BMWF650CSRepairManual

BMWMotorradAfterSalesF650CSRepairManualIssuedby©BMWMotorradAfterSalesUX-VS-2Allrightsreserved.Nottobereprinted,translatedorduplicatedeitherwhollyorinpartwithoutpriorwrittenpermission.Errorsandomissionsexcepted;subjecttotechnicalamendment.PrintedinGermany06/01IntroductionThisRepairManualwillhelpyoutoperformallthemainmaintenanceandrepairworkcorrectlyandeffi-ciently.IfitisconsultedregularlybyworkshoppersonnelitwillformausefuladditiontothetheoreticalandpracticalknowledgeacquiredattheBMWTrainingCentre.ItisacontributiontowardachievingevenhigherServicequality.Anewissueofthisrepairmanualwillbepublishedifamendmentsoradditions(supplements)areneeded.AllinformationinbothtextandillustrationsreferstomotorcyclesinstandardconditionorwithgenuineBMWaccessoriesinstalled,andnottomotorcycleswhichhavebeenmodifiedinanywaytodepartfromthemanufacturer’sspecification.TheRepairManualisstructuredinthelogicalsequenceoftheworktobeperformed:Removal,Disas-sembling,Repair,Assembly,Installation.Theentirecontentsaredividedintoindividualchapters,correspondingtotheConstructionGroups.11.10ChapterPagenumberwithinchapterIfareferenceisneededtoadifferentpageorchapter,anarrowsymbolisshownfollowedbythechapterandpagenumbers,e.g.(a12.5).WorktobeperformedduringanInspectionisdescribedinGroup“00”.ThevariousinspectionroutinesarenumberedI,II,IIIandIV.Thisnumberingisrepeatedintheworkdescriptionswhichfollow,sothatworkcantakeplacewithoutinterruption.UseoftheBMWspecialtoolsneededforcertaintasksisdescribedintheworkinstructions.Iftheneedarises,repairinstructionsarealsoissuedintheformofServiceInformation.ThisinformationisofcourseincorporatedintothenextissueoftheRepairManual.Wealsorecommend,asanadditionalsourceofinformation,theElectronicPartsCatalogue(ETK),whichcontainsclearandeasy-to-followillus-trations.Iftheworkdescribedhereisrestrictedtoaparticularequipmentspecification,forinstanceifaspecificop-tionalextra(OE)isfitted,thisisstatedinsquarebracketsatthestartoftheitemconcerned,e.g.[Heatedhandlebargrips].Pleaserefertothefollowingpagesaswellforadescriptionofothersymbolsusedandhowtoworkwiththem.BMWMotorradAfterSalesIssuedbyBMWMotorradAfterSalesUX-VS-2D-80788MünchenAllrightsreserved.Nottobereprinted,translatedorduplicatedeitherwhollyorinpartwithoutpriorwrittenpermission.Errorsandomissionsexcepted;subjecttotechnicalamendment.ProducedinGermanyUseEachchapterstartswiththelistofcontents.Thelistofcontentsisfollowedbythetechnicaldatatable.KeytosymbolsInthisRepairManualfortheF650CSmodel,thefollowingsymbolsareused;theirmeaningsareexplainedinthetable.SpecialinstructionsaimedatimprovingtheworkproceduresLNote:Specialinformationonoperatingandinspectingthemotorcycleaswellasmaintenanceandadjustmentprocedures.eAttention:Instructionsandprecautionsspecificallyintendedtopreventdamagetothemotorcycle.Failuretocomplywiththemcouldinvalidatethewarranty.dWarning:Thissymbolstandsforprecautionsandmeasureswhichareessentialinordertoprotecttheriderorotherpersonsfrompossiblysevereorfatalinjury.ContentsThetitlesofthetasksdescribedinthischapter.............completewithpagenumbersActivitiesActivitiesThebulletsymbolindicatesworkstepsthataredescribedingreaterdetailunderanotherheadline–Precedingactivities–AlineindicatesworkstepsthataredescribedingreaterdetailunderanotherheadlineorinanotherchapterThetermremovemeansthat:thefastener(e.g.screw)mustbebackedoffcompletelyandremovedoracomponent(e.g.injectionrail)hastoberemovedtotheextentthatcomponentsbehindit(e.g.throttlevalverail)arerenderedaccessibleThetermloosenorslackenmeansthat:thefastener(e.g.screw)mustbebackedoff,butnotremovedXTighteningtorque:ValuesarestatediftheydifferfromDINEN24014orDIN912ISOindustrialstandards.BMWMotorradMaintenancescheduleF650CSCustomerLicenceNo.MileageJobOrderNo.DateMechanic’ssignatureBMWInspectionat1,000km/600milesBMWMaintenanceServiceevery10,000km/6,000milesBMWInspectionevery20,000km/12,000milesBMWAnnualServiceReadthefaultcodememorywiththeBMWMoDiTeCChangetheengineoil[engineonly]whileatregularoperatingtemperatureandreplacetheoilfilterelementChangetheengineoil[engineandoiltank]whileatregularoperatingtemperatureandreplacetheoilfilterelementifmotorcycleisusedonlyforshortjourneysoratoutsidetemperaturesbelow0°C(32°F):every3monthsoratthelatestafter3,000km(1,800miles)Cleanoilstrainerinframeonceonlyat10,000km/6,000milesCheckthecoolantandrestoretocorrectlevelifnecessaryGreaserubbergrommetsforcoverinsertReplacethecoolant*)every2yearsCheckvalveclearances,adjustifnecessary*)ReplacethesparkplugDraintheoutlethosefromtheairfilterboxReplaceintakeairfilterIfmotorcycleisoperatedinverydirtyordustyconditions,cleanorreplacetheintakeairfilterevery10,000km(6,000miles);checkevery3,000km(1,800miles)Replacefuelfilterevery40,000km(24,000miles)Checkclutchplay,adjustifnecessaryExaminebrakepadsanddiscsforwear,replaceifnecessary*)Checkfront/rearcircuitbrakefluidCheckforoperationofbrakesystemandfreedomfromleaks;repair/replaceifnecessary*)Renewbrakefluidatleastonceayear[ABS]Replacetheprimaryfront/rearbrakemastercylindercup*)every40,000km(24,000miles)Replaceto