Bmw F650Cs Service Repair Manual-21215B320075.pdf -Bookmark created by https://wimanual.com Repair Manual Introduction Use Key to symbols Contents Activities Maintenance schedule Pre-delivery check Service data Contents 00 Tightening torques, Operating fluids Tightening torques Table of operating fluids 00 Pre-delivery check General view of crated motorcycle Checking the shipping crate for damage In case of damage in Germany In case of damage in importer markets Unpack the motorcycle Inspecting motorcycle for damage Checking that delivery is complete Installing remaining items on motorcycle Filling and charging the battery Removing the battery Filling and charging the battery Checking engine oil level Checking tyre pressures Final inspection and function check Final cleaning Handover 00 Maintenance Key to maintenance intervals Reading the fault code memory with the MoDiTeC (Inspections I, II, III and IV) Changing the engine oil [engine only] and oil filter element (Inspection I) Preparatory work Draining engine oil Replacing oil filter element Filling with engine oil Changing the engine oil [engine and oil tank] and oil filter element (Inspections II, III and IV) Preparatory work Draining engine oil Replacing oil filter element Filling with engine oil Cleaning oil strainer in frame (Inspection II, once only) Greasing rubber grommets for cover insert (Inspections I, II, III and IV) Checking coolant, topping up if necessary (Inspections I, II and III) Checking coolant Adding coolant Changing coolant (Inspection IV, every 2 years) Checking and adjusting valve clearances (Inspections II and III) Checking valve clearances Preparatory work Remove the intake air silencer together with the intake air pipe. Exposing the radiator Exposing cylinder head Turning crankshaft to TDC position Checking valve clearance Adjusting valve clearances Installing cylinder head cover Replacing spark plug (Inspection III) Emptying drain from intake air silencer (Inspections I, II and III) Replacing air cleaner element (Inspection III) Replacing fuel filter (Inspection III, every 40,000 km Checking clutch play, adjusting ifnecessary (Inspections I, II and III) Checking brake pads and discs for wear, replacing if necessary (Inspections II and III) Checking brake pads for wear Brake pads, front brake Brake pads, rear brake Replacing brake pads Brake pads, front brake Brake pads, rear brake Checking the brake discs Checking brake fluid level at front and rear (Inspections II and III) Brake fluid level (front brake) Checking brake fluid level (front brake) Brake fluid level (rear brake) Checking brake fluid level (rear brake) Checking operation of brake system and checking for leaks; repairing (Inspection III) Changing brake fluid and bleeding brake system (Inspection IV) Changing brake fluid and bleeding brake system (front brakes) Changing brake fluid and bleeding brake system (rear brakes) Replacing primary sealing boot, front brake master cylinder (Inspection III, every 40,000 km Replacing primary sealing boot, rear brake master cylinder (Inspection III, every 40,000 km Checking toothed belt pulley and sprocket, replacing if necessary (Inspection III) Replacing toothed belt (Inspection III) Checking belt tension, adjusting if necessary (Inspections I, II and III) Checking belt tension Adjusting belt tension Used belt, new belt Checking battery acid level, adding distilled water if necessary (Inspections II, III and IV) Checking battery acid level Adding distilled water Cleaning and greasing battery terminals, if necessary (Inspection IV) Checking and adjusting steering head bearing play, replacing if necessary (Inspections II and III) Checking steering head bearing play Adjusting steering head bearing play Greasing side stand (Inspections II and III) Side stand Checking specified torque of threaded fasteners with torque wrench (Inspections I, II, III and IV) Final inspection with road safety and functional check (Inspections I, II, III and IV) Road safety check Tyre tread depth (recommended minimum value) Tyre pressures (tyres cold) Roadworthiness check 11 Engine Technical Data Cutaway view of engine Engine oil circuit Engine and oil-tank system Valve gear Valves, components Oil pumps, components Removing and installing oil pressure switch with engine installed Removing and installing oil pressure switch Cleaning oil tank and oil lines Removing and installing cylinder head, engine installed Preparatory work Removing camshafts Removing cylinder head Removing cylinder, engine installed Removing engine Preparatory work Removing engine Transferring engine to assembly frame Disassembling engine Removing cylinder head Removing camshafts Checking camshaft for wear Removing and installing timing-chain sprockets Checking centrifugal decompressor lever Disassembling and assembling the centrifugal decompressor Removing cylinder head Checking timing chain for wear Disassembling and assembling cylinder head Removing valves Bore for bucket tappet Checking valve guide for wear Removing valve guide Installing valve guide Checking valve seat for wear Installing valve stem seal Checking valve for wear Installing valves Removing cylinder Checking cylinder Removing piston Disassembling piston Determining clearance of piston in cylinder Determining piston ring gaps Determining piston pin clearance Assembling pistons Removing ignition magneto Removing countershaft for starter Disassembling and assembling freewheel Disassembling freewheel Assembling freewheel Removing clutch Removing pressure plate Removing clutch plates Removing and installing oil pump Removing oil pump Inspecting oil pump Installing oil pump Removing double drive gear Removing crankshaft and balancing shaft Checking