Professional Documents
Culture Documents
F 0175 ST 1003 F650GS 07
F 0175 ST 1003 F650GS 07
BMW Motorrad
On-board
documentation
consisting of
Rider's Manual
and Maintenance
Instructions
20r13bku4.book Seite 82 Montag, 29. September 2003 12:33 12
Please note
This symbol indicates pre-
cautions and measures which
are essential in protecting the
rider or other persons from
severe or fatal injury.
Specific instructions and safety
precautions intended to pre-
vent damage to the motorcycle.
Disregarding them may render
the warranty invalid.
Specific instructions on how to
operate, control, adjust or look
after items of equipment on the
motorcycle.
20r13bku4.book Seite 1 Montag, 29. September 2003 12:33 12
1
1
BMW Service
For safety reasons and to main-
have service and maintenance
tain the value of your motorcy-
performed by your authorized
cle, regular maintenance
BMW motorcycle retailer’s spe-
intervals have been laid down.
cially trained, expert personnel,
Always keep to the specified
and confirmed by an entry in the
maintenance intervals. This is
Maintenance Instructions.
the only way to ensure that war-
Authorized BMW motorcycle
ranty claims are not invalidated.
retailers are supplied with the
The contents of the mainte-
latest technical information and
nance schedules are subject to
have the necessary technical
change, for reasons of safety,
know-how and specially trained
due to modifications in, among
staff.
other things, materials.
It is advisable to contact your
Your authorized BMW motorcy-
authorized BMW motorcycle
cle retailer is best placed to
retailer if you have any ques-
provide information on the cur-
tions regarding your motorcy-
rently specified Service,
cle.
Inspection and Annual Inspec-
Authorized BMW motorcycle
tion work needed.
retailers are fully informed about
Important: all aspects of your motorcycle
BMW refuses to accept liability and will gladly advise and assist
for damage or consequential you.
damage due to repairs or ser-
vice work performed by other Best wishes,
than BMW-authorized work-
shops. BMW Motorrad
20r13bku4.book Seite 2 Montag, 29. September 2003 12:33 12
1
2
Maintenance
BMW Service
BMW Service
After the first 10,000 km
(6,000 miles) and every further
20,000 km (12,000 miles)
(30,000 km…, 50,000 km …,
70,000 km…) (18,000 miles...,
30,000 miles..., 42,000 miles)
BMW Inspection
After the first 20,000 km
(12,000 miles) and every further
20,000 km (40,000 km…, Every authorized BMW motor-
60,000 km …, 80,000 km…) cycle retailer has a fixed scale
(24,000 miles..., of charges based on work times
36,000 miles..., 48,000 miles) and carefully calculated hourly
BMW Annual Inspection rates.
Certain items of maintenance Fuel, lubricants and similar sub-
depend on elapsed time as well stances, filters, gaskets, etc.
as the distance the motorcycle are charged separately.
has covered. These tasks must
therefore be performed at least Maintenance schedule
once a year (e.g. changing the If you like, you can view the cur-
brake fluid). rent maintenance schedule for
If these items cannot be per- your motorcycle on the Internet
formed during a Service or an and download the file from
Inspection, an Annual Inspec- www.bmw-motorrad.com/
tion must be performed. maintenance.
20r13bku4.book Seite 4 Montag, 29. September 2003 12:33 12
Confirmation of maintenance
Confirmation of maintenance
BMW Service
Date, stamp, signature Date, stamp, signature
Confirmation of maintenance
Confirmation of maintenance
BMW Service
Date, stamp, signature Date, stamp, signature
Confirmation of maintenance
BMW BMW
Annual Inspection Annual Inspection
Performed in accordance with Performed in accordance with
BMW BMW
Annual Inspection Annual Inspection
Performed in accordance with Performed in accordance with
manufacturer’s instructions manufacturer’s instructions
Confirmation of maintenance
BMW BMW
Annual Inspection Annual Inspection
Performed in accordance with Performed in accordance with
manufacturer’s instructions manufacturer’s instructions
1
Brake fluid changed: Brake fluid changed: 9
yes no yes no
BMW Service
Coolant changed: Coolant changed:
yes no yes no
BMW BMW
Annual Inspection Annual Inspection
Performed in accordance with Performed in accordance with
manufacturer’s instructions manufacturer’s instructions
Confirmation of maintenance
BMW BMW
Annual Inspection Annual Inspection
Performed in accordance with Performed in accordance with
BMW BMW
Annual Inspection Annual Inspection
Performed in accordance with Performed in accordance with
manufacturer’s instructions manufacturer’s instructions
Confirmation of service
1
11
BMW Service
Confirmation of service
1
12
BMW Service
Confirmation of service
BMW Service
Date, stamp, signature Date, stamp, signature
General instructions
2
14
Maintenance and care
with a digital electronic engine
management system and a
high-power ignition system.
If you intend to perform the
maintenance and general care
work described in the following
When the engine is running or section yourself, you must pos-
the ignition is switched on, do sess the necessary knowledge
not touch electrically live of technical matters and
components, terminals or mechanical skills.
wiring. Your motorcycle is built to high
– Risk of fatal accident technological standards. Spe-
Work on the electrical system cial tools and purpose-
only when the circuit has designed diagnosis and testing
been interrupted (ignition equipment, together with the
switched off). For greater appropriate knowledge, are
safety, disconnect and insu- needed to keep your motorcy-
late the negative battery lead. cle in optimum working order.
