BMW F 650 GS DAKAR - Operating instructions

BMW Motorrad
After Sales
F 650 GS/GS Dakar
Repair Manual

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 towards achieving even high-
er 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
Chap. 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
illustrations.
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. [Dakar].
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
Published by BMW Motorrad
After Sales
UX-VS-2
D-80788 München
All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written
permission.
Errors and omissions excepted; subject to technical amendment.
Produced in Germany

Structure
Each chapter starts with the list of contents.
The list of contents is followed by the technical data table.
Chapter 00 “Maintenance and general instructions”lists all tightening torques and the operating fluids.
Key to symbols
In this Repair Manual for the F 650 GS/GS Dakar, the following symbols are used; their meanings are ex-
plained in the tables.
Special instructions aimed at improving the work procedures
LNote:
Special information on operating and inspecting the motorcycle as well as maintenance and adjustment
procedures.
eImportant:
Instructions and precautions specifically intended to prevent damage to the motorcycle. Disregarding them
may render the warranty invalid.
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
Headlines for the work described in the chapter............. with the relevant page number
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 slackened off and taken out
or
a component (e.g. injection rail) has to be removed to the extent that components behind it (e.g. throttle
valve) are rendered accessible
The term “loosen”means that:
the fastener (e.g. screw) must be backed off, but not removed
X Tightening torques:
Values are stated if they differ from the DIN EN 24 014 or DIN 912 ISO industrial standards.

Order No. 01 71 0 021 836 UX-VS-2, 02/00 Printed in Germany
Customer Licence plate no.
Order No. Mechanic’s signature
BMW Inspection at 1,000 km (600 miles) BMW Service 10,0 00 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 while at regular operating temperature; 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)
Renew oil in telescopic forks [Dakar version only]
Check the coolant and restore to correct level if necessary *)
Replace the coolant
(every 2 years) every
2years
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 20,000 km/12,000 miles) 20,000
km
Check clutch play, adjust if necessary
Check wheel spoke tension and tighten if necessary
more frequently if motorcycle is ridden in severe off-road conditions
Examine brake pads and discs for wear, replace if necessary *)
more frequently if motorcycle is ridden in severe off-road conditions
Check 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 year
Replace the primary front/rear brake master cylinder cup
(every 40,000 km/24,000 miles on a motorcycle with ABS)40,000
km
Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion *)
more frequently if motorcycle is ridden in severe off-road conditions
Check chain tension and adjust if necessary *)
Check battery acid level, add distilled water if necessary
more frequently if motorcycle is ridden in severe off-road conditions
Clean and grease the battery terminals, if necessary
Check steering head bearings and adjust *)or replace if necessary *)
Grease the side and main stands
Grease the brake pedal
Check bolts and nuts on engine mountings, frame connections, exhaust system
mountings, pivot lever [Dakar version only], main and side stands for tightness
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
–Test ride, if necessary
*)Associated work invoiced separately, see Flat rates brochure, Motorcycle 2000
BMW Motorcycle
Maintenance schedule
F 650 GS/F 650 GS Dakar

Order No. 01 71 0 021 836 UX-VS-2, 02/00 Printed in Germany
Customer Licence plate no.
Order No. Mechanic’s signature
BMW
Pre-delivery check
Check the shipping crate for damage
Motorcycle:
–unpack
–inspect for damage
–install remaining items
–clean
Battery:
–remove
–add acid
–charge
–grease terminal posts
–fit (mark with fitting date)
Check that the delivery is complete:
–Toolkit
–Documentation
–Motorcycle keys
–Optional extras
Read the fault code memory with the BMW MoDiTeC
Check tyre pressures
Fill fuel tank
Final inspection as functional check:
–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
BMW Motorcycle
Pre-delivery Check
F 650 GS/F 650 GS Dakar

