BMW F650, F650CS, F650GS, F650ST, F650 Funduro, F650ST Strada Repair Service Manuals
Complete service repair manual with electrical wiring diagrams for BMW F650, F650CS, F650GS, F650ST, F650 Funduro, F650ST Strada 1994-2008, with workhop information to maintain, diagnose, repair, ans service like professional mechanics.
BMW F650 Motorcycles workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
BMW F650CS Repair Manual '01-'06 (EN).pdf
BMW F650 (F650ST Strada, F650 Funduro) Repair Manual '94-'95 (ES).pdf
BMW F650 (F650ST Strada, F650 Funduro) Repair Manual '94-'95 (FR).pdf
BMW F650, F650ST Repair Manual '94-'00 (EN).pdf
BMW F650GS Repair Manual '00-'08 (EN).pdf
BMW F650GS Service Manual '00-'08 (DE).pdf
Total Pages: 2,021 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English German French Spanish
Table of Contents
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
17 Radiator
18 Exhaust system
21 Clutch
23 Gearbox
27 Chain/belt drive
31 Front forks
32 Steering
33 Rear wheel drive
34 Brakes
36 Wheels and tires
46 Frame
51 Equipment
61 General electrical equipment
62 Instruments
63 Lights
17 40 000 Removing and installing fan
Remove right cover ( a 46.6).
Unclip the MoDiTeC plug from its holder.
Disconnect plug for fan.
Disengage the clips at top and bottom and remove the fan.
If necessary, remove fan from fan shroud.
Installation is the reverse of the removal procedure, pay particular attention to the following.
Slide the rubber grommet of the fan onto the pin of the expansion tank and then engage the tabs of the fan on the radiator.
33 Rear wheel drive
Technical Data .. 3
Removing and installing suspension strut..5
Removing and installing rear swinging arm..6
Removing and installing needle roller races in rear swinging arm..8
Removing needle roller races ..8
Installing needle roller races ..8
Removing and installing needle bearings in rear swinging arm..9
Removing needle roller bearing ..9
Installing needle roller bearing ..10
Removing and installing reaction link ..10
Removing and installing angled lever .. 11
Removing and installing needle roller bearings and needle roller races in angled lever .. 11
Removing needle roller bearings and needle roller races .. 11
Installing needle roller bearings and needle roller races .. 12
Removing and installing drive damper..15
Measuring runout of belt pulley..13
Removing and installing eccentric with drive shaft
Separating eccentric from drive shaft 16
Removing and installing floating bearing of eccentric 16
Removing and installing fixed bearing of eccentric ..17
Pressing eccentric onto drive shaft ..17
Contents
General view of crated motorcycle
Checking the shipping crate for damage
In case of damage in Germany
In case of damage in importer markets
Unpacking the motorcycle
Inspecting motorcycle for damage
Installing remaining items on motorcycle
Installing windscreen
Installing front mudguard, mirrors and handlebar weights
Filling and charging the battery
Removing right and centre covers
Filling and charging the battery
Checking that delivery is complete
Reading the fault code memory with the BMW MoDiTeC
Checking tyre pressures
Adding fuel to tank
Final inspection and function check
Final cleaning
Handing over the motorcycle
Inhalt
Übersicht Verpackung
Transportverschlag auf Schäden prüfen
Im Schadensfall in Deutschland
Im Schadensfall in Importeursmärkten
Motorrad auspacken
Motorrad auf Schäden prüfen
Motorrad komplettieren
Windschild anbauen
Vorderradkotflügel, Spiegel und Lenkergewichte anbauen
Batterie befüllen und laden
Cover rechts/mitte ausbauen
Batterie befüllen und laden
Vollständigen Lieferumfang prüfen
Fehlerspeicher mit BMW MoDiTeC auslesen
Reifenluftdruck prüfen
Kraftstoff einfüllen
Funktionsprüfung als Endkontrolle
Abschlußreinigung
Fahrzeugübergabe
BMW F650 (F650ST Strada, F650 Funduro) Repair Manual '94-'95 (ES)....2
BMW F650 (F650ST Strada, F650 Funduro) Repair Manual '94-'95 (FR)....65
BMW F650, F650ST Repair Manual '94-'00 (EN)....129
BMW F650CS Repair Manual '01-'06 (EN)....513
Repair Manual....513
Introduction....515
Use....516
Key to symbols....516
Contents....516
Activities....516
Maintenance schedule....517
Pre-delivery check....518
Service data....519
Contents....520
00 Tightening torques, Operating fluids....522
Tightening torques....524
Table of operating fluids....534
00 Pre-delivery check....536
General view of crated motorcycle....538
Checking the shipping crate for damage....539
In case of damage in Germany....539
In case of damage in importer markets....539
Unpack the motorcycle....539
Inspecting motorcycle for damage....540
Checking that delivery is complete....540
Installing remaining items on motorcycle....540
Filling and charging the battery....541
Removing the battery....541
Filling and charging the battery....542
Checking engine oil level....543
Checking tyre pressures....543
Final inspection and function check....544
Final cleaning....544
Handover....544
00 Maintenance....546
Key to maintenance intervals....550
Reading the fault code memory with the MoDiTeC....551
(Inspections I, II, III and IV)....551
Changing the engine oil [engine only] and oil filter element....551
(Inspection I)....551
Preparatory work....551
Draining engine oil....551
Replacing oil filter element....552
Filling with engine oil....552
Changing the engine oil [engine and oil tank] and oil filter element....553
(Inspections II, III and IV)....553
Preparatory work....553
Draining engine oil....553
Replacing oil filter element....554
Filling with engine oil....554
Cleaning oil strainer in frame....555
