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BMW F650GS Service Repair Manual 2000-2007

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🏷️ Basic Information Identification Make: BMW Model: F650GS Model Variant: Dual Sport / Adventure Touring Motorcycle Generation Generation: 1st Generation (Rotax-built engine) Codes Chassis Code: E169 (for early models), R13 (for later models, often associated with the F650CS and Dakar variants) Engine Code: Rotax 654F (single-cylinder) 👋 Introduction Market Position Segment: Lightweight Adventure Touring / Dual Sport Motorcycle Target Audience: Riders seeking a versatile motorcycle for commuting, touring, and light off-road use. Competitive Analysis Key Competitors Era: Honda Transalp, Suzuki V-Strom 650, Kawasaki KLR650, Yamaha XT660R. Key Features Engine Layout: Single-cylinder, four-stroke (Rotax engine), known for its torque and simplicity. Chassis Design: Steel frame, capable suspension for mixed terrain, comfortable ergonomics. Versatility: Designed for on-road comfort and off-road capability, making it a practical choice for various riding conditions. 📋 Manual Details Coverage Areas Coverage Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Models Covered: All F650GS models within the specified year range (including potential variations like standard and Dakar models, though specific trim level coverage is assumed) Page Count Page Count Estimate: Extensive (typical for professional workshop manuals, often 500+ pages depending on specific model variants and inclusion of all systems) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English (standard for professional manuals, assuming comprehensive technical language) Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, piston, crankshaft, camshaft, valve train, oil system, cooling system, lubrication. Fuel System: Fuel injection system (Bosch Motronic), throttle body, injectors, fuel pump, fuel pressure regulator, fuel tank, fuel lines. Ignition System: Ignition coils, spark plugs, crankshaft position sensor, camshaft position sensor, ignition timing. Exhaust System: Exhaust manifold, catalytic converter, muffler, oxygen sensors (lambda sensors). Transmission Drivetrain: Clutch operation, gearbox (5-speed sequential), final drive (chain drive), sprocket replacement, chain maintenance. Brakes: Front and rear brake systems (disc brakes), brake calipers, brake pads, brake lines, master cylinders, ABS system (if equipped). Suspension: Front telescopic forks (Marzocchi), rear monoshock (WP Suspension), linkage system, spring preload, damping adjustment. Electrical System: Battery, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlights, tail lights, indicators), wiring diagrams, fuses, relays. Bodywork Chassis: Frame inspection, body panels, fairings, seat, handlebars, footpegs, luggage rack system, fuel tank mounting. Wheels Tires: Wheel bearings, spoke tension (if applicable for wire-spoke wheels), tire removal/installation, tire pressure specifications. Diagnostics: Troubleshooting guides, fault codes (OBD-II or similar diagnostic port), diagnostic procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, brake fluid checks, coolant checks, spark plug replacement. Major Repairs: Engine rebuilds, gearbox overhauls, suspension fork servicing, brake system bleeding and component replacement. Troubleshooting: Step-by-step diagnostic flowcharts for common and uncommon issues. Electrical Troubleshooting: Use of wiring diagrams for fault finding in the electrical system. Component Disassembly Reassembly: Detailed instructions for removing, inspecting, and reinstalling all major components. Technical Depth Depth Level: Comprehensive (covering everything from basic maintenance to complete engine and transmission rebuilds). Diagnostic Capabilities: Advanced diagnostic procedures, including potential use of diagnostic tools (if applicable to the system). Special Tools: Identification and usage of specialized tools required for specific repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text-based PDF, allowing for keyword searching of procedures and specifications. Print Quality Print Readability: High quality, designed for clear viewing and printing of text, diagrams, and illustrations. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Rotax 654F, Single Cylinder, Four-Stroke, DOHC Displacement: 652 cc (cubic centimeters) Bore X Stroke: 100 mm x 83 mm (approximately) Compression Ratio: 10.0:1 (typical) Performance Horsepower: Approx. 47-50 hp (at 6,500 rpm) Torque: Approx. 44-45 lb-ft (at 5,000 rpm) Fuel System Fuel Delivery: Bosch Motronic Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (95 RON recommended) Lubrication Oil Type: SAE 15W-50 Synthetic Motorcycle Oil (API SG or higher, JASO MA) Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: 5-speed sequential manual gearbox Clutch Type: Multi-plate wet clutch Features Final Drive: Chain drive (O-ring sealed) Gear Ratios: Specific ratios would be detailed in the manual, typical for this class of bike. Fluid Specifications Transmission Oil: SAE 75W-90 Synthetic Gear Oil (for final drive gearbox, if applicable, otherwise engine oil serves this function) 📐 Dimensions Exterior Overall Length: Approx. 2,180 mm (85.8 in) Overall Width: Approx. 850 mm (33.5 in) Overall Height: Approx. 1,320 mm (52.0 in) Seat Height: Approx. 800 mm (31.5 in) (standard), 870 mm (34.3 in) (Dakar model) Ground Clearance: Approx. 170 mm (6.7 in) (standard), 200 mm (7.9 in) (Dakar model) Weights Dry Weight: Approx. 187 kg (412 lbs) Wet Weight: Approx. 202 kg (445 lbs) (fully fueled) Gross Vehicle Weight Rating: Not typically specified for motorcycles in this format, but total load capacity would be detailed. Cargo Luggage Capacity: Designed to accept BMW...