Order No. 01 71 0 021 845 UX-VS-2, 02/00 Printed in Germany
Item Rated value Unit of
measurement/
specification
Oil capacities
Engine (with filter)
Telescopic fork –for each post [Dakar version only]
2.3 (4.05/2.43)
0.55 (0.97/0.58)
Litres (Imp. pints/US quarts)
Specification: see current
Service Information
Litres (Imp. pints/US quarts)
BMW telescopic fork oil
Coolant
Cooling system (entire)
Expansion tank
1.3 (2.29/1.37)
0.1 (0.18/0.11)
Litres (Imp. pints/US quarts)
Litres (Imp. pints/US quarts)
Composition:
Water: 50%
Antifreeze: 50%
Antifreeze protection
to –25 °C ( –13 °F)
Brake fluid DOT 4
Valve clearances
Measured cold (max. 35 °C/95 °F)
Inlet: 0.10-0.15
(0.004-0.006)
Exhaust: 0.25-0.30
(0.010-0.012)
mm (in)
mm (in)
Spark plugs
Electrode gap 0.6...0.7 (0.02...0.03)
NGK D8 EA
mm (in)
Idle speed 1350 +100 rpm
Clutch cable play
Hand lever cable 1.0 - 2.0
(0.004 - 0.008)
mm (in)
Tyre pressure (on cold tyres)
solo
when fully loaded
front/rear
1.9/2.1 (27/30)
2.1/2.3 (30/33)
bar (psi)
bar (psi)
Tightening torques:
Engine oil drain plug
Engine water drain plug
Oil tank drain plug
Oil filter cap
Valve cap
Camshaft bracket
Spark plug
Telescopic fork oil drain plug
Round nut, steering bearing
Steering bearing locking tube
Flanged nut on locking tube
Fork stabilizer clamping screws
Brake caliper at fork slider tube
Deflection lever/frame
Deflection lever/spring strut
Deflection lever/tension strut
40
10
21
10
10
10
20
6
25
65
65
21
41
50
47
71
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
BMW Motorcycle
Service data
F 650 GS/F 650 GS Dakar

B
W
M
00 Tightening torques Operating fluids
00 Pre-delivery check
00 Maintenance
11 Motor
12 Engine electrics
13 Fuel preparation and control
16 Fuel tank and lines
17 Radiator
18 Exhaust system
21 Clutch
23 Gearbox
27 Drive chain
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
00
Tightening torques .......................................................................................................................3
11 Engine ...........................................................................................................................................3
12 Engine electrics ........................................................................................................................4
13 Fuel preparation and control ...............................................................................................4
16 Fuel tank and lines ...................................................................................................................5
17 Radiator ........................................................................................................................................5
18 Exhaust system .........................................................................................................................5
21 Clutch ............................................................................................................................................6
23 Transmission ..............................................................................................................................6
27 Drive chain ..................................................................................................................................6
31 Front forks ...................................................................................................................................6
32 Steering ........................................................................................................................................7
33 Rear wheel drive .......................................................................................................................7
34 Brakes ...........................................................................................................................................7
46 Frame ............................................................................................................................................8
51 Equipment .................................................................................................................................10
61 General electrical equipment ............................................................................................10
62 Instruments ...............................................................................................................................10
63 Lights ...........................................................................................................................................10
Table of operating fluids ......................................................................................................... 11
00 Tightening torques
Operating fluids