(Inspection II, once only)....555
Greasing rubber grommets for cover insert....555
(Inspections I, II, III and IV)....555
Checking coolant, topping up if necessary....556
(Inspections I, II and III)....556
Checking coolant....556
Adding coolant....556
Changing coolant....557
(Inspection IV, every 2 years)....557
Checking and adjusting valve clearances....559
(Inspections II and III)....559
Checking valve clearances....559
Preparatory work....559
Remove the intake air silencer together with the intake air pipe....559
Exposing the radiator....559
Exposing cylinder head....560
Turning crankshaft to TDC position....560
Checking valve clearance....561
Adjusting valve clearances....561
Installing cylinder head cover....562
Replacing spark plug....563
(Inspection III)....563
Emptying drain from intake air silencer....563
(Inspections I, II and III)....563
Replacing air cleaner element....564
(Inspection III)....564
Replacing fuel filter....565
(Inspection III, every 40,000 km24,000 miles)....565
Checking clutch play, adjusting ifnecessary....566
(Inspections I, II and III)....566
Checking brake pads and discs for wear, replacing if necessary....566
(Inspections II and III)....566
Checking brake pads for wear....566
Brake pads, front brake....566
Brake pads, rear brake....566
Replacing brake pads....567
Brake pads, front brake....567
Brake pads, rear brake....568
Checking the brake discs....568
Checking brake fluid level at front and rear....569
(Inspections II and III)....569
Brake fluid level (front brake)....569
Checking brake fluid level (front brake)....569
Brake fluid level (rear brake)....569
Checking brake fluid level (rear brake)....569
Checking operation of brake system and checking for leaks; repairing replacing as necessary....570
(Inspection III)....570
Changing brake fluid and bleeding brake system....570
(Inspection IV)....570
Changing brake fluid and bleeding brake system (front brakes)....570
Changing brake fluid and bleeding brake system (rear brakes)....571
Replacing primary sealing boot, front brake master cylinder....573
(Inspection III, every 40,000 km24,000 miles for motorcycles with ABS)....573
Replacing primary sealing boot, rear brake master cylinder....574
(Inspection III, every 40,000 km24,000 miles for motorcycles with ABS)....574
Checking toothed belt pulley and sprocket, replacing if necessary....575
(Inspection III)....575
Replacing toothed belt....575
(Inspection III)....575
Checking belt tension, adjusting if necessary....577
(Inspections I, II and III)....577
Checking belt tension....577
Adjusting belt tension....578
Used belt, new belt....578
Checking battery acid level, adding distilled water if necessary....580
(Inspections II, III and IV)....580
Checking battery acid level....580
Adding distilled water....580
Cleaning and greasing battery terminals, if necessary....580
(Inspection IV)....580
Checking and adjusting steering head bearing play, replacing if necessary....581
(Inspections II and III)....581
Checking steering head bearing play....581
Adjusting steering head bearing play....581
Greasing side stand....582
(Inspections II and III)....582
Side stand....582
Checking specified torque of threaded fasteners with torque wrench....582
(Inspections I, II, III and IV)....582
Final inspection with road safety and functional check....583
(Inspections I, II, III and IV)....583
Road safety check....583
Tyre tread depth (recommended minimum value)....583
Tyre pressures (tyres cold)....583
Roadworthiness check....583
11 Engine....584
Technical Data....588
Cutaway view of engine....594
Engine oil circuit....595
Engine and oil-tank system....596
Valve gear....597
Valves, components....598
Oil pumps, components....599
Removing and installing oil pressure switch with engine installed....600
Removing and installing oil pressure switch....600
Cleaning oil tank and oil lines....600
Removing and installing cylinder head, engine installed....601
Preparatory work....601
Removing camshafts....603
Removing cylinder head....603
Removing cylinder, engine installed....605
Removing engine....606
Preparatory work....606
Removing engine....607
Transferring engine to assembly frame....608
Disassembling engine....609
Removing cylinder head....609
Removing camshafts....609
Checking camshaft for wear....610
Removing and installing timing-chain sprockets....610
Checking centrifugal decompressor lever....610
Disassembling and assembling the centrifugal decompressor....610
Removing cylinder head....611
Checking timing chain for wear....611
Disassembling and assembling cylinder head....612
Removing valves....612
Bore for bucket tappet....612
Checking valve guide for wear....613
Removing valve guide....613
Installing valve guide....614
Checking valve seat for wear....614
Installing valve stem seal....615
Checking valve for wear....615
Installing valves....616
Removing cylinder....616
Checking cylinder....616
Removing piston....617
Disassembling piston....617
Determining clearance of piston in cylinder....617
Determining piston ring gaps....618
Determining piston pin clearance....618
Assembling pistons....618
Removing ignition magneto....618
Removing countershaft for starter....619
Disassembling and assembling freewheel....620
Disassembling freewheel....620
Assembling freewheel....620
Removing clutch....621
Removing pressure plate....621
Removing clutch plates....621
Removing and installing oil pump....622
Removing oil pump....622
Inspecting oil pump....622
Installing oil pump....622
Removing double drive gear....623
Removing crankshaft and balancing shaft....623