20r13bku4.book Seite 15 Montag, 29. September 2003 12:33 12
General instructions
2
15
General instructions
2
16 Technical modifications are
only allowable to a limited
extent.
Maintenance and care
The motorcycle must not
infringe your national road-vehi-
Technical modifications cle construction and use regu-
lations.
Your authorized BMW motorcy-
cle retailer will gladly advise you
The data stored in the elec- on technical requirements, the
tronic engine management manufacturer’s recommenda-
system is the result of exten- tions and the overall benefit
sive experimental and testing likely to be obtained.
work.
Tampering with the electronic Genuine BMW parts
engine management system For reasons of safety, use only
represents an increased safe- genuine BMW parts and acces-
ty risk for the rider. sories.
Genuine BMW parts are identi-
cal with those fitted to your
motorcycle as original equip-
Manipulation of the electronic ment.
engine management system BMW Motorrad refuses to
voids the warranty in all instanc- accept any liability whatsoever
es of damage consequential to for other-make spare parts and
such manipulation. accessories.
20r13bku4.book Seite 17 Montag, 29. September 2003 12:33 12
Toolkit
2
17
Contents
1 case
1 screwdriver, reversible blade
1 cross-head screwdriver,
small
4 open-ended wrenches, 1 Allen key
8 x 10 mm (0.39 in), 8 mm (0.31 in)
14 x 19 mm (0.75 in), 4 Torx screwdrivers T25, T30,
15 mm (0.59 in), T40, T45
24 mm (0.94 in) 4 fuses 4 A, 7.5 A, 10 A, 15 A
1 spark plug wrench 1 puller for fuses
20r13bku4.book Seite 18 Montag, 29. September 2003 12:33 12
Troubleshooting chart
2 position b Chapter 1
interrupted
Gear engaged, clutch Select neutral or Rider’s Manual
not disengaged pull clutch lever b Chapter 3
Troubleshooting chart
It is advisable to have other
faults – not described on pages
14 ...62 – attended to by a spe-
More detailed technical infor-
mation is available in the follow-
cialized workshop, preferably ing publications:
an authorized BMW motorcycle – Repair Manual
retailer. – Electrical circuit diagrams
20r13bku4.book Seite 20 Montag, 29. September 2003 12:33 12
2
20
Maintenance and care
BMW special tool the brake lever when the brake
No. 36 3 970, or a suitable calipers have been removed.
auxiliary stand Motorcycle equipped with
ABSOE:
Do not damage the ABS sensor
cable, the ABS sensor ring and
Make sure that the front-wheel the ABS sensor.
stand is set to the correct width
and height. OE Optional equipment
20r13bku4.book Seite 21 Montag, 29. September 2003 12:33 12
1
2
21
• Remove securing screw 2,
Make sure that the motorcy- using 0.39 in (10 mm) open-
cle is standing firmly and can- ended wrench (b 17)
not topple forward or to either
side.
3
1 2
2
22
Maintenance and care
Make sure that the motorcy- Check the brake pads
cle is standing firmly and can- (b 33) (have them replaced if
not topple forward or to either necessary).
side.
5 2
23
7
Maintenance and care
6
the ABS sensor ringOE or the di- bushing 1 and spacer 4 and
rection-of-rotation arrow on the insert them into the wheel
tire. hub.
As viewed in forward direction
of travel:
– left: spacer 4 on right:
Do not damage the brake disk spacer bushing 1 with collar
or pads when fitting the wheel. toward the wheel hub
Motorcycle equipped with • Clean quick-release axle 2,
ABSOE: grease it and insert it from the
Do not damage the ABS sensor right (raising the wheel slightly
cable, the ABS sensor ring and as necessary) and hand-
the ABS sensor. tighten
• Insert ABS sensorOE 5 until
• Roll the front wheel between approx. 2/3 of its length are
the forks and carefully posi- inside the bore
tion the brake disk in the • Insert spacer 7
brake caliper. (if originally fitted)
• Install securing screw 6 and
OE Optional equipment tighten to specified torque
20r13bku4.book Seite 24 Montag, 29. September 2003 12:33 12
2
24
Maintenance and care
to the specified tightening Axle clamp screw 1....... 23 Nm
torque Securing screw,
• Tighten axle clamping ABS sensorOE ................ 9 Nm
screws 1 to the specified
tightening torque
2
2
25
1 1
Avoid damage to brake lines,
disk and pads when removing
the wheel.
Make sure that the motorcy-
cle is standing firmly and can-
not topple forward or to either
side.
Do not damage the ABS sensor
cableOE, ABS sensor ringOE and • Place the motorcycle on its
the speedometer sensor. main stand (Dakar: use auxil-
Do not press the brake pedal iary stand, BMW special tool
down when the wheel is number 00 1 610, or some
removed. other, suitable auxiliary stand)
Keep dirt and moisture away – Make sure the ground is
from the wheel bearings. level and firm.
• Remove 4 retaining screws 1
OE Optional equipment • Remove rear wheel cover 2
20r13bku4.book Seite 26 Montag, 29. September 2003 12:33 12
1 2 3
2
26
6
Maintenance and care
5
4
• Hold the brake caliper and roll
the wheel out toward the rear
2
27
When tensioning the chain,
note correct wheel alignment
• Roll the rear wheel between
the rear swinging arm forks
and carefully position the
brake disk in the brake caliper.