crankshaft for wear Removing compensating gear Removing and installing crankshaft gear Removing and installing gearbox mainshaft bearings Removing and installing gearbox countershaft bearings Removing and installing grooved ball bearings of balancing shaft Removing and installing main bearings Removal Installation Assembling engine Installing crankshaft and balancing shaft Shimming crankshaft Installing double drive gear Installing oil pump gears Installing clutch Installing clutch cage Installing driver Installing pressure plate Installing countershaft for starter motor Installing magnetic ignition trigger Installing piston Installing cylinder Installing cylinder head Installing camshaft and adjusting valves Installing engine Bleeding engine oil circuit 12 Engine electrics Technical Data Ignition magneto Ignition magneto, components Removing ignition magneto Removing right engine block cover Removing and installing ignition trigger Removing and installing stator Installing ignition magneto Installing magnet rotor Removing and installing, disassembling starter motor Removing and installing starter motor Disassembling and assembling starter motor Replacing spark plug (a00.42) Removing and installing coil 13 Fuel preparation and control Technical Data Removing and installing BMS control unit Removing and installing intake air pipe Removing and installing air temperature sensor Replacing air filter element (a00.43) Removing and installing intake air silencer Removing and installing intake air pipe Removing and installing injection nozzle Removing and installing throttle-valve actuator Replacing throttle-valve potentiometer Removing and installing throttle flap stub Removing and installing intake stub Checking fuel pressure Removing and installing fuel hoses Removing and installing feed and return lines Removing and installing line to fuel injector Removing and installing throttle cable (a32.12) 16 Fuel tank and lines Technical Data Removing and installing fuel tank Removing fuel tank Installing fuel tank Removing and installing fuel filler cap Removing and installing roll- over valve Replacing fuel filter (a00.44) Removing and installing fuel pump Removing and installing fuel- evaporation control valve [USA version] Removing and installing activated charcoal filter [USA version] 17 Radiator Technical Data Coolant circuit Thermostat, components Removing and installing coolant pump Removing coolant pump Installing coolant pump Adding coolant Removing and installing coolant-temperature sensor Checking cooling system for leaks Removing and installing coolant hoses Replacing coolant hose (cylinder head Replacing coolant hose (radiator Replacing coolant hose (filler bowl Changing coolant (a00.36) Removing and installing fan Removing and installing radiator Removing and installing thermostat 18 Exhaust system Technical Data Removing and installing exhaust system Removing and installing silencer (muffler) Removing and installing exhaust elbow and oxygen sensor Removing exhaust elbow and oxygen sensor Installing exhaust elbow and oxygen sensor Replacing guard for silencer 21 Clutch Technical Data Clutch, components Removing and installing clutch Removing clutch Removing pressure plate Disassembling and reassembling pressure plate Removing clutch plates, driver and clutch cage Installing clutch cage Installing driver Installing pressure plate Check clutch discs for wear Removing and installing release shaft Installing clutch 23 Gearbox Technical Data Gearbox shafts, components Gear shift pedal, components Replacing shaft sealing rings with engine installed Replacing sealing ring of selector shaft Replacing shaft sealing ring of belt sprocket Removing and installing gearbox Removing selector shaft with pawl and index lever Removing selector forks Removing selector drum Removing, disassembling and reassembling gearbox shafts Removing gearbox shafts Disassembling and reassembling mainshaft Checking mainshaft for wear Disassembling and reassembling countershaft Checking countershaft for wear Replacing gearbox mainshaft bearings Replacing gearbox countershaft bearings Installing gearbox shafts Installing selector shaft Installing selector forks Installing selector drum 27 Chain Technical Data Removing and installing belt, belt drive gear and belt sprocket Removing and installing belt (a00.54) Removing and installing belt sprocket (a33.13) Removing and installing belt sprocket Adjust belt tension (a00.56). 31 Front forks Technical Data Telescopic fork, components Removing and installing telescopic fork Removing telescopic fork Installing telescopic fork Disassembling telescopic fork Removing fixed tube Measuring telescopic fork Checking lower fork bridge Checking parallel alignment of fixed tubes Checking fixed tube runout Assembling telescopic fork Assembling fixed tube Complete assembly of telescopic fork. Removing and installing steering head bearing Upper steering head bearing Lower steering head bearing 32 Steering Technical Data Removing and installing left and right handlebar fittings Removing and installing left handlebar fitting Removing and installing clutch switch Removing and installing right handlebar fitting Removing and installing handlebar Removing and installing clutch cable Removing and installing throttle cable Removing and installing left and right handlebar levers Removing and installing left handlebar lever Removing and installing right handlebar lever Checking and adjusting steering head bearing play, replacing if necessary (a 00.60) 33 Rear wheel drive Technical Data Removing and installing suspension strut Removing and installing rear swinging arm Removing and installing needle roller races in rear swinging arm Removing