Checking crankshaft for wear....624
Removing compensating gear....624
Removing and installing crankshaft gear....624
Removing and installing gearbox mainshaft bearings....625
Removing and installing gearbox countershaft bearings....625
Removing and installing grooved ball bearings of balancing shaft....626
Removing and installing main bearings....626
Removal....626
Installation....627
Assembling engine....628
Installing crankshaft and balancing shaft....628
Shimming crankshaft....628
Installing double drive gear....629
Installing oil pump gears....630
Installing clutch....631
Installing clutch cage....631
Installing driver....631
Installing pressure plate....632
Installing countershaft for starter motor....632
Installing magnetic ignition trigger....633
Installing piston....634
Installing cylinder....635
Installing cylinder head....635
Installing camshaft and adjusting valves....637
Installing engine....639
Bleeding engine oil circuit....640
12 Engine electrics....641
Technical Data....643
Ignition magneto....645
Ignition magneto, components....646
Removing ignition magneto....647
Removing right engine block cover....647
Removing and installing ignition trigger....648
Removing and installing stator....648
Installing ignition magneto....648
Installing magnet rotor....648
Removing and installing, disassembling starter motor....649
Removing and installing starter motor....649
Disassembling and assembling starter motor....650
Replacing spark plug (a00.42)....651
Removing and installing coil....651
13 Fuel preparation and control....652
Technical Data....654
Removing and installing BMS control unit....656
Removing and installing intake air pipe....657
Removing and installing air temperature sensor....657
Replacing air filter element (a00.43)....657
Removing and installing intake air silencer....658
Removing and installing intake air pipe....658
Removing and installing injection nozzle....659
Removing and installing throttle-valve actuator....659
Replacing throttle-valve potentiometer....660
Removing and installing throttle flap stub....660
Removing and installing intake stub....661
Checking fuel pressure....661
Removing and installing fuel hoses....662
Removing and installing feed and return lines....662
Removing and installing line to fuel injector....662
Removing and installing throttle cable (a32.12)....662
16 Fuel tank and lines....663
Technical Data....665
Removing and installing fuel tank....667
Removing fuel tank....667
Installing fuel tank....669
Removing and installing fuel filler cap....670
Removing and installing roll- over valve....670
Replacing fuel filter (a00.44)....670
Removing and installing fuel pump....671
Removing and installing fuel- evaporation control valve....672
[USA version]....672
Removing and installing activated charcoal filter....673
[USA version]....673
17 Radiator....674
Technical Data....676
Coolant circuit....678
Thermostat, components....679
Removing and installing coolant pump....680
Removing coolant pump....680
Installing coolant pump....681
Adding coolant....682
Removing and installing coolant-temperature sensor....683
Checking cooling system for leaks....683
Removing and installing coolant hoses....684
Replacing coolant hose (cylinder headframe - frameradiator)....684
Replacing coolant hose (radiatorwater pump)....684
Replacing coolant hose (filler bowlexpansion tank)....684
Changing coolant (a00.36)....684
Removing and installing fan....685
Removing and installing radiator....685
Removing and installing thermostat....686
18 Exhaust system....687
Technical Data....689
Removing and installing exhaust system....691
Removing and installing silencer (muffler)....691
Removing and installing exhaust elbow and oxygen sensor....693
Removing exhaust elbow and oxygen sensor....693
Installing exhaust elbow and oxygen sensor....693
Replacing guard for silencer....694
21 Clutch....695
Technical Data....697
Clutch, components....699
Removing and installing clutch....700
Removing clutch....700
Removing pressure plate....700
Disassembling and reassembling pressure plate....700
Removing clutch plates, driver and clutch cage....701
Installing clutch cage....702
Installing driver....702
Installing pressure plate....702
Check clutch discs for wear....702
Removing and installing release shaft....703
Installing clutch....704
23 Gearbox....705
Technical Data....707
Gearbox shafts, components....709
Gear shift pedal, components....710
Replacing shaft sealing rings with engine installed....711
Replacing sealing ring of selector shaft....711
Replacing shaft sealing ring of belt sprocket....712
Removing and installing gearbox....713
Removing selector shaft with pawl and index lever....713
Removing selector forks....713
Removing selector drum....713
Removing, disassembling and reassembling gearbox shafts....714
Removing gearbox shafts....714
Disassembling and reassembling mainshaft....714
Checking mainshaft for wear....715
Disassembling and reassembling countershaft....716
Checking countershaft for wear....717
Replacing gearbox mainshaft bearings....717
Replacing gearbox countershaft bearings....718
Installing gearbox shafts....718
Installing selector shaft....719
Installing selector forks....719
Installing selector drum....720
27 Chainbelt drive....721
Technical Data....723
Removing and installing belt, belt drive gear and belt sprocket....725
Removing and installing belt (a00.54)....725
Removing and installing belt sprocket (a33.13)....725
Removing and installing belt sprocket....725
Adjust belt tension (a00.56)....725