• Lift chain 5 onto sprocket 6
(marks on swinging fork arms). • Grease quick-release axle 1
To avoid damaging the chain or and insert it
more extensive damage, • Install axle nut 3 with
always adjust the chain so that washer 2 and hand-tighten
it has the correct amount of • Set chain tensioning screws 4
slack. on left and right such that
Do not damage the brake disk chain sag is correct
or pads when fitting the wheel. (setting b 31) as stated on
Do not damage the ABS sensor label 7
cableOE, ABS sensor ringOE and
the speedometer sensor. OE Optional equipment
20r13bku4.book Seite 28 Montag, 29. September 2003 12:33 12
2 1 1
28
Maintenance and care
2
3
2
29
Always have the security of the
fasteners checked by a special-
ized workshop, preferably an
authorized BMW motorcycle re-
tailer.
Checking chain
1
2
30
Maintenance and care
Checking chain for wear
Adjusting chain
2
31
Adjusting chain
Adjusting chain
1 1
2
32
Maintenance and care
3 3 2
Always have the chain tension
and the security of the fasteners
checked by a specialized work-
• Make sure that the same shop, preferably an authorized
number of notches has been BMW motorcycle retailer.
reached at marking point 1 on
the left and right swinging fork
arms X
Tightening torques
• Tighten axle nut 2 Axle nut 2 ................... 100 Nm
• Tighten chain tensioning Chain tensioning
screws 3 screws 3 ....................... 10 Nm
20r13bku4.book Seite 33 Montag, 29. September 2003 12:33 12
2
33
Front brake
Have brake pads replaced be- pads from in front
fore the minimum allowable • Check brake pad thickness
thickness is reached. Minimum pad thickness:
Wear indicating marks 1 must
be clearly visible on the pads.
– If the wear indicating mark is
For your safety, we recommend no longer clearly visible:
having work on the brake sys- have the brake pads replaced
tem performed by a specialized by a specialized workshop,
workshop, preferably an autho- preferably an authorized
rized BMW motorcycle retailer. BMW motorcycle retailer.
20r13bku4.book Seite 34 Montag, 29. September 2003 12:33 12
2
34
Maintenance and care
Rear brake
Have brake pads replaced be- • Check brake pad thickness
fore the minimum allowable Minimum pad thickness:
thickness is reached. Angled wear indicating mark
1 must be clearly visible on
the pads.
– If the wear indicating mark is
For your safety, we recommend no longer clearly visible:
having work on the brake sys- have the brake pads replaced
tem performed by a specialized by a specialized workshop,
workshop, preferably an autho- preferably an authorized
rized BMW motorcycle retailer. BMW motorcycle retailer.
20r13bku4.book Seite 35 Montag, 29. September 2003 12:33 12
Adding coolant
2
35
Use only nitrite-free antifreeze
and corrosion inhibitor.
Check coolant level only when
the engine is cold.
Top up the fluid in the expan- • Place the motorcycle on its
sion tank only if the loss of cool- main stand [Dakar: side stand]
ant is minor. – Make sure the ground is
Mixing ratio: level and firm.
• 50% antifreeze • Remove the seat
• 50% water (b Rider's Manual)
Frost protection down to: • Remove the left side panel
-25 °C (-13 °F) (b 44-45)
20r13bku4.book Seite 36 Montag, 29. September 2003 12:33 12
Adding coolant
2
36
Maintenance and care
MAX
MIN
• Recheck the coolant level;
correct if necessary
• Reinstall the cap of the
expansion tank
37
with a digital electronic engine bulbs for the turn indicators.
management system and a If any of these bulbs should fail,
high-power ignition system. you may have problems in see-
ing and being seen.
You should therefore always
carry spare bulbs on the motor-
Work on the electrical system cycle.
only when the circuit has
been interrupted (ignition and
lights switched off). For
greater safety, disconnect Do not touch the glass of new
and insulate the negative bat- bulbs with your fingers.
tery lead. Use a clean, dry cloth to hold
When the engine is running or the bulbs when inserting them.
the ignition is switched on, do Dirt deposits, in particular oil
not touch electrically live and grease, interfere with heat
components, terminals or radiation from the bulb. This
wiring. leads to overheating and short-
– Risk of fatal accident ens the bulb’s operating life.
20r13bku4.book Seite 38 Montag, 29. September 2003 12:33 12
Changing bulbs
2
38
Maintenance and care
1 2 3
• Place the motorcycle on its
Turn indicators main stand [Dakar: side stand]
– Make sure the ground is
level and firm.
• Remove securing screw 1
Switch off the ignition before • Remove turn indicator glass 3
changing a bulb. • Press bulb 2 back, turn it
counter-clockwise to disen-
gage it and remove
• Installation is the reverse of
Avoid touching the glass of new the removal procedure
bulbs with your fingers. Use a – Bulbs for front/rear turn indi-
clean, dry cloth to hold the cators:
bulbs when inserting them. 12 V 10 W
20r13bku4.book Seite 39 Montag, 29. September 2003 12:33 12
Changing bulbs
1 2
39
2
3
Tail light/brake light
The rear light is also the license
plate light. • Place the motorcycle on its
main stand [Dakar: side stand]
– Make sure the ground is
level and firm.
Switch off the ignition before • Remove retaining screws 1
changing a bulb. • Remove rear light glass 2
• Press bulb 3 back, turn it
counter-clockwise to disen-
gage it and remove
Avoid touching the glass of new • Installation is the reverse of
bulbs with your fingers. Use a the removal procedure
clean, dry cloth to hold the – Brake/rear light bulb:
bulbs when inserting them. 12 V 21/5 W
20r13bku4.book Seite 40 Montag, 29. September 2003 12:33 12
Changing bulbs
1
2
2 4
40
3
Maintenance and care
• Place the motorcycle on its
main stand [Dakar: side stand]
Parking light – Make sure the ground is
level and firm.
