopic fork219
Removing telescopic fork219
Installing telescopic fork220
Disassembling telescopic fork222
Removing fixed tube222
Measuring telescopic fork224
Checking lower fork bridge224
Checking parallel alignment of fixed tubes225
Checking fixed tube runout225
Assembling telescopic fork226
Assembling fixed tube226
Complete assembly of telescopic fork229
Removing and installing steering head bearing230
Upper steering head bearing230
Lower steering head bearing230
32 Steering231
Technical Data233
Removing and installing left and right handlebar fittings235
Removing and installing left handlebar fitting235
Removing and installing clutch switch236
Removing and installing right handlebar fitting237
Removing and installing handlebar239
Removing and installing clutch cable240
Removing and installing throttle cable242
Removing and installing left and right handlebar levers243
Removing and installing left handlebar lever243
Removing and installing right handlebar lever243
Checking and adjusting steering head bearing play, replacing if necessary (a 0060)243
33 Rear wheel drive244
Technical Data246
Removing and installing suspension strut248
Removing and installing rear swinging arm249
Removing and installing needle roller races in rear swinging arm251
Removing needle roller races251
Installing needle roller races251
Removing and installing needle bearings in rear swinging arm252
Removing needle roller bearing252
Installing needle roller bearing253
Removing and installing reaction link253
Removing and installing angled lever254
Removing and installing needle roller bearings and needle roller races in angled lever254
Removing needle roller bearings and needle roller races254
Installing needle roller bearings and needle roller races255
Removing and installing drive damper256
Removing drive damper256
Removing pulley256
Disassembling drive damper256
Assembling drive damper257
Installing pulley257
Installing drive damper257
Measuring runout of belt pulley258
Removing and installing eccentric with drive shaft259
Separating eccentric from drive shaft259
Removing and installing floating bearing of eccentric259
Removing and installing fixed bearing of eccentric260
Pressing eccentric onto drive shaft260
34 Brakes261
Technical Data263
Removing and installing front brake caliper265
Removing and installing front brake pads (a0046)265
Removing and installing front brake pistons266
Removing and installing front brake disc267
Checking brake disc for wear (a0045)267
Checking front brake disc for lateral runout267
Removing and installing rear brake caliper268
Removing and installing rear brake pads (a0046)268
Removing and installing rear brake pistons269
Removing and installing rear brake disc270
Checking brake disc for wear (a0047)270
Checking rear brake disc for lateral runout270
Replacing primary sealing boot, front brake master cylinder (a0052)270
Removing and installing front brake master cylinder271
Removing and installing handbrake lever (a3213)271
Replacing primary sealing boot, rear brake master cylinder (a0053)271
Removing and installing rear brake master cylinder272
Removing and installing brake pedal273
Checking blow-by clearance at piston thrust rod, adjusting if necessary274
Checking blow-by clearance at piston rod274
Adjusting play at piston rod274
Removing and installing front ABS sensor275
Removing and installing front ABS sensor ring275
Removing and installing rear ABS sensor276
Removing and installing ABS control unit277
Removing and installing front brake lines/hoses (with ABS)278
Removing and installing brake lines278
Removing and installing front brake hoses279
Removing and installing rear brake lines/hoses (with ABS)279
Removing and installing brake lines279
Removing and installing brake hose280
Checking front ABS sensor ring for runout283
36 Wheels and tyres284
Technical Data286
Removing and installing front wheel288
Removing front wheel288
Installing front wheel288
Removing and installing front wheel bearing289
Removing left-hand wheel bearing289
Removing right-hand wheel bearing289
Installing wheel bearings290
Removing and installing rear wheel290
Checking front and rear wheel rims291
Checking rims291
Static balancing of front/rear wheel292
46 Frame293
Technical Data295
Overview of trim panels297
Removing and installing trim panels298
Removing and installing left and right covers298
Removing and installing rear cover298
Removing and installing front cover298
Removing and installing left and right covers299
Removing and installing windscreen and windscreen holder300
Removing and installing headlight surround300
Removing and installing instrument cover300
Removing and installing left/right connector covers301
Removing and installing left connector cover301
Removing and installing right connector cover301
Removing and installing fairing bracket302
Removing and installing front mudguard303
Removing and installing rear mudguard303
Removing and installing number- plate carrier304
Removing and installing spray guard304
Removing and installing number-plate carrier304
Removing and installing left/right rear trim panel305
Removing and installing luggage rack305
Removing and installing stowage- compartment frame306
Removing and installing oil-tank trim panels306
Raising, removing and installing rear frame307
Raising rear frame307
Removing and installing rear frame308
Removing frame310
Removing and installing left and right footrests313
Removing and installing rear footrest313
Removing and installing side stand truss314
Removing and installing side stand314
Measuring wheel track offset315
Measurement record, wheel track offset316
Key to measurement result:316
Checking frame with gauge317
Front wheel316
Rear wheel316
Example316
51 Equipment319
Technical Data321
Removing and installing ignition switch/steering lock323
Removing and installing lock barrel324
Removing and installing lock for rear stowage compartment325
Removing and installing lock barrel for fuel tank filler cap325
Replacing mirrors326
61 General electrical equipment327
Technical Data329
Wiring harness331
View from left331
View from right332
Component positions in electronic equipment box333
Relay positions in electronic equipment box333
Connectors, electronics box333
Removing and installing battery (a0020)333
Removing and installing battery carrier (a3417)333
Replacing fuses333
Motorcycle fuses333
Fuses333
Removing and installing holder for BMS control unit334
Removing and installing coolant-temperature sensor (a1710)334
Removing and installing side stand switch334
Removing and installing rear-brake switch for brake light335
Removing and installing front-brake switch for brake light335
Removing and installing horn336
Removing and installing neutral-indicator switch336
Removing and installing front/rear ABS sensors (a3415)/(a3416)336
Removing and installing voltage regulator337
Removing and installing switch for hazard warning flashers337
62 Instruments338
Technical Data340
Telltale/warning lights342
Removing and installing instrument panel343
Replacing telltale/warning lights343
Disassembling and assembling instrument cluster343
Removing and installing wiring harness344
63 Lights345
Technical Data347
Removing and installing headlight349
Removing and installing rear light350
Removing and installing number- plate light350
Replacing bulbs351
Bulb for low-beam headlight/ high-beam headlight351
Bulb, parking light351
Flashing turn indicator352
Rear lights352
Bulb for number-plate light352
Checking and adjusting headlight beam throw352
Vertical adjustment352
Lateral adjustment352