31 Front forks....726
Technical Data....728
Telescopic fork, components....730
Removing and installing telescopic fork....731
Removing telescopic fork....731
Installing telescopic fork....732
Disassembling telescopic fork....734
Removing fixed tube....734
Measuring telescopic fork....736
Checking lower fork bridge....736
Checking parallel alignment of fixed tubes....737
Checking fixed tube runout....737
Assembling telescopic fork....738
Assembling fixed tube....738
Complete assembly of telescopic fork....741
Removing and installing steering head bearing....742
Upper steering head bearing....742
Lower steering head bearing....742
32 Steering....743
Technical Data....745
Removing and installing left and right handlebar fittings....747
Removing and installing left handlebar fitting....747
Removing and installing clutch switch....748
Removing and installing right handlebar fitting....749
Removing and installing handlebar....751
Removing and installing clutch cable....752
Removing and installing throttle cable....754
Removing and installing left and right handlebar levers....755
Removing and installing left handlebar lever....755
Removing and installing right handlebar lever....755
Checking and adjusting steering head bearing play, replacing if necessary (a 00.60)....755
33 Rear wheel drive....756
Technical Data....758
Removing and installing suspension strut....760
Removing and installing rear swinging arm....761
Removing and installing needle roller races in rear swinging arm....763
Removing needle roller races....763
Installing needle roller races....763
Removing and installing needle bearings in rear swinging arm....764
Removing needle roller bearing....764
Installing needle roller bearing....765
Removing and installing reaction link....765
Removing and installing angled lever....766
Removing and installing needle roller bearings and needle roller races in angled lever....766
Removing needle roller bearings and needle roller races....766
Installing needle roller bearings and needle roller races....767
Removing and installing drive damper....768
Removing drive damper....768
Removing pulley....768
Disassembling drive damper....768
Assembling drive damper....769
Installing pulley....769
Installing drive damper....769
Measuring runout of belt pulley....770
Removing and installing eccentric with drive shaft....771
Separating eccentric from drive shaft....771
Removing and installing floating bearing of eccentric....771
Removing and installing fixed bearing of eccentric....772
Pressing eccentric onto drive shaft....772
34 Brakes....773
Technical Data....775
Removing and installing front brake caliper....777
Removing and installing front brake pads (a00.46)....777
Removing and installing front brake pistons....778
Removing and installing front brake disc....779
Checking brake disc for wear (a00.45)....779
Checking front brake disc for lateral runout....779
Removing and installing rear brake caliper....780
Removing and installing rear brake pads (a00.46)....780
Removing and installing rear brake pistons....781
Removing and installing rear brake disc....782
Checking brake disc for wear (a00.47)....782
Checking rear brake disc for lateral runout....782
Replacing primary sealing boot, front brake master cylinder (a00.52)....782
Removing and installing front brake master cylinder....783
Removing and installing handbrake lever (a32.13)....783
Replacing primary sealing boot, rear brake master cylinder (a00.53)....783
Removing and installing rear brake master cylinder....784
Removing and installing brake pedal....785
Checking blow-by clearance at piston thrust rod, adjusting if necessary....786
Checking blow-by clearance at piston rod....786
Adjusting play at piston rod....786
Removing and installing front ABS sensor....787
Removing and installing front ABS sensor ring....787
Removing and installing rear ABS sensor....788
Removing and installing ABS control unit....789
Removing and installing front brake lineshoses (with ABS)....790
Removing and installing brake lines....790
Removing and installing front brake hoses....791
Removing and installing rear brake lineshoses (with ABS)....791
Removing and installing brake lines....791
Removing and installing brake hose....792
Checking front ABS sensor ring for runout....795
36 Wheels and tyres....796
Technical Data....798
Removing and installing front wheel....800
Removing front wheel....800
Installing front wheel....800
Removing and installing front wheel bearing....801
Removing left-hand wheel bearing....801
Removing right-hand wheel bearing....801
Installing wheel bearings....802
Removing and installing rear wheel....802
Checking front and rear wheel rims....803
Checking rims....803
Static balancing of frontrear wheel....804
46 Frame....805
Technical Data....807
Overview of trim panels....809
Removing and installing trim panels....810
Removing and installing left and right covers....810
Removing and installing rear cover....810
Removing and installing front cover....810
Removing and installing left and right covers....811
Removing and installing windscreen and windscreen holder....812
Removing and installing headlight surround....812
Removing and installing instrument cover....812
Removing and installing leftright connector covers....813
Removing and installing left connector cover....813
Removing and installing right connector cover....813
Removing and installing fairing bracket....814
Removing and installing front mudguard....815
Removing and installing rear mudguard....815
Removing and installing number- plate carrier....816