• Pull off multi-pin plug 2
• Pull the rubber sleeve 1 to the
Switch off the ignition before rear to remove
changing a bulb. • Pull bulb holder 4 to the rear
and out of the headlight hous-
ing
• Pull bulb 3 out of bulb
Avoid touching the glass of new holder 4
bulbs with your fingers. • Installation is the reverse of
Use a clean, dry cloth to hold the removal procedure
the bulbs when inserting them. – Parking light bulb: 12 V 5 W
20r13bku4.book Seite 41 Montag, 29. September 2003 12:33 12
Changing bulbs
1 2
3 4
2
41
• Pull off multi-pin plug 2
High-beam/low-beam • Pull rubber sleeve 1 to the
headlight rear to remove
• Turn retainer 4 counter-
clockwise to disengage
• Remove bulb 3
Switch off the ignition before • Installation is the reverse of
changing a bulb. the removal procedure
– Low/high beam headlight
bulb: H4 12 V 55/60 W
Fuses
2
2
42
1
Maintenance and care
Changing fuses
• Place the motorcycle on its • Squeeze clips 1 together and
main stand [Dakar: side stand] remove the cover of the fuse
– Make sure the ground is box
level and firm. • Use puller 2 (b 17) to remove
• Remove the seat the blown fuse from its socket
• Insert a new fuse of the cor-
rect rating
• Close the fuse box lid
Before changing a fuse, switch • Close and lock the seat
off the ignition.
Never attempt to repair a blown
fuse – risk of fire
For this reason, always carry a It is advisable to have the elec-
number of spare fuses in the trical system checked by a spe-
toolkit (b 17). cialized workshop, preferably
Use only fuses of the specified an authorized BMW motorcycle
rating and type. retailer, if fuses blow frequently.
20r13bku4.book Seite 43 Montag, 29. September 2003 12:33 12
Fuses
2
5 3 43
Equipment connected to
fuses
1 Engine electronics ..... 15 A
2 Instrument panel,
on-board socket,
diagnosis plug, 6 Brake light,
OA plug ...................... 10 A turn indicators,
3 Horn, instrument panel,
headlight flasher ........ 7.5 A instrument lighting ..... 7.5 A
4 Low-beam headlight .. 7.5 A 7 Parking light, tail light... 4 A
5 High-beam headlight 7.5 A 8 Heated handlebar grips 4 A
20r13bku4.book Seite 44 Montag, 29. September 2003 12:33 12
Side panel
1 2
2
44
3
Maintenance and care
Side panel
2
45
Removing and installing
left side panel
Jump starting
2 1
46
Maintenance and care
3 2
Jump starting
Battery adapter points Do not use proprietary start-
BMW calls an easily accessible assist sprays to start the
battery positive terminal 1 and a engine.
defined grounding point 2 the Use only jump leads fitted with
battery adapter points. fully insulated crocodile clips at
The battery adapter points both ends for jump starting.
make it easy to recharge the
battery and are also convenient
for jump starting.
If you switch on the ignition and
the indicator lights fail to light
up, the battery is completely
Never establish a direct con- flat. In this case, do not attempt
nection between battery posi- to jump-start the motorcycle:
tive terminal 1 and earth (frame/ recharge the battery instead.
drive). Risk of damaging the control
– Risk of short-circuit units.
20r13bku4.book Seite 47 Montag, 29. September 2003 12:33 12
Jump starting
from the positive terminal
• Connect one end of a jump
lead to positive terminal 1 of
the discharged battery, and
the other end to the positive
terminal of the donor battery
Do not attempt to jump-start • Connect one end of the sec-
the motorcycle using the on- ond jump lead to the negative
board socket terminal/grounding point of
– Risk of fire the donor battery and the
The wires leading to the power other end to negative termi-
socket do not have a load-ca- nal/grounding point 2 of the
pacity rating adequate for jump- discharged battery
starting the engine. • Start the engine of the donor
vehicle and allow it to run at
fast idle
• Start the engine of the vehicle
Make sure that the battery of with the discharged battery in
the other vehicle has a voltage the usual way
rating of 12 V • Allow both engines to idle for
a few minutes
• Switch off the ignition sys- • Disconnect the jump leads by
tems of both vehicles reversing the connection
• Switch off all electrical con- sequence, and reinstall cap 3
sumers on both vehicles on the positive terminal
20r13bku4.book Seite 48 Montag, 29. September 2003 12:33 12
2
48
Always wear protective gog-
gles and protective gloves
when performing work asso-
Maintenance and care
ined by a physician without
delay.
First aid prior to treatment by
a physician:
• Contact with skin: rinse with
plenty of clean water
Battery acid is highly caustic. • Acid swallowed: victim
Do not allow it to contact the must drink plenty of water
eyes, face, hands, clothing or or milk (into which a raw
paint work. egg should be stirred).
KEEP OUT OF REACH OF Do not cause the victim to
CHILDREN vomit.