DESCRIPTION:

BMW F 650 CS Repair Manual - PDF DOWNLOAD

IntroductionThis Repair Manual is designed to guide you through the correct and efficient performance of all main maintenance and repair tasks. By regularly consulting this manual, workshop personnel will gain valuable insight, complementing both theoretical knowledge and practical skills learned at the BMW Training Centre. The manual aims to contribute to enhancing service quality.A new issue of this repair manual will be released if amendments or supplements are necessary. All information, including both text and illustrations, pertains to motorcycles in their standard condition or equipped with genuine BMW accessories. It does not apply to motorcycles that have been modified from the manufacturer's specifications.Manual Structure

• The Repair Manual is structured to follow the logical order of tasks to be performed: Removal, Disassembling, Repair, Assembly, Installation.
• The content is divided into chapters, each corresponding to a specific Construction Group.
• Each chapter lists page numbers for easy navigation. If a reference to another chapter or page is needed, an arrow symbol will indicate the respective chapter and page number, e.g., (12.5).

Inspection Work

• Work to be carried out during an inspection is described in Group "00".
• Various inspection routines are numbered I, II, III, and IV. This numbering system is used consistently throughout the manual to ensure tasks can be completed without interruption.

Special Tools and Service Information

• Specific instructions for the use of BMW special tools required for certain tasks are included in the manual.
• Repair instructions may also be provided as Service Information, which will be integrated into the subsequent release of the Repair Manual.
• As an additional reference, we recommend the Electronic Parts Catalogue (ETK). This catalogue provides clear, easy-to-understand illustrations and is a useful resource for parts and components.

G.B 21/03/25