Removing and installing spray guard....816
Removing and installing number-plate carrier....816
Removing and installing leftright rear trim panel....817
Removing and installing luggage rack....817
Removing and installing stowage- compartment frame....818
Removing and installing oil-tank trim panels....818
Raising, removing and installing rear frame....819
Raising rear frame....819
Removing and installing rear frame....820
Removing frame....822
Removing and installing left and right footrests....825
Removing and installing rear footrest....825
Removing and installing side stand truss....826
Removing and installing side stand....826
Measuring wheel track offset....827
Measurement record, wheel track offset....828
Key to measurement result:....828
Checking frame with gauge....829
Front wheel....828
Rear wheel....828
Example....828
51 Equipment....831
Technical Data....833
Removing and installing ignition switchsteering lock....835
Removing and installing lock barrel....836
Removing and installing lock for rear stowage compartment....837
Removing and installing lock barrel for fuel tank filler cap....837
Replacing mirrors....838
61 General electrical equipment....839
Technical Data....841
Wiring harness....843
View from left....843
View from right....844
Component positions in electronic equipment box....845
Relay positions in electronic equipment box....845
Connectors, electronics box....845
Removing and installing battery (a00.20)....845
Removing and installing battery carrier (a34.17)....845
Replacing fuses....845
Motorcycle fuses....845
Fuses....845
Removing and installing holder for BMS control unit....846
Removing and installing coolant-temperature sensor (a17.10)....846
Removing and installing side stand switch....846
Removing and installing rear-brake switch for brake light....847
Removing and installing front-brake switch for brake light....847
Removing and installing horn....848
Removing and installing neutral-indicator switch....848
Removing and installing frontrear ABS sensors (a34.15)(a34.16)....848
Removing and installing voltage regulator....849
Removing and installing switch for hazard warning flashers....849
62 Instruments....850
Technical Data....852
Telltalewarning lights....854
Removing and installing instrument panel....855
Replacing telltalewarning lights....855
Disassembling and assembling instrument cluster....855
Removing and installing wiring harness....856
63 Lights....857
Technical Data....859
Removing and installing headlight....861
Removing and installing rear light....862
Removing and installing number- plate light....862
Replacing bulbs....863
Bulb for low-beam headlight high-beam headlight....863
Bulb, parking light....863
Flashing turn indicator....864
Rear lights....864
Bulb for number-plate light....864
Checking and adjusting headlight beam throw....864
Vertical adjustment....864
Lateral adjustment....864
BMW F650GS Repair Manual '00-'08 (EN)....865
Repair Manual....865
Introduction....866
U sage....867
Key to symbols....867
Contents....867
Activities....867
Maintenance schedule....868
Pre-delivery Check....869
Service data....870
Instructions for pre-delivery check....871
General view of crated motorcycle....875
Checking the shipping crate for damage....875
In case of damage in Germany....875
In case of damage in importer markets....875
Unpacking the motorcycle....875
Inspecting motorcycle for damage....876
Installing remaining items on motorcycle....876
Installing windscreen....876
Installing front mudguard, mirrors and handlebar w....876
Filling and charging the battery....877
Removing right and centre covers....877
Filling and charging the battery....878
Checking that delivery is complete....879
Reading the fault code memory with the BMW MoDiTeC....879
Checking tyre pressures....879
Adding fuel to tank....879
Final inspection and function check....879
Final cleaning....880
Handing over the motorcycle....880
Contents....881
00 Maintenance and general instructions....883
Table of operating fluids....887
Tightening torques....888
Key to maintenance intervals....897
Reading the fault code memory with the MoDiTeC....898
(Inspections I, II, III and IV)....898
Changing the engine oil and oil filter element....898
(Inspections I, II, III and IV)....898
Preparatory work....898
Draining engine oil....898
Replacing oil filter element....899
Filling with engine oil....899
Checking coolant, topping up if necessary....900
(Inspections I, II and III)....900
Checking coolant....900
Adding coolant....900
Changing coolant....900
(Inspection IV, every 2 years)....900
Changing oil in telescopic forks....902
(Inspection III)....902
Checking and adjusting valve clearances....903
(Inspections I, II and III)....903
Checking valve clearances....903
Preparatory work....903
Removing the intake air silencer together with the....903
Exposing the radiator....903
Exposing cylinder head....903
Turning crankshaft to TDC position....903
Checking valve clearance....904
Adjusting valve clearances....904
Installing cylinder head cover....905
Installing fan shroud....905
Installing intake air silencer....905
Installing the intake air duct....905
Replacing spark plugs....906
(Inspection III)....906
Emptying drain hose from intake air silencer....906
(Inspections II and III)....906
Replacing air cleaner element....906
(Inspection III)....906
Replacing fuel filter....907
(Inspection III, every 20,000 km12,000 miles)....907
Checking clutch play, adjusting if necessary....908
(Inspections I, II and III)....908
Checking wheel spoke tension, adjusting if necess....908
