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BMW F650GS Workshop Service Repair Manual

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This manual covers the F650GS (Single Cylinder), chassis code E169, a versatile dual-sport/adventure touring motorcycle produced from approximately 1993 to 2007. Known for its accessible seat height and a robust,...
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BMW F650GS Workshop Service Repair Manual
This manual covers the F650GS (Single Cylinder), chassis code E169, a versatile dual-sport/adventure touring motorcycle produced from approximately 1993 to 2007. Known for its accessible seat height and a robust, Rotax-built single-cylinder engine, the F650GS is celebrated for its reliability and adaptability for both on-road commuting and light off-road exploration. This model, with its 652 cc liquid-cooled engine featuring electronic fuel injection, offers a balance of performance and efficiency, making it a popular choice in its segment, often compared to models from Honda, Suzuki, Kawasaki, and Yamaha. This comprehensive Workshop Service Repair Manual provides detailed information for the maintenance and repair of the F650GS. It encompasses a wide range of systems including lubrication, suspension, brakes, cooling, electrical, engine, fuel, exhaust, and transmission. The manual details routine maintenance procedures, engine overhaul, chassis system repairs, electrical diagnostics, and troubleshooting for common issues. With extensive coverage including detailed wiring diagrams and specifications, this manual serves as an indispensable resource for owners, mechanics, and technicians seeking to maintain and repair this iconic motorcycle.
🏷️ Basic Information
Identification
Make:
BMW
Model:
F650GS
Generation
Generation Identifier:
F650GS (Single Cylinder)
Codes
Chassis Code:
E169
👋 Introduction
Market Position
Segment:
Dual-sport / Adventure Touring Motorcycle
Competitive Analysis
Competitors:
Honda Transalp, Suzuki V-Strom 650, Kawasaki KLR650, Yamaha XT660R/X
Key Features
Distinctive Attributes:
Known for its accessible seat height, robust single-cylinder engine (Rotax-built), versatility for both on-road commuting and light off-road excursions. Often praised for its reliability and ease of maintenance, especially for a BMW motorcycle.
📋 Manual Details
Coverage Areas
Systems Covered:
Lubrication & Maintenance, Suspension, Brakes, Cooling System, Electrical System, Engine, Fuel System, Exhaust System, Transmission, Heating and Air Conditioning, Emission Control Systems, Body, Wiring Diagrams
Page Count
Estimated Page Count:
Extensive (Likely 500+ pages based on scope)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, cylinder head, valve train, piston and connecting rod, crankshaft, oil pump, cooling system, fuel injection system, ignition system, exhaust system, emission control systems
Transmission Systems:
Clutch, gearbox, final drive (chain and sprockets)
Chassis Systems:
Frame, suspension (front fork, rear shock absorber), steering system, braking system (front and rear brakes, hydraulic lines, ABS if equipped)
Electrical Systems:
Battery, starter motor, alternator, ignition, lighting, instrumentation, onboard computer, ABS electronics, wiring diagrams
Body And Trim:
Fairings, seat, fuel tank, body panels, fenders, ergonomics
Procedures Included
Maintenance Procedures:
Regular servicing, oil changes, filter replacements, chain maintenance, brake pad replacement, coolant flush, spark plug replacement, air filter cleaning/replacement
Repair Procedures:
Engine disassembly and assembly, clutch service, gearbox repair, suspension overhaul, brake caliper rebuilding, electrical component troubleshooting and replacement
Troubleshooting:
Diagnostic procedures for common issues, fault finding based on symptoms, electrical system diagnostics
Diagnostic Procedures:
Step-by-step diagnostic guides for identifying and rectifying faults within various vehicle systems, including electrical troubleshooting trees.
Technical Depth
Depth Of Information:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, including detailed specifications and torque values.
Wiring Diagrams:
Complete and detailed wiring diagrams for all electrical systems, including engine management, lighting, instruments, and optional accessories.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or the entire manual. Supports clear reproduction of images and diagrams.