Never create sparks or bring • Eyes attacked by battery
a naked flame or a glowing acid or fumes from battery:
cigarette near the battery. Rinse the eyes out several
Batteries generate explosive times with plenty of clean
gases. water. The eyelid should be
Charge batteries only in well- held open while doing so.
ventilated areas. Be sure to • Thoroughly rinse clothing
open the plugs of all the bat- wetted by battery acid
tery cells. immediately with water
20r13bku4.book Seite 49 Montag, 29. September 2003 12:33 12
2
49
• Check battery acid level with the BMW battery trickle
• Store the battery in a cool, dry charger OA.
room – Charge the battery prior to
lay-ups and before returning
to use – always comply with
the instructions for charging.
If the battery is not recharged at – In case of doubt ask a spe-
regular intervals while out of use cialist, preferably an autho-
it will self-discharge until it is rized BMW motorcycle
completely flat, in which case retailer, to prepare the vehicle
the guarantee is voided. for storing and to carry out the
necessary battery mainte-
OA Optional accessory nance and storage
20r13bku4.book Seite 50 Montag, 29. September 2003 12:33 12
Removing battery
5 2 1
2
50
Maintenance and care
4 3
• Place the motorcycle on its
main stand [Dakar: side stand]
– Make sure the ground is
level and firm.
• Remove the seat
• Remove the side panel
Do not damage cables and (b 44-45)
hoses when removing. • Disconnect battery breather
Before disconnecting the bat- hose 4
tery, switch off the ignition. • Disconnect negative battery
To avoid short-circuits: lead 3 and swing it away from
• Disconnect negative battery the negative post of the bat-
lead (—) 3 first, tery or insulate it
• then positive battery lead • Push aside protective cap 1
(+) 2. for the positive terminal of the
battery
• Disconnect positive battery
lead 2
Do not, under any circumstanc- • Release battery retaining
es, set the battery on the motor- strap 5
cycle. • Take out the battery
20r13bku4.book Seite 51 Montag, 29. September 2003 12:33 12
Installing battery
2
51
4
Before connecting the bat-
tery, make sure the ignition is
switched off. Make sure that breather hose 4
To avoid short-circuits: for the battery is routed free of
• Connect positive battery kinks and is not clogged.
lead (+) 2 first
• Seat protective cap 1 on the • Grease the battery posts
battery positive terminal • Installation is the reverse of
– Never install the battery the removal procedure
without the protective cap • Install the side panel
• Connect negative battery (b 44-45)
lead (—) 3 • Install the seat
20r13bku4.book Seite 52 Montag, 29. September 2003 12:33 12
Battery
MAX
2
52
MIN
Maintenance and care
• Top up with distilled water
only as far as the MAX
(UPPER) mark
Checking battery
acid level
– Check the level of acid in the
battery every three months or Do not set the battery on the
more frequently if ambient motorcycle when you are top-
temperatures are high ping up the acid level. Use only
• Remove the side panel distilled water: do not top up
(b 44-45) with battery acid.
20r13bku4.book Seite 53 Montag, 29. September 2003 12:33 12
3 4
2
53
1
5
• Remove the right side panel • From this point on, installation
(b 44-45) is the reverse of the removal
• Remove two securing procedure
screws 1
• Pull bow 2 of the connecting
flange off intake stub 3
• Pull intake stub 3 out of the When installing intake stub 3,
connecting flange and front begin by slipping the projection
holder 4 into front holder 4.
20r13bku4.book Seite 54 Montag, 29. September 2003 12:33 12
Spark plugs
2
54
Maintenance and care
When the engine is running or
the ignition is switched on, do
not touch electrically live
components, terminals or
wiring.
– Risk of fatal accident
• Work on the electrical sys-
tem only when the circuit
has been interrupted (igni-
Your motorcycle is equipped tion and lights switched off).
with a digital electronic engine For greater safety, discon-
management system and a nect and insulate the nega-
high-power ignition system. tive battery lead.
20r13bku4.book Seite 55 Montag, 29. September 2003 12:33 12
Spark plugs
1
2
55
Changing secondary
spark plug
• Turn direct ignition coil 1 as
far as it will go clockwise
(arrow)
The direct ignition coils have
different color codes: take care
not to mix them up. Direct igni-
• Pry direct ignition coil 1 up tion coil of the
and off, using 0.59 in (15 mm) primary spark plug: black
open-ended wrench (b 17) secondary spark plug: white
• Remove spark plug 2, using
X
spark plug socket wrench
(b 17) Tightening torques
• Installation is the reverse of Secondary
the removal procedure spark plug 2 ................. 20 Nm
20r13bku4.book Seite 56 Montag, 29. September 2003 12:33 12
Spark plugs
2 1
56
Maintenance and care
coil of the secondary spark
Changing primary plug
spark plug • Turn direct ignition coil 1 as
far as it will go counter-clock-
wise (arrow)
• Pry direct ignition coil 1 up
In order to prevent foreign mat- and off, using 0.59 in (15 mm)
ter from entering the combus- open-ended wrench (b 17)
tion chamber, allow the sec- • Remove spark plug 2, using
ondary spark plug to remain in the spark plug socket wrench
the cylinder head. and extension (b 17)
The direct ignition coils have • Installation is the reverse of
different color codes: take care the removal procedure
not to mix them up. Direct igni-
X
tion coil of the
primary spark plug: black Tightening torques
secondary spark plug: white Primary spark plug 2 ... 20 Nm
20r13bku4.book Seite 57 Montag, 29. September 2003 12:33 12
Cleaning/care
2
57
Do not use aggressive or pene-
trating cleaning agents or sol-
vents, as they would cause
damage to rubber and plastic
parts.