(Inspection II)....908
Checking brake pads and discs for wear, replacing ....909
(Inspections II and III)....909
Checking brake pads for wear....909
Brake pads, front brake....909
Brake pads, rear brake....909
Replacing brake pads....909
Brake pads, front brake....909
Brake pads, rear brake....910
Checking the brake discs....910
Checking the brake fluid level and topping up if n....910
(Inspection II)....910
Brake fluid level (front brake)....910
Checking brake fluid level (front brake)....910
Topping up brake fluid level (front brake)....910
Brake fluid level (rear brake)....911
Checking brake fluid level (rear brake)....911
Topping up brake fluid level (rear brake)....911
Checking operation of brake system and freedom fro....911
(Inspection III)....911
Changing brake fluid....912
(Inspection IV)....912
Changing brake fluid (front brake)....912
Changing brake fluid (rear brake)....912
Replacing primary sealing boot, front brake master....913
(Inspection III, every 40,000 km24,000 miles for ....913
Replacing primary sealing boot, rear brake master ....914
(Inspection III, every 40,000 km24,000 miles for ....914
Inspecting front and rear wheel bearings, replacin....915
(Inspection III)....915
Checking chain, chainwheel and chain sprocket, rep....915
(Inspections II and III)....915
Checking chain tension, adjusting if necessary....915
(Inspections I, II, III and IV)....915
Checking chain tension....915
Adjusting chain tension....916
Checking battery acid level, adding distilled wate....916
(Inspections II, III and IV)....916
Checking battery acid level....916
Adding distilled water....916
Cleaning and greasing the battery terminals, if ne....917
(Inspections III and IV)....917
Checking and adjusting steering head bearing play,....917
(Inspections II and III)....917
Checking steering head bearing play....917
Checking and adjusting steering head bearing play,....918
(Inspections II and III)....918
Adjusting steering head bearing play....918
Greasing the side and main stands and the brake pe....919
(Inspections II and III)....919
Side stand....919
Main (centre) stand....919
Brake pedal....920
Checking security of threaded fasteners....920
(Inspections I, II, III and IV)....920
Final inspection with road safety and functional c....921
(Inspections I, II, III and IV)....921
Road safety check....921
Tyre tread depth (recommended minimum value)....921
Tyre pressures (tyres cold)....921
Roadworthiness check....921
11 Motor....923
Sectional view of engine....933
Engine oil circuit....934
Valve gear....935
Valves, components....936
Oil pumps, components....937
Removing and installing cylinder head, engine inst....938
Preparatory work....938
Removing camshafts....940
Removing cylinder head....940
Removing cylinder, engine installed....942
Removing engine....943
Preparatory work....943
Removing engine....944
Transferring engine to assembly frame....944
Lowering engine....945
Preparatory work....945
Lowering the engine....946
Disassembling engine....948
Removing cylinder head....948
Removing camshafts....948
Checking camshaft for wear....949
Removing and installing timing-chain sprockets....949
Checking centrifugal decompressor lever....949
Disassembling and assembling the centrifugal deco....949
Removing cylinder head....950
Checking timing chain for wear....950
Disassembling and assembling cylinder head....951
Removing valves....951
Bore for bucket tappet....951
Checking valve guide for wear....952
Removing valve guide....952
Installing valve guide....953
Checking valve seat for wear....953
Installing valve stem seal....954
Checking valve for wear....954
Installing valves....955
Removing cylinder....955
Checking cylinder....955
Removing piston....956
Disassembling piston....956
Determining clearance of piston in cylinder....956
Determining piston ring gaps....957
Determining piston pin clearance....957
Assembling pistons....957
Removing ignition magnet....957
Removing countershaft for starter....958
Disassembling and assembling freewheel....959
Disassembling freewheel....959
Assembling freewheel....959
Removing clutch....960
Removing pressure plate....960
Removing clutch plates....960
Removing and installing oil pump....961
Removing oil pump....961
Inspecting oil pump....961
Installing oil pump....961
Removing double drive gear....962
Removing crankshaft and balancing shaft....962
Checking crankshaft for wear....963
Removing compensating gear....963
Removing and installing crankshaft gear....963
Removing and installing gearbox mainshaft bearings....964
Removing and installing gearbox compensating shaft....964
Removing and installing grooved ball bearings of g....965
Removing and installing main bearings....965
Removal....965
Installation....966
Assembling engine....967
Installing crankshaft and balancing shaft....967
Shimming crankshaft....967
Installing double drive gear....968
Installing oil pump gears....969
Installing clutch....970
Installing clutch cage....970
Installing driver....970
Installing pressure plate....971
Installing countershaft for starter motor....971
Installing magnetic ignition trigger....972
Installing piston....973
Installing cylinder....974
Installing cylinder head....974
Installing camshaft and adjusting valves....976
Installing engine....978
Bleeding engine oil circuit....978
12 Engine electrics....979
Ignition magneto....983
Ignition magneto, components....984
Removing ignition magnet....985
Removing right engine housing cover....985
Removinginstalling ignition trigger....986
Removinginstalling stator....986