Binding Type
Binding Type:
Digital (No physical binding; user can print and bind as desired)
Paper Type
Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, DOHC, 4 valves per cylinder
Engine Displacement:
652 cc
Bore X Stroke:
100 mm x 83 mm
Compression Ratio:
10.0:1
Cooling System:
Liquid-cooled
Fuel Delivery:
Electronic Fuel Injection (EFI) - BOSCH Motronic MA 2.4
Ignition System:
Electronic, digital ignition
Engine Block Material:
Aluminum alloy
Engine Manufacturer:
Rotax (Bombardier Recreational Products)
Performance
Horsepower Output:
Approx. 50 HP (37 kW) at 6500 rpm (exact may vary by year/market)
Torque Output:
Approx. 6.2 kg⋅m (61 Nm) at 5000 rpm (exact may vary by year/market)
Fuel System
Fuel Type:
Unleaded gasoline (minimum 91 octane recommended)
Fluid Specifications
Engine Oil Type:
SAE 20W-50 or 15W-50 API SG or higher (refer to manual for specific BMW approval)
Engine Oil Capacity:
Approx. 3.0 liters (3.2 US quarts) with filter change
Coolant Type:
BMW approved anti-freeze/anti-corrosion mixture (typically ethylene glycol based)
🔧 Transmission
Standard
Gearbox Type:
Constant-mesh five-speed
Optional
ABS:
Optional ABS system available on some models
Features
Final Drive:
Sealed O-ring chain
Fluid Specifications
Gearbox Oil Type:
SAE 75W/90 GL-4 or GL-5 API
Gearbox Oil Capacity:
Approx. 1.2 liters (1.3 US quarts)
📐 Dimensions
Exterior
Seat Height:
Approx. 800 mm (31.5 in) standard, lower and higher options available
Weights
Dry Weight:
Approx. 178 kg (392 lbs)
Wet Weight:
Approx. 199 kg (439 lbs) (fully fueled)
Fuel Capacity:
17 liters (4.5 US gallons)
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycle safety is assessed differently than automobiles; focus is on design and component integrity)
Active Features
Braking System:
Dual disc front brake, single disc rear brake. Optional ABS available (typically can be switched off).
Lighting:
Halogen headlight, LED taillight, incandescent turn signals (some variations may exist)
Passive Features
Frame Construction:
Steel diamond-type frame
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, coolant temperature gauge, warning lights.
Driver Assistance
ABS System:
Optional Anti-lock Braking System (ABS) available on many F650GS models, offering enhanced braking control.
Connectivity
Diagnostic Port:
Onboard diagnostics port for connection to BMW diagnostic tools or compatible aftermarket scanners.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually, whichever comes first
Air Filter Check Interval:
Every 10,000 km (6,000 miles)
Spark Plug Replacement Interval:
Every 20,000 km (12,000 miles)
Chain Lubrication Interval:
Every 500-1,000 km (300-600 miles) and after riding in wet conditions
Valve Clearance Check Interval:
Every 20,000 km (12,000 miles)
Brake Fluid Change Interval:
Every 2 years
Fluid Specifications
Brake Fluid Type:
DOT 4
Coolant Capacity:
Approx. 1.5 liters (1.6 US quarts)
Known Issues
Common Wear Items:
Clutch plates, fork seals, rear shock absorber, wheel bearings, regulator/rectifier (on some models), chain and sprockets.
Electrical Concerns:
Intermittent issues with the sidestand switch, regulator/rectifier failure leading to charging problems.
Engine Performance Notes:
Occasional idle instability, potential for oil consumption with high mileage.
📚 Vehicle History
Brand Heritage
Manufacturer Focus:
BMW Motorrad has a long history of producing robust, reliable, and technologically advanced motorcycles, particularly in the touring and adventure segments.
Model Evolution
Introduction Year:
Introduced in 1993 as the F650 ('Funduro')
Name Change And Updates:
The F650GS designation (replacing the earlier F650 ST and F650) was used from 2000 onwards for the dual-sport variant. It was powered by a Rotax-built single-cylinder engine, sharing some architecture with parallel-twin BMW models of the era. It received minor updates throughout its production run.
Production
Production Period:
Approximately 1993-2007 (for the single-cylinder F650GS, later replaced by the parallel-twin F650GS '800')
Manufacturing Location:
Austria (engine by Rotax), final assembly in Germany
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