Do not use a steam jet or high-
pressure cleaning equipment.
Correct and regular cleaning is
an important factor in maintain-
ing the value of your motorcy-
High water pressure can dam- cle.
age seals, the hydraulic brake It also ensures that safety-rele-
system or the complete electri- vant parts remain in full working
cal system. order.
20r13bku4.book Seite 58 Montag, 29. September 2003 12:33 12
Cleaning/care
2
58
Maintenance and care
• Thoroughly dry all wet sur-
Washing motorcycle faces
• Do not use solvents or clean-
ing products on the instru-
ment group, switches or
After cleaning and before windshield
starting a journey, always test • Do not scratch the wind-
the brakes. shield.
• Remove tar splashes only
• Place the motorcycle on its with an approved product –
main stand [Dakar: side stand] rinse thoroughly with water
– Make sure the ground is afterwards.
level and firm. • Clean dead flies and other
• Apply a mild cleaning agent to insects or similar dirt deposits
the wheels, engine block and off the fork stanchions.
swinging arm, in accordance • Treat painted and chrome-
with the manufacturer's plated surfaces regularly with
instructions the approved care products.
20r13bku4.book Seite 59 Montag, 29. September 2003 12:33 12
Cleaning/care
2
59
• Wash the motorcycle down
immediately with cold water at Cleaning windshield
the end of the journey. • Remove dirt and dead insects
with a soft sponge and plenty
of water
Soften stubborn dirt or insects
• Thoroughly dry the motorcy- by soaking with a wet paper
cle. towel.
• Apply a wax-based corrosion
inhibiting product to chrome-
plated parts.
• After cleaning and drying the Do not use cleaning agents. Fuel
fairing and trim panels, apply or chemical solvents attack the
a recommended wax polish. windshield material.
20r13bku4.book Seite 60 Montag, 29. September 2003 12:33 12
Cleaning/care
2
60
Maintenance and care
surface can be touched up
with a BMW touch-up pencil
of the correct color
Care of chain
• Regularly apply a spray lubri-
cant to the chain; spray lubri-
cants are available from your Comply with the manufacturer's
authorized BMW motorcycle working instructions and safety
retailer. precautions.
Care of muffler
• Changes in the appearance of
the exhaust system during The correct color is stated on a
operation or as a result of label under the seat.
environmental influences can It is advisable to have more ex-
be treated with a polish avail- tensive paint damage repaired
able from your authorized by your authorized BMW motor-
BMW motorcycle retailer. cycle retailer.
20r13bku4.book Seite 61 Montag, 29. September 2003 12:33 12
Storing
2
61
• Clean the motorcycle (b 58)
• Remove the battery (b 50)
comply with the maintenance
instructions (b 49).
• Spray the brake and clutch
lever pivots and the main and
side stand pivots with a suit- Before storing the motorcycle,
able lubricant it is advisable to have the en-
• Coat bright metal/chrome- gine oil changed by your autho-
plated parts with an acid-free rized BMW motorcycle retailer.
grease (e.g. Vaseline) Work needed in conjunction
• Place the motorcycle on its with storing or returning to use
center stand in a dry place can best be combined with the
• Support it under the engine Service or Inspection work per-
so that both wheels are clear formed when due by the autho-
of the ground. rized BMW motorcycle retailer.
20r13bku4.book Seite 62 Montag, 29. September 2003 12:33 12
Returning to use
2
62
Maintenance and care
Returning to use
• If necessary, remove protec-
tive wax coating
• Clean the motorcycle (b 58) • Check/correct tire pressures
• Install a charged battery (b Rider's Manual, Chapter 2)
(b 51) • Check brakes
• Coat the battery terminals (b Rider's Manual, Chapter 2)
with grease suitable for bat- • Run all safety checks
tery posts (b Rider's Manual, Chapter 2)
20r13bku4.book Seite 63 Montag, 29. September 2003 12:33 12
Engine
F 650 GS F 650 GS
[37 kW] [25 kW]
Type Liquid-cooled single-cylinder four-
stroke engine with 4 valves with
bucket tappets, 2 overhead cam- 3
shafts, dry-sump lubrication 63
Displacement 652 cc 652 cc
Technical data
Maximum rated output in accordance with DIN 70 020
37 kW 25 kW
50 hp 34 hp
at engine speed 6,500 rpm 5,500 rpm
Maximum torque 60 Nm 51 Nm
at engine speed 4,800 rpm 4,000 rpm
Allowable speeds
Maximum engine speed 7,400 rpm 7,400 rpm
Idle speed 1,500 rpm 1,500 rpm
Bore/stroke 3.94/3.27 in 3.94/3.27 in
(100/83 mm) (100/83 mm)
Compression ratio 11.5 : 1 11.5 : 1