Installing magnetic ignition trigger....986
Installing magnet wheel....986
Removinginstalling or dismantling starter motor....987
Removinginstalling starter motor....987
Disassemblingassembling starter motor....988
Replacing spark plug....989
See Group 00....989
Replacing ignition lead....989
Remove the intake air silencer together with the i....989
Removinginstalling coil....989
Remove the intake air silencer together with the i....989
13 Fuel preparation and control....991
Removing and installing BMS control unit....995
Removing and installing intake air pipe....995
Removinginstalling air temperature sensor....995
Replacing air filter element....996
See Group 00....996
Removing and installing intake air silencer....996
Removing and installing intake air pipe....996
Removing and installing injection nozzle....997
Removing and installing throttle valve actuator....997
Replacing throttle-valve potentiometer....998
Removing and installing throttle-valve stub pipe....998
Removing and installing intake pipe....999
Checking fuel pressure....999
Removing and installing fuel hoses....1000
Removing and installing feed and return lines....1000
Removing and installing line to fuel injector....1000
Removing and installing throttle cable....1000
See Group32....1000
16 Fuel tank and lines....1001
Removing and installing fuel tank....1005
Removing fuel tank....1005
Installing fuel tank....1007
Removing and installing fuel filler cap....1007
Removing and installing roll-over valve....1008
Replacing fuel filter....1008
See Group 00....1008
Removing and installing fuel pump....1008
Removing and installing fuel pump....1009
Removing and installing fuel strainer....1009
Removing and installing warning-contact switch for....1009
Removing and installing fuel-evaporation control v....1010
[USA version]....1010
Removing and installing activated charcoal filter....1010
[USA version]....1010
17 Radiator....1011
Coolant circuit....1015
Thermostat, components....1016
Removing and installing coolant pump....1017
Removing coolant pump....1017
Installing coolant pump....1018
Adding coolant....1018
Removing and installing coolant-temperature sensor....1019
Checking cooling system for leaks....1020
Removing and installing coolant hoses....1020
Replacing coolant hose (radiatorwater pump)....1020
Replacing coolant hose (fillerbowlexpansion tank....1020
Replacing coolant....1020
See Group 00....1020
Removing and installing fan....1020
Removing and installing radiator....1021
Removing and installing thermostat....1021
18 Exhaust system....1023
Removing and installing exhaust system....1027
Removing and installing right-hand silencer....1027
Removing and installing left-hand silencer....1027
Removing and installing exhaust manifold and oxyge....1028
Removing exhaust manifold and oxygen sensor....1028
Installing exhaust manifold and oxygen sensor....1028
Replacing guard for silencer....1029
21 Clutch....1031
Clutch, components....1035
Removing and installing clutch....1036
Removing clutch....1036
Removing pressure plate....1036
Disassembling and reassembling pressure plate....1036
Removing clutch plates, driver and clutch cage....1037
Installing clutch cage....1038
Installing driver....1038
Installing pressure plate....1038
Removing and installing releaser shaft....1039
Installing clutch....1040
23 Gearbox....1041
Gearbox shafts, components....1045
Gear shift pedal, components....1046
Removinginstalling gearbox....1047
Removing selector shaft with pawl and index lever....1047
Removing selector forks....1047
Removing selector drum....1047
Removing, disassembling and reassembling gearbox s....1048
Removing gearbox shafts....1048
Disassembling and reassembling mainshaft....1048
Checking mainshaft for wear....1049
Disassembling and reassembling compensating shaft....1050
Checking countershaft for wear....1051
Replacing gearbox mainshaft bearings....1051
Replacing gearbox compensating shaft bearings....1052
Installing gearbox shafts....1052
Installing selector shaft....1053
Installing selector forks....1053
Installing selector drum....1053
27 Drive chain....1055
Removing and installing chain, chainwheel and chai....1059
Removing and installing chain....1059
Removing and installing chain guide rail....1059
Removing and installing chain takeup roller....1059
Removing chainwheel....1060
Removing chain sprocket....1060
Removing and installing chain guide rail with swin....1061
Adjusting chain tension....1061
See Group 00....1061
32 Steering....1063
Removing and installing left and right handlebar f....1067
Removing and installing left handlebar fitting....1067
Removing and installing clutch switch....1068
Removing and installing right handlebar fitting....1069
Removing and installing handlebar....1071
Removing and installing clutch cable....1072
Removing and installing throttle cable....1074
Checking and adjusting steering head bearing play,....1075
(Inspections II and III)....1075
Checking steering head bearing play....1075
Checking and adjusting steering head bearing play,....1075
(Inspections II and III)....1075
Adjusting steering head bearing play....1075
Removing and installing left and right handlebar l....1077
Removing and installing left handlebar lever....1077
Removing and installing right handlebar lever....1077
33 Rear wheel drive....1079
Removing and installing suspension strut....1083
Removing and installing rear swinging fork....1084
Removing and installing needle roller races in re....1085
Removing needle roller races....1085
Installing needle roller races....1086
Removing and installing struts....1086