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BMW F650GS Service Repair Manual 2000-2007
🏷️ Basic Information
Identification
Make:
BMW
Model:
F650GS
Model Variant:
Dual Sport / Adventure Touring Motorcycle
Generation
Generation:
1st Generation (Rotax-built engine)
Codes
Chassis Code:
E169 (for early models), R13 (for later models, often associated with the F650CS and Dakar variants)
Engine Code:
Rotax 654F (single-cylinder)
👋 Introduction
Market Position
Segment:
Lightweight Adventure Touring / Dual Sport Motorcycle
Target Audience:
Riders seeking a versatile motorcycle for commuting, touring, and light off-road use.
Competitive Analysis
Key Competitors Era:
Honda Transalp, Suzuki V-Strom 650, Kawasaki KLR650, Yamaha XT660R.
Key Features
Engine Layout:
Single-cylinder, four-stroke (Rotax engine), known for its torque and simplicity.
Chassis Design:
Steel frame, capable suspension for mixed terrain, comfortable ergonomics.
Versatility:
Designed for on-road comfort and off-road capability, making it a practical choice for various riding conditions.
📋 Manual Details
Coverage Areas
Coverage Years:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Models Covered:
All F650GS models within the specified year range (including potential variations like standard and Dakar models, though specific trim level coverage is assumed)
Page Count
Page Count Estimate:
Extensive (typical for professional workshop manuals, often 500+ pages depending on specific model variants and inclusion of all systems)
Manual Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
English (standard for professional manuals, assuming comprehensive technical language)
Format
Format:
PDF (Portable Document Format)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, cylinder head, piston, crankshaft, camshaft, valve train, oil system, cooling system, lubrication.
Fuel System:
Fuel injection system (Bosch Motronic), throttle body, injectors, fuel pump, fuel pressure regulator, fuel tank, fuel lines.
Ignition System:
Ignition coils, spark plugs, crankshaft position sensor, camshaft position sensor, ignition timing.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, oxygen sensors (lambda sensors).
Transmission Drivetrain:
Clutch operation, gearbox (5-speed sequential), final drive (chain drive), sprocket replacement, chain maintenance.
Brakes:
Front and rear brake systems (disc brakes), brake calipers, brake pads, brake lines, master cylinders, ABS system (if equipped).
Suspension:
Front telescopic forks (Marzocchi), rear monoshock (WP Suspension), linkage system, spring preload, damping adjustment.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlights, tail lights, indicators), wiring diagrams, fuses, relays.
Bodywork Chassis:
Frame inspection, body panels, fairings, seat, handlebars, footpegs, luggage rack system, fuel tank mounting.
Wheels Tires:
Wheel bearings, spoke tension (if applicable for wire-spoke wheels), tire removal/installation, tire pressure specifications.
Diagnostics:
Troubleshooting guides, fault codes (OBD-II or similar diagnostic port), diagnostic procedures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, brake fluid checks, coolant checks, spark plug replacement.
Major Repairs:
Engine rebuilds, gearbox overhauls, suspension fork servicing, brake system bleeding and component replacement.
Troubleshooting:
Step-by-step diagnostic flowcharts for common and uncommon issues.
Electrical Troubleshooting:
Use of wiring diagrams for fault finding in the electrical system.
Component Disassembly Reassembly:
Detailed instructions for removing, inspecting, and reinstalling all major components.
Technical Depth
Depth Level:
Comprehensive (covering everything from basic maintenance to complete engine and transmission rebuilds).
Diagnostic Capabilities:
Advanced diagnostic procedures, including potential use of diagnostic tools (if applicable to the system).
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text-based PDF, allowing for keyword searching of procedures and specifications.