F 650 GS
Fuel grade Regular unleaded fuel to DIN 51607
or equivalent standard, min. octane
number 91 (RON) or 81 (MON)
Tank capacity (usable) 4.57 gal (17.3 l),
including 1 gal (4 l) reserve
Fuel consumption
constant 90 km/h (55 mph) 73.5 mpg (3.2 l/100 km)
constant 120 km/h (75 mph) 54.7 mpg (4.3 l/100 km)
20r13bku4.book Seite 64 Montag, 29. September 2003 12:33 12
Power train
F 650 GS
Clutch Multi-plate clutch running in oil bath
Primary transmission 37/72 = 1:1.946
3 Transmission 5-speed, with claw-action shift,
integrated into engine block
64
Gear ratios 1st gear = 2.75
in the transmission 2nd gear = 1.75
Technical data
F 650 GS
Frame Bridge-type frame with bottom rail
Location
of type plate On top rail of main frame, right
3
Location
65
of vehicle identification On right of steering head
number (VIN)
Technical data
Front brake Hydraulically actuated single-disk
brake with 2-piston floating caliper
Rear brake Hydraulic disk brake with
1-piston floating caliper
20r1303u4.fm Seite 66 Montag, 6. Oktober 2003 2:58 14
F 650 GS
Suspension
Front Telescopic fork with stabilizer
3 Total suspension travel 6.69 in (170 mm)
66 Dakar version 8.27 in (210 mm)
Fixed tube diameter 1.61 in (41 mm)
Technical data
F 650 GS F 650 Dakar
Wheels and tires Spoked wheel
3
You can obtain detailed information 67
on approved tire sizes and makes
from your authorized BMW motor-
Technical data
cycle retailer or by visiting
www.bmw-motorrad.com on the
Internet
Front wheel
Size and designation 2.50“ x 19“ MT 1.6" x 21"
Tire size and designation 100/90-19 90/90-21
Rear wheel
Size and designation 3.00“ x 17“ MT
Tire size and designation 130/80 R 17 130/80-17
Tire pressures (tires cold)
One-up Front 27.56 psi (1.9 bar)
Rear 30.46 psi (2.1 bar)
Fully loaded Front 30.46 psi (2.1 bar)
Rear 33.36 psi (2.3 bar)
Recommended minimum tire tread depth
Front wheel 0.08 in (2 mm)
Rear wheel 0.12 in (3 mm)
F 650 GS
Engine oil
Brand-name HD oil of API classification SF, SG or SH;
3 CD or CE amendments are permissible; or brand-name HD
oil of CCMC classification G4 or G5;
68
amendment PD2 is permissible.
SAE 20
Technical data
SAE 30
SAE 40
–30 –20 –10 0 10 20 30
°C
–20 0 20 40 60 80
°F
SAE 15 W-50
SAE 15 W-40
SAE 10 W-40
SAE 10 W-30
SAE 10 W-X Special Oils (X≥40)
SAE 5 W-X Special Oils (X≥40)
With filter change 2.3 l
Maximum oil 2,352 US miles/gal
consumption (1 l/1000 km)
F 650 GS
Telescopic fork oil
Approved grades BMW telescopic fork oil
Refill after disassembly 0.64 US quarts (0.61 l)
3
Dakar version 0.59 US quarts (0.56 l)
69
Oil change 0.63 US quarts (0.60 l)
Dakar version 0.58 US quarts (0.55 l)
Technical data
Battery terminal Acid-free grease,
corrosion protection e.g. Vaseline
Bearing lubrication and Brand-name anti-friction bearing
lubricating points grease, usable temperature range
-22 °F ... +284 °F
(-30 °C...+140 °C),
drip point 302 °F ... 446 °F
(150 °C...230 °C),
high corrosion protection,
good resistance to water and oxi-
dation; e.g. Staburags
NBU 30 PTM
20r13bku4.book Seite 70 Montag, 29. September 2003 12:33 12
F 650 GS
Brake fluid DOT 4
We recommend BMW brake fluids
3
70 Use only new brake fluid to DOT 4
specification.
Technical data
Electrical system
F 650 GS
Spark plugs
Approved makes/types
NGK DR8 EB
3
Electrode gap 0.02 - 0.03 in
71
(0.6 - 0.7 mm)
Wear limit 0.0354 in
Technical data
(0.9 mm)
Fuses “Minifuse”
flat-socket fuses
Ratings 4 A, 7.5 A, 10 A and 15 A
Headlights Halogen headlight
Bulbs
High-beam/low-beam H4 halogen bulb, 12 V, 60/55 W
headlight
Parking light 12 V 5 W
Rear light
Brake/tail light 12 V 21/5 W
Turn indicators 12 V 10 W
Other warning/indicator lights
and instrument lighting 12 V 1.2 W
20r13bku4.book Seite 72 Montag, 29. September 2003 12:33 12
F 650 GS
Overall length 86.02 in (2,185 mm)
Dakar version 86.18 in (2,189 mm)
3 Width
across mirrors 35.82 in (910 mm)
72
acr. handlebars (with 31.69 in (805 mm)
weights)
Technical data
F 650 GS
Wet weight
(ready to ride, tank full) 428 lbs (194 kg)
Maximum allowable 3
weight 838 lbs (380 kg) 73
Allowable wheel loads
Technical data
Front 273 lbs (124 kg)
Rear 564 lbs (256 kg)
20r13bku4.book Seite 74 Montag, 29. September 2003 12:33 12
Performance data
F 650 GS F 650 GS
[37 kW] [25 kW]
Maximum speed
Power/weight ratio
ready for road + rider 15.96 lbs/kW 23.63 lbs/kW
(75 kg/165 lbs) (7.24 kg/kW) (10.72 kg/kW)
at gross weight limit 22.64 lbs/kW 33.51 lbs/kW
(10.27 kg/kW) (15.20 kg/kW)
Flexibility
4th gear 80-120 km/h
(50-75 mph) 5.4 s 7.9 s
5th gear 80 -120 km/h