00.2
Contents Page

00.3
00
Tightening torques
Model F 650 GS / GS Dakar
Connection
11 Engine
Freewheel housing and freewheel Nm 35
(clean thread + Loctite 648)
Engine block Nm 10
Double drive gear on crankshaft Nm 180
(clean thread + Loctite 243)
Driver Nm 140
(clean thread + Loctite 243)
Pressure plate Nm 10
Magnet hub Nm 180
(clean thread + Loctite 243)
Signal transmitter Nm 8
Ignition cover Nm 10
Cylinder base Nm 10
Spark plug Nm 20
Fastener for chain tensioner Nm 40
Oil circuit
Oil tank to intake air silencer Nm 9
Oil filter cover Nm 10
Oil pressure switch Nm 12
(clean thread + Loctite 243)
Oil tank drain plug Nm 21
Engine oil drain plug Nm 40
Oil supply/oil return lines to engine Nm 42
(with copper seals)
Oil pump cover Nm 6
(clean thread + Loctite 243)
Oil pressure valve Nm 24
Oil check valve Nm 24
Cylinder head
Collar nuts for cylinder head Nm 60
Collar screws for cylinder head Nm 33
Machine screws (chaincase) Nm 10
Camshaft mount Nm 10
Chain sprockets to camshafts Nm 60
threads oiled
Chain guide to camshaft mount Nm 10
(clean thread + Loctite 243)

00.4
Cylinder head cover Nm 10
Machine screw (hole for locating pin) Nm 25
Cylinder head to frame Nm 41
Cylinder head to frame, adjusting sleeve Nm zero play, max. 5
Cylinder head to frame, locknut Nm 100
Model F 650 GS / GS Dakar
Connection
12 Engine electrics
Magnet hub Nm 180
(clean thread + Loctite 243)
Signal transmitter Nm 8
Engine block cover, left/right Nm 10
Starter to clutch cover Nm 10
Necked-down bolts, starter housing Nm 6
Cable cover to engine block Nm 4
Ignition coil and holder Nm 9
Model F 650 GS / GS Dakar
Connection
13 Fuel preparation and control
Air intake pipe to cylinder head Nm 25
Fuel filter to frame Nm 9
Injector holder to throttle valve Nm 5
Connecting flange, air filter box to battery
carrier Nm 5
Intake air silencer to retainer Nm 9
Oil tank to intake air silencer Nm 9
Throttle-valve potentiometer to
throttle valve stub Nm 3
Throttle lifter to throttle valve stub Nm 5
(clean thread + Loctite 243)
Model F 650 GS / GS Dakar
Connection
11 Engine

00.5
Model F 650 GS / GS Dakar
Connection
16 Fuel tank and lines
Fuel tank to rear frame (M 8 stud) Nm 21
Fuel filler cap to fuel tank Nm 3
Roll-over valve to fuel tank Nm 2
Bracket, activated charcoal filter to fuel tank Nm 3
Fuel pump to fuel tank Nm 36
Model F 650 GS / GS Dakar
Connection
17 Radiator
Air duct to frame trussing Nm 3
Expansion tank to radiator Nm 9
Radiator to main frame Nm 9
Water pump drain screw Nm 10
Left engine block cover to engine block Nm 10
Water pump cover Nm 10
Temperature sensor in cylinder head Nm 15
Bleed screw Nm 12
Model F 650 GS / GS Dakar
Connection
18 Exhaust system
Oxygen sensor to exhaust Nm 45
Exhaust manifold to cylinder head Nm 20
Silencer to exhaust manifold
(Torca clamp) Nm 55
Silencer to rear frame Nm 9
Heat shield to silencer Nm 9

00.6
Model F 650 GS / GS Dakar
Connection
21 Clutch
Driver Nm 140
(clean thread + Loctite 243)
Pressure plate Nm 10
Engine block cover, left Nm 10
Model F 650 GS / GS Dakar
Connection
23 Transmission
Selector lever to selector shaft Nm 15
Model F 650 GS / GS Dakar
Connection
27 Drive chain
Drive pinion cover to engine Nm 2
Chain takeup roller to frame Nm 21
Chain sprocket to chain sprocket mount Nm 21
Quick-release shaft nut Nm 100
Drive chain tensioning screws Nm 10
Central nut to main shaft Nm 140
(clean thread + Loctite 243)
Model F 650 GS F 650 GS Dakar
Connection
31 Front forks
Fork stabiliser to fork leg Nm 21
Clamp screws for fork bridges, top/bottom Nm 21
Plate for bottom fork bridge to fork bridge Nm 9
Oil drain plug Nm 6
Damper retaining screw Nm 20
Round nut
Preload Nm 25
Back off through angle of rotation °60
Counter-tube to steering head bearing Nm 65
Hexagon nut to counter-tube Nm 65
Screw plug in fork Nm –25