Print Quality
Print Readability:
High quality, designed for clear viewing and printing of text, diagrams, and illustrations.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotax 654F, Single Cylinder, Four-Stroke, DOHC
Displacement:
652 cc (cubic centimeters)
Bore X Stroke:
100 mm x 83 mm (approximately)
Compression Ratio:
10.0:1 (typical)
Performance
Horsepower:
Approx. 47-50 hp (at 6,500 rpm)
Torque:
Approx. 44-45 lb-ft (at 5,000 rpm)
Fuel System
Fuel Delivery:
Bosch Motronic Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (95 RON recommended)
Lubrication
Oil Type:
SAE 15W-50 Synthetic Motorcycle Oil (API SG or higher, JASO MA)
Cooling System
Cooling Method:
Liquid-cooled
🔧 Transmission
Standard
Transmission Type:
5-speed sequential manual gearbox
Clutch Type:
Multi-plate wet clutch
Features
Final Drive:
Chain drive (O-ring sealed)
Gear Ratios:
Specific ratios would be detailed in the manual, typical for this class of bike.
Fluid Specifications
Transmission Oil:
SAE 75W-90 Synthetic Gear Oil (for final drive gearbox, if applicable, otherwise engine oil serves this function)
📐 Dimensions
Exterior
Overall Length:
Approx. 2,180 mm (85.8 in)
Overall Width:
Approx. 850 mm (33.5 in)
Overall Height:
Approx. 1,320 mm (52.0 in)
Seat Height:
Approx. 800 mm (31.5 in) (standard), 870 mm (34.3 in) (Dakar model)
Ground Clearance:
Approx. 170 mm (6.7 in) (standard), 200 mm (7.9 in) (Dakar model)
Weights
Dry Weight:
Approx. 187 kg (412 lbs)
Wet Weight:
Approx. 202 kg (445 lbs) (fully fueled)
Gross Vehicle Weight Rating:
Not typically specified for motorcycles in this format, but total load capacity would be detailed.
Cargo
Luggage Capacity:
Designed to accept BMW System cases and top case, integrated mounting points.
🛡️ Safety Features
Ratings
Safety Standards:
Complies with relevant European and international motorcycle safety regulations for its era.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on some models.
Braking Performance:
Dual disc front brake, single disc rear brake, providing strong stopping power.
Passive Features
Lighting:
Halogen headlight, LED tail light, standard turn signals.
Chassis Stability:
Robust steel frame and balanced suspension contribute to stability.
💡 Technology Features
Infotainment
Display Instrumentation:
Analog speedometer and tachometer, LCD multi-function display (odometer, trip meter, coolant temperature, clock).
Driver Assistance
ABS Availability:
Optional ABS system, typically a two-channel system.
Connectivity
Diagnostic Port:
Likely features a diagnostic connector for engine management system (BMW's proprietary system or early OBD-II compatibility).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually, whichever comes first.
Oil Filter Replacement:
At every oil change (10,000 km / 6,000 miles).
Air Filter Cleaning Replacement:
Check every 10,000 km (6,000 miles), replace as needed.
Spark Plug Replacement:
Every 20,000 km (12,000 miles).
Valve Clearance Check:
Every 20,000 km (12,000 miles).
Chain Maintenance:
Lubricate and adjust chain every 5,000 km (3,000 miles) or more frequently if used in adverse conditions.
Fluid Specifications
Engine Oil Capacity:
Approx. 2.3 liters (2.4 US quarts) with filter change.
Coolant Type:
BMW approved ethylene glycol-based coolant (e.g., BMWcoolant 11 or equivalent).
Brake Fluid Type:
DOT 4 (or DOT 5.1 if specified for ABS models).
Known Issues
Common Wear Items:
Clutch wear, regulator/rectifier failures (especially on earlier models), swingarm bearings, wheel bearings, throttle position sensor (TPS) issues.
Potential Failures:
Water pump seal leaks, stator failures, ABS sensor issues (if equipped).
📚 Vehicle History
Brand Heritage
Bmw Motorcycle Legacy:
BMW has a long and distinguished history in motorcycle manufacturing, dating back to the 1920s, known for quality, innovation, and durability.
Model Evolution
F Series Introduction:
The F-series introduced a new era for BMW's single-cylinder motorcycles, often utilizing engines produced in partnership with Rotax (Austria).
F650 Legacy:
The F650 series began with the F650 Funduro (using a similar Rotax engine but with a more traditional adventure styling) in the mid-1990s, evolving into the F650GS for improved on-road manners and features.
Production
Production Location:
Assembled in Berlin, Germany (BMW Motorrad's primary manufacturing facility).
Production Period:
The F650GS, with the Rotax engine, was produced from approximately 1999/2000 until 2007/2008, when it was succeeded by models with the new parallel-twin engine.
🏆 Awards & Recognition
Recognitions
Market Reception:
Widely praised for its versatility, reliability, and value for money within the adventure touring segment. Often cited as a great entry-level adventure bike.
Ratings
Reliability Perception:
Generally considered reliable, especially the Rotax engine, though routine maintenance is crucial.
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