(50 -75 mph) 6.9 s 10.2 s
4th gear 60-140 km/h
(37-87 mph) 12.6 s –
5th gear 60 -140 km/h
(37 - 87 mph) 16.6 s –
Ride-past noise level
to 97/24-9/EC 79 dB (A) 79 dB (A)
Stationary noise level
to 97/24-9/EC 86 dB (A) 86 dB (A)
20r13bku4.book Seite 75 Montag, 29. September 2003 12:33 12
A-C
A parking light, 40
Accessories, genuine BMW rear light/brake light, 39
parts, 16 turn indicators, 38
Air filter, 53 Technical data, 71
Allowable gross weight, 73
Annual Inspection C
i
Confirmation of Capacity, engine, 68 75
maintenance, 8, 9, 10 Castor, 66
Annual Inspection, notes, 3 Chain, 31
Index
Adjusting, 31
B Checking, 30
Battery Cleaning/care
Maintenance instructions, 52 General instructions, 57, 59
Preparation for prolonged lay- Paint damage, 60
up, 49 Removing road salt, 59
Safety instructions, 48 Washing, 58
Battery acid, 49 Windshield, 59
Battery adapter point, 46 Clutch technical data, 64
Battery trickle charger, 49 Compression ratio, 63
Bearing lubrication, 69 Confirmation of maintenance
Bore/stroke, 63 Annual Inspection, 8, 9, 10
Brake fluid, 70 Inspection, 4, 5, 6
Brake light bulb Service, 4, 5, 6
Changing, 39 Confirmation of odometer
Brakes change, 13
Minimum pad Confirmation of service
thickness, 33, 34 work, 11, 12
Technical data, 65 Consumption, 63
Bulbs Coolant, 70
Changing Antifreeze, 35
high-beam/low-beam Mixture ratio, 35
headlight, 41
license plate light, 39
20r13bku4.book Seite 76 Montag, 29. September 2003 12:33 12
D-P
D G
Dimensions and weights, 72, 73 Gear ratios, 64
Displacement, 63 General instructions, 14, 15
Drive chain Ground clearance, 72
i Check, 31
H
76 E Headlights, 71
Elasticity, 74
Engine oil I
Index
F L
Frame, 65 Lights, technical data, 71
Front brake Low-beam/high-beam headlight
Checking pads, 33 bulb
Technical data, 65 Changing, 41
Front wheel
Installing, 23, 24 M
Removing, 20, 21 Maximum speed, 63, 74
Technical data, 67
Front-wheel stand, 20 O
Fuel Odometer change,
Consumption, 63 confirmation, 13
Grade, 63 Oil capacity, engine, 68
Fuel tank capacity, 63
Fuses P
Equipment connected to, 43 Parking light bulb
Ratings, 71 Changing, 40, 41
Replacing, 42 Performance data, 74
Plastics, cleaning, 57
20r13bku4.book Seite 77 Montag, 29. September 2003 12:33 12
P-Z
Power output, 63 T
Power/weight ratio, 74 Technical modifications, 15
Pre-delivery check, 4 Telescopic forks, 69
Primary drive ratio, 64 Tires, 67
R
Approved sizes, 67
Technical data, 67
i
Rear brake Tire pressures, 67 77
Checking pads, 34 Tread depth, 67
Technical data, 65 Toolkit, 17
Index
Rear wheel Torque, 63
Installing, 27, 28, 29 Touching up minor damage, 60
Removing, 25, 26 Transmission
Technical data, 67 Ratios, 64
Rear wheel drive, technical Technical data, 64
data, 64 Tread depth, 67
Ride-past noise level, 74 Type plate, 65
S V
Safety information, 2 VIN, 65
Safety instructions, 14, 37, 54
Explanation, 82 W
Salt damage, 59 Weights and dimensions, 72, 73
Seat height, 72 Wet weight, 73
Service, notes, 3 Wheel loads, 73
Spark plug, 54 Wheel suspension, technical
Primary spark plug, 56 data, 66
Secondary spark plug, 55 Wheelbase, 72
Spark plugs, technical data, 71 Wheels, technical data, 67
Stationary noise level, 74 Windshield, cleaning, 59
Steam-jet/high-pressure cleaning
equipment, 57
Steering lock angle, 66
20r13bku4.book Seite 78 Montag, 29. September 2003 12:33 12
i
78
20r13bku4.book Seite 79 Montag, 29. September 2003 12:33 12
i
79
20r13bku4.book Seite 80 Montag, 29. September 2003 12:33 12
Motorcycle data
Model
i
80
Frame no.
Color no.
First registered on
Registration no.
Retailer data
Ms./Mr.
Tel. no.
BMW Motorrad
On-board
documentation
consisting of
Rider's Manual
and Maintenance
Instructions
20r13bku4.book Seite 82 Montag, 29. September 2003 12:33 12
Please note
This symbol indicates pre-
cautions and measures which
are essential in protecting the
rider or other persons from
severe or fatal injury.
Specific instructions and safety
precautions intended to pre-
vent damage to the motorcycle.
Disregarding them may render
the warranty invalid.
Specific instructions on how to
operate, control, adjust or look
after items of equipment on the
motorcycle.
20r13bku4.book Seite 83 Montag, 29. September 2003 12:33 12
BMW Motorrad
Printed information
Order No.:
01 47 7 685 947
10.2003
1st edition US / RF The Ultimate
Driving Machine
20r13bku4.book Seite 83 Montag, 29. September 2003 12:33 12
BMW Motorrad
Printed information
Order No.:
01 47 7 685 947
10.2003
1st edition US / RF The Ultimate
Driving Machine