00.7
Model F 650 GS / GS Dakar
Connection
32 Steering
Handlebars to fork bridge Nm 21
(apply Optimoly TA to thread)
Handlebar weight to handlebars Nm 9
Clutch fitting to handlebars, M 6 Nm 9
Clutch switch to handlebar fitting Nm 5
Pivot pin for brake lever Nm 6
Locknut for pivot pin, clutch lever Nm 8
Model F 650 GS / GS Dakar
Connection
33 Rear wheel drive
Suspension strut to frame Nm 58
Wrench angle °45
Suspension strut to angled lever Nm 47
Knob for adjusting suspension-strut
damping to holder Nm 21
Holder, suspension-strut damping to
frame Nm 9
Swinging-fork pivot shaft Nm 100
Reaction link to swinging fork Nm 41
Reaction link to angled lever Nm 71
Angled lever to frame Nm 58
Wrench angle °45
Model F 650 GS / GS Dakar
Connection
34 Brakes
Bleed screw in front/rear brake caliper Nm 7
Brake caliper to fork slider tube Nm 41
Brake disc and sensor ring to front wheel Nm 9
(clean thread + Loctite 243)
Brake disc to rear wheel Nm 9
(clean thread + Loctite 243)
Brake fluid reservoir for rear brake to rear
frame Nm 1.5
Brake pedal to frame Nm 21

00.8
Brake lines/hoses
Brake hose to brake caliper Nm 18
Brake hose to brake lever fitting Nm 18
Brake hose/brake line interfaces Nm 18
Brake line to master brake cylinder, rear
wheel Nm 18
ABS
ABS sensor front/rear Nm 9
ABS pressure modulator to holder Nm 21
Holder for ABS pressure modulator to
frame transverse tube Nm 9
Brake line to ABS pressure modulator Nm 18
Sensor ring to rear wheel Nm 5
(clean thread + Loctite 243)
Brake disc and sensor ring to front wheel Nm 9
(clean thread + Loctite 243)
Model F 650 GS / GS Dakar
Connection
36 Wheels and tyres
Clamp nut, front quick-release axle Nm 21
Front quick-release axle to fork leg Nm 45
Rear quick-release axle to swinging fork Nm 100
Chain sprocket to chain sprocket mount Nm 21
Model F 650 GS / GS Dakar
Connection
46 Frame
Body
Fairing sections/covers Nm 3
Fairing support bracket to frame Nm 21
Grip to rear frame Nm 9
End trimmer to rear frame Nm 9
Tail to rear frame Nm 4
Tail section (mounting for case holder) to
rear frame Nm 4 (clean thread + Loctite 243)
Model F 650 GS / GS Dakar
Connection
34 Brakes

00.9
Seat lock to rear frame Nm 9
Number-plate carrier to rear section of rear
mudguard Nm 3 (clean thread + Loctite 243)
Mudguards/wheel guards
Front mudguard, rear section to front section Nm 3
Front mudguard to fork bridge Nm 3
(clean thread + Loctite 243)
Rear mudguard, front and rear sections to
rear frame Nm 9
Rear mudguard, front section to bracket
for case carrier Nm 21
Wheel cover, bottom, to bracket Nm 3
(clean thread + Loctite 243)
Wheel cover bracket to swinging fork Nm 9
Frame
Footrest plate to main frame Nm 21
Footrest rubber to rear footrest Nm 5
Retaining bracket for intake air silencer to
main frame Nm 9
Engine guard to frame truss Nm 9
Rear frame to main frame, top Nm 21
Rear frame to main frame, bottom Nm 21
(clean thread + Loctite 2701)
Centre stand to main frame Nm 41
Side stand to bottom truss Nm 40
Side stand bottom truss to main frame Nm 21
Engine mounts
Engine/crankcase to main frame at rear Nm 41
Cylinder head to frame Nm 41
Cylinder head to frame, adjusting sleeve Nm zero play, max. 5
Cylinder head to frame, locknut Nm 100
Engine/cylinder head to main frame at top Nm 41
Engine shell to engine Nm 41
Engine shell to bracing tube Nm 21
Model F 650 GS / GS Dakar
Connection
46 Frame

