f 650 gs repair manual,
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//-->Repair ManualF 650 GSBMW AG Motorcycle DivisionAfter SalesDownloaded fromwww.Manualslib.commanuals search engineIntroductionThis repair manual will help you to perform all the main maintenance and repair work correctly and efficient-ly. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and prac-tical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even higherService 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 genuineBMW accessories installed, and not to motorcycles which have been modified in any way to depart fromthe manufacturer’s specification.••The repair manual is structured in the logical sequence of the work to be performed: Removal, Disas-sembly, Repair, Assembly, Installation.The entire contents are divided into individual chapters, corresponding to the Construction Groups.11 . 10ChapterPage number within chapterAn arrow symbol followed by the chapter and page numbers is a reference to another chapter,e.g.Ób............................................See Group 46••Work to be performed during an Inspection is described in Group “00”. The various inspection routinesare numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so thatwork 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 isof course incorporated into the next issue of the repair manual. We also recommend, as an additionalsource of information, the Electronic Parts Catalogue (ETC), 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.[With heat-ed handlebar grips].Please refer to the following pages as well for a description of other symbols used and how to work with it.BMW AG Motorcycle DivisionAfter SalesPublished by:BMW AG Sparte MotorradAfter SalesUX-VS-2D - 80788 MünchenAll rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior writtenpermission.Errors and omissions excepted; subject to technical amendment.Produced in GermanyDownloaded fromwww.Manualslib.commanuals search engineUsageEach chapter starts with the list of contents.The list of contents is followed by the Technical Data table.Chapter 00 “Maintenance and general instructions” details the handover checklist and lists all tighteningtorques and operating fluids.Key to symbolsIn this Workshop Manual for the F 650 GS model, the following symbols are used; their meanings are ex-plained in the table.Special instructions aimed at improving the work proceduresLNote:Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenanceprocedures.eCaution:precautions specifically intended to prevent damage to the motorcycle. Failure to complyInstructions andwith them could invalidate the warranty.Warning:This symbol stands for precautions and measures which are essential in order to protect the rider or otherpersons from possibly severe or fatal injury.dContentsHeadlines for the work described in the chapter........................................... with the relevant page numberActivities••––ActivitiesThe bullet symbol means that work steps are described in greater detail under another headlinePreceding activitiesA line indicates work steps described in greater detail under another headline or in another chapterIf the term “release” or “remove” is used:the fastener (e.g. screw) must be slackened off and taken outora component (e.g. fuel rail) must be removed to the extent that other components which it conceals (e.g.throttle-valve rail) are accessibleIf the term “loosen” or “slacken” is used:the fastener (e.g. screw) must only be slackened off but not taken outTightening torques:Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.XDownloaded fromwww.Manualslib.commanuals search engineBMW AG Motorcycle DivisionMaintenance scheduleF 650 GS20,000 km (12,000 miles)10,000 km (6,000 miles)CustomerLicence plate no.BMW Annual Serviceevery2 yearsOrder No.Mechanic’s signatureRead the fault code memory with the BMW MoDiTeCChange the engine oil while at regular operating temperature; replace the oil filterelementif motorcycle is used only for short journeys or at outside temperatures below 0°C (32°F): every3 months or at the latest after 3,000 km (1,800 miles)Replace oil in telescopic forksCheck the coolant and restore to correct level if necessary*)Replace the coolant(every 2 years)Check valve clearances, adjust if necessaryReplace the spark plugDrain the outlet hose from the air filter boxReplace intake air filterIf motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every10,000 km (6,000 miles); check every 3,000 km (1,800 miles)Replace fuel filter (every 20,000 km/12,000 miles)Check clutch play, adjust if necessaryCheck wheel spoke tension and tighten if necessarymore frequently if motorcycle is ridden in severe off-road conditions20,000kmExamine brake pads and discs for wear, replace if necessary*)more frequently if motorcycle is ridden in severe off-road conditionsCheck brake fluid level at front and rear and top up if necessary*)Check for operation of brake system and freedom from leaks; repair/replace if necessary*)Replace the brake fluid at least once a yearReplace the primary front/rear brake master cylinder cup(every 40,000 km/24,000 miles on a motorcycle withABS)Check wheel bearings and replace if necessary*)Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion*)more frequently if motorcycle is ridden in severe off-road conditions40,000kmCheck chain tension and adjust if necessary*)Check battery acid level, add distilled water if necessarymore frequently if motorcycle is ridden in severe off-road conditionsClean and grease the battery terminals, if necessaryCheck steering head bearings and adjust*)or replace if necessary*)Grease the side and main standsGrease the brake pedalCheck bolts and nuts on engine mountings, frame connections, exhaust systemmountings, swinging fork pivot, suspension levers, brake pedal, main and sidestands and quick-release axles for tightnessFinal inspection with road safety and functional check:––––––(Clutch, gearshift)SteeringFront and rear brakesSide stand contact switchCondition of tyres and wheels, tyre pressuresLights and signalling equipment, indicator and warning lights, instrumentsTest ride, if necessary*)Associated work invoiced separately, see Flat rates brochure, Motorcycle ’98UX-VS-2, 10/99Printed in GermanyOrder No. 01 71 0 010 183Downloaded fromwww.Manualslib.commanuals search engineBMW Inspection every1,000 km (600 miles)BMW Inspection atBMW Service everyBMW AG Motorcycle DivisionPre-delivery CheckF 650 GSCustomerLicence plate no.BMWPre-delivery checkOrder No.Mechanic’s signatureCheck the shipping crate for damageMotorcycle:––––unpackinspect for damageinstall remaining itemscleanBattery:–––––removeadd acidchargegrease terminal postsfit (mark with fitting date)Check that the delivery is complete:––––ToolkitDocumentationMotorcycle keysOptional extrasRead the fault code memory with the BMW MoDiTeCCheck tyre pressuresFill fuel tankFinal inspection as functional check:–––––––Oil inspectionEngine idle speedClutch, gearshiftSteeringHand brakes and foot brakesCheck lights and signalling equipment, warning and indicator lights,instruments, ABSTest ride, if necessaryOrder No. 01 71 0 010 183UX-VS-2, 10/99Printed in GermanyDownloaded fromwww.Manualslib.commanuals search engine
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