needle roller races Installing needle roller races Removing and installing needle bearings in rear swinging arm Removing needle roller bearing Installing needle roller bearing Removing and installing reaction link Removing and installing angled lever Removing and installing needle roller bearings and needle roller races in angled lever Removing needle roller bearings and needle roller races Installing needle roller bearings and needle roller races Removing and installing drive damper Removing drive damper Removing pulley Disassembling drive damper Assembling drive damper Installing pulley Installing drive damper Measuring runout of belt pulley Removing and installing eccentric with drive shaft Separating eccentric from drive shaft Removing and installing floating bearing of eccentric Removing and installing fixed bearing of eccentric Pressing eccentric onto drive shaft 34 Brakes Technical Data Removing and installing front brake caliper Removing and installing front brake pads (a00.46) Removing and installing front brake pistons Removing and installing front brake disc Checking brake disc for wear (a00.45) Checking front brake disc for lateral runout Removing and installing rear brake caliper Removing and installing rear brake pads (a00.46) Removing and installing rear brake pistons Removing and installing rear brake disc Checking brake disc for wear (a00.47) Checking rear brake disc for lateral runout Replacing primary sealing boot, front brake master cylinder (a00.52) Removing and installing front brake master cylinder Removing and installing handbrake lever (a32.13) Replacing primary sealing boot, rear brake master cylinder (a00.53) Removing and installing rear brake master cylinder Removing and installing brake pedal Checking blow-by clearance at piston thrust rod, adjusting if necessary Checking blow-by clearance at piston rod Adjusting play at piston rod Removing and installing front ABS sensor Removing and installing front ABS sensor ring Removing and installing rear ABS sensor Removing and installing ABS control unit Removing and installing front brake lines Removing and installing brake lines Removing and installing front brake hoses Removing and installing rear brake lines Removing and installing brake lines Removing and installing brake hose Checking front ABS sensor ring for runout 36 Wheels and tyres Technical Data Removing and installing front wheel Removing front wheel Installing front wheel Removing and installing front wheel bearing Removing left-hand wheel bearing Removing right-hand wheel bearing Installing wheel bearings Removing and installing rear wheel Checking front and rear wheel rims Checking rims Static balancing of front 46 Frame Technical Data Overview of trim panels Removing and installing trim panels Removing and installing left and right covers Removing and installing rear cover Removing and installing front cover Removing and installing left and right covers Removing and installing windscreen and windscreen holder Removing and installing headlight surround Removing and installing instrument cover Removing and installing left Removing and installing left connector cover Removing and installing right connector cover Removing and installing fairing bracket Removing and installing front mudguard Removing and installing rear mudguard Removing and installing number- plate carrier Removing and installing spray guard Removing and installing number-plate carrier Removing and installing left Removing and installing luggage rack Removing and installing stowage- compartment frame Removing and installing oil-tank trim panels Raising, removing and installing rear frame Raising rear frame Removing and installing rear frame Removing frame Removing and installing left and right footrests Removing and installing rear footrest Removing and installing side stand truss Removing and installing side stand Measuring wheel track offset Measurement record, wheel track offset Key to measurement result: Checking frame with gauge Front wheel Rear wheel Example 51 Equipment Technical Data Removing and installing ignition switch Removing and installing lock barrel Removing and installing lock for rear stowage compartment Removing and installing lock barrel for fuel tank filler cap Replacing mirrors 61 General electrical equipment Technical Data Wiring harness View from left View from right Component positions in electronic equipment box Relay positions in electronic equipment box Connectors, electronics box Removing and installing battery (a00.20) Removing and installing battery carrier (a34.17) Replacing fuses Motorcycle fuses Fuses Removing and installing holder for BMS control unit Removing and installing coolant-temperature sensor (a17.10) Removing and installing side stand switch Removing and installing rear-brake switch for brake light Removing and installing front-brake switch for brake light Removing and installing horn Removing and installing neutral-indicator switch Removing and installing front Removing and installing voltage regulator Removing and installing switch for hazard warning flashers 62 Instruments Technical Data Telltale Removing and installing instrument panel Replacing telltale Disassembling and assembling instrument cluster Removing and installing wiring harness 63 Lights Technical Data Removing and installing headlight Removing and installing rear light Removing and installing number- plate light Replacing bulbs Bulb for low-beam headlight Bulb, parking light Flashing turn indicator Rear lights Bulb for number-plate light Checking and adjusting headlight beam throw Vertical adjustment Lateral adjustment . Notice: This is a preview not fully updated, please download the full version at https://wimanual.com