00.10
Model F 650 GS / GS Dakar
Connection
51 Equipment
Ignition/steering lock to fork bridge Nm 21
Model F 650 GS / GS Dakar
Connection
61 General electrical equipment
ABS sensor cable to sliding tube Nm 9
ABS sensor to brake caliper mount, rear Nm 9
Clutch switch to clutch handlebar fitting Nm 5
Brake light switch to handlebar fitting Nm 3
Brake light switch, footbrake, to frame Nm 5
Wiring harness with electronic equipment
box to frame Nm 7
Lid of electronic equipment box to frame Nm 4
Positive/ground leads, battery Nm 7
Battery holder to battery tray Nm 9
Voltage regulator to bracket Nm 7
Horn to fork bridge Nm 18
Ground terminal, wiring harness to engine
block, right Nm 8
Model F 650 GS / GS Dakar
Connection
62 Instruments
Instrument cover to instrument cluster Nm 2
Model F 650 GS / GS Dakar
Connection
63 Lights
Front turn indicator with cover to cockpit
fairing Nm 3
Rear light cluster to number-plate carrier Nm 4

00.11
Table of operating fluids
Item Use Order number Quantity
Lubricant
Staburags NBU 30 PTM High-performance lubricating paste 07 55 9 056 992 75 g tube
Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube
Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube
Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube
Retinax EP2 Wheel, steering head and taper roller
bearing grease 83 22 9 407 845 100 g tube
Contact spray Contact spray 81 22 9 400 208 300 ml spray
Chain spray Drive chain 72 60 2 316 676
72 60 2 316 667 50 ml spray 300 ml spray
Sealants
3-Bond 1110 B Surface sealant 07 58 9 056 998 5 g tube
3-Bond 1209 Surface sealant 07 58 9 062 376 30 g tube
omni VISC 1002 Surface sealant (max. 200 °C/392 °F) 07 58 1 465 170 90 g tube
Loctite 574 Surface sealant 81 22 9 407 301 50 ml tube
Curil K 2 Heat-conductive sealant 81 22 9 400 243 250 g can
Hylomar SQ 32 M Permanently elastic sealant 81 22 9 400 339 100 g tube
Adhesives and retainers
Loctite 648 Joint adhesive (narrow gap) 07 58 9 067 732 5 g bottle
Loctite 638 Joint adhesive (wide gap) 07 58 9 056 030 10 ml bottle
Loctite 243 Thread retainer, medium-strength 07 58 9 056 031 10 ml bottle
Loctite 270 Thread retainer, strong 81 22 9 400 086 10 ml bottle
Loctite 2701 Thread retainer, strong 33 17 2 331 095 10 ml bottle
Loctite 454 Cyanacrylate adhesive (gel) 07 58 9 062 157 20 g tube
Cleaners
Brake cleaner Brake cleaner 83 11 9 407 848 600 ml spray
Metal Polish Polish for chrome-plated parts 82 14 9 400 890 100 g tube
Testing agents
Penetrant MR 68 Crack testing agent for aluminium
housings 83 19 9 407 855 500 ml spray
Developer MR 70 Crack testing agent for aluminium
housings 81 22 9 407 495 500 ml spray
Installation aid
BMW chilling spray Chilling components before assembly 83 19 9 407 762 300 ml spray

00.12