Removing and installing needle roller bearing in ....1087
Removing needle roller bearing....1087
Installing needle roller bearing....1087
Removing and installing angled lever....1088
Removing and installing needle roller bearings an....1088
Removing needle roller bearings and needle roller....1088
Installing needle roller bearings and needle rolle....1089
34 Brakes....1091
Removing and installing front brake calliper....1095
Removing and installing front brake pads....1095
See Group 00....1095
Removing and installing front brake pistons....1096
Removing and installing front brake disc....1097
Checking brake disc for wear....1097
See Group 00....1097
Checking front brake disc for lateral runout....1097
Removing and installing rear brake calliper....1098
Removing and installing rear brake pads....1098
See Group 00....1098
Removing and installing rear brake piston....1099
Removing and installing rear brake disc....1100
Checking brake disc for wear....1100
See Group 00....1100
Checking rear brake disc for lateral runout....1100
Replacing primary sealing boot front brake master ....1100
See Group 00....1100
Removing and installing front brake master cylinde....1101
Removing and installing handbrake lever....1101
See Group 32....1101
Replacing primary sealing boot, rearbrake master ....1101
See Group 00....1101
Removing and installing rear brake master cylinder....1101
Removing and installing footbrake lever....1102
Checking play at piston thrust rod, adjusting if n....1102
Checking play at piston thrust rod....1102
Adjusting play at piston thrust rod....1103
Removing and installing front ABS sensor....1103
Removing front ABS sensor ring....1104
Removing and installing rear ABS sensor....1104
Removing and installing rear ABS sensor ring....1105
Removing and installing ABS control unit....1105
Removing and installing front brake lineshoses (w....1106
Removing and installing brake lines....1106
Removing and installing front brake hoses....1107
Removing and installing rear brake lineshoses (wi....1107
Removing and installing brake lines....1107
Removing and installing brake hose....1108
Checkingadjusting front ABS sensor gap....1109
Adjusting ABS sensor gap....1109
Checkingadjusting rear speedABS sensor gap....1109
Adjusting ABS sensor gap....1109
36 Wheels and tyres....1111
Removinginstalling front wheel....1115
Removing front wheel....1115
Installing the front wheel....1115
Removinginstalling front wheel bearing....1116
Removing left-hand wheel bearing....1116
Removing right-hand wheel bearing....1116
Installing wheel bearings....1117
Removinginstalling rear wheel....1117
Removinginstalling rear wheel bearings....1118
Removing left-hand wheel bearing....1118
Removing right-hand wheel bearing....1118
Installing wheel bearings....1119
Removinginstalling bearing in chainwheel carrier....1119
Removinginstalling wheel spokes....1120
Removinginstalling front wheel spokes....1120
Outer left spokes....1120
Inner left spokes....1120
Outer right spokes....1121
Inner right spokes....1121
Removinginstalling rear wheel spokes....1122
Outer left and right spokes....1122
Inner left and right spokes....1122
Checking and centering front and rear wheel rims....1123
Checking rims....1123
Centering lateral runout....1124
Centering vertical runout....1124
Static balancing of frontrear wheel....1125
46 Frame....1127
Removing and installing covers....1131
Removing and installing leftright cover....1131
Removing and installing centre cover....1131
Removing and installing cockpit fairing....1132
Removing and installing fairing bracket....1132
Raising rear frame....1133
Removing and installing front mudguard....1134
Removing and installing rear frame....1134
51 Equipment....1137
Removing and installing ignition switchsteering l....1141
Removing and installing lock barrel....1142
Removing and installing lock for rear stowage comp....1142
Removing and installing lock barrel for fuel tank ....1142
Replacing mirrors....1143
61 General electrical equipment....1145
Wiring harness....1149
View from left....1149
View from right....1150
Component positions in electronic equipment box....1151
Relay positions in electronic equipment box....1151
Connectors, electronic equipment box....1151
Removing and installing battery....1152
Removing and installing battery carrier....1153
Replacing fuses....1153
Motorcycle fuses....1153
Fuses....1153
Removing and installing electronic equipment box....1153
Removing and installing coolant-temperature sensor....1154
See Group 17....1154
Removing and installing side stand switch....1154
Removing and installing rear-brake switch for brak....1154
Removing and installing front-brake switch for bra....1155
Removing and installing horn....1156
Removing and installing idle-indicator switch....1156
Removing and installing front and rear ABS sensors....1156
See Group 34....1156
62 Instruments....1157
Telltalewarning lights....1161
Removing and installing instrument panel....1162
Replacing telltalewarning lights....1162
Disassembling and assembling instrument cluster....1162
Removing and installing wiring harness....1163
63 Lights....1165
Removing and installing headlight....1169
Removing and installing rear light....1169
Replacing bulb....1170
Bulb for low-beam headlight high-beam headlight....1170
Bulb, parking light....1170
Flashing turn indicator....1171
Rear lights....1171
Checking and adjusting headlight beam angle....1171
Vertical adjustment....1171
Lateral adjustment....1171
BMW F650, F650CS, F650GS, F650ST, F650 Funduro, F650ST Strada Repair Service Manuals
