BMW F650 CS 2001 2002 2003 Service Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: F650 CS Years Covered: 2001, 2002, 2003 Codes Chassis Code: E169 👋 Introduction Market Position Segment: Sport Touring / Commuter Motorcycle Target Audience: Riders seeking a reliable, comfortable, and versatile motorcycle for daily commuting and light touring, with a premium feel associated with the BMW brand. Competitive Analysis Competitors: Honda VFR800, Yamaha FZ6, Ducati ST2, Suzuki SV650S (depending on specific market positioning and rider priorities). Key Features Design: Distinctive single-sided swingarm, under-seat exhaust, aerodynamic fairing, comfortable riding posture. Performance: Torquey engine providing good low-to-mid-range power, suitable for urban riding and open roads. Practicality: Optional luggage solutions, user-friendly controls, relatively low maintenance requirements for a BMW. 📋 Manual Details Coverage Areas Primary Coverage: Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics Page Count Estimated Pages: Approximately 300-400 pages (typical for this era and scope) Manual Type Type: Service Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Engine overhaul, cylinder head, pistons, crankshaft, lubrication system, cooling system, fuel injection system, exhaust system Transmission: Gearbox, clutch, final drive, chain maintenance Chassis: Frame, suspension (front forks, rear shock absorber), steering, wheels, tires Brakes: Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake discs Electrical: Battery, charging system (alternator, regulator), ignition system, lighting, starter motor, instrumentation, wiring diagrams, ECU (Engine Control Unit) Fuel System: Fuel tank, fuel pump, fuel filter, fuel injection (throttle body, injectors, sensors) Exhaust System: Exhaust manifold, catalytic converter, mufflers Bodywork: Fairings, seat, fuel tank cover, body panels, fasteners Procedures Included Maintenance: Oil change, filter replacement, chain adjustment, brake fluid flush, coolant replacement, spark plug replacement, air filter cleaning/replacement, battery maintenance Troubleshooting: Diagnostic codes, common fault finding, electrical system diagnostics, engine performance issues Repair: Engine rebuild, transmission repair, suspension overhaul, brake caliper replacement, electrical component repair, body panel repair Disassembly Assembly: Complete step-by-step instructions for component removal and installation Technical Depth Depth: Comprehensive (covers routine maintenance to complete engine and chassis rebuilds) Diagnostics: Detailed diagnostic procedures, symptom-based troubleshooting, component testing Specifications: Torque specifications, clearances, tolerances, fluid capacities, electrical resistance values 📊 Manual Specifications File Format Format: PDF Searchability: Text-searchable (allows for quick keyword lookup) Print Quality: High-resolution scans, suitable for printing individual pages or the entire manual Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, parallel-twin Displacement: 652 cc Bore X Stroke: 100 mm x 83 mm Compression Ratio: 10.1:1 Valvetrain: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Power Output Hp: 50 hp (approx. at 6500 rpm) Torque Nm: 63 Nm (approx. at 5000 rpm) Engine Management: Electronic Fuel Injection (EFI) with Motronic MA 2.4 Fuel System Fuel Type: Unleaded gasoline (95 RON recommended) Fuel Tank Capacity: 17 Liters (4.5 US gallons) 🔧 Transmission Standard Type: 5-speed manual Clutch: Wet multi-disc, cable-actuated Final Drive: O-ring sealed chain drive 📐 Dimensions Exterior Length: 2105 mm (82.9 in) Width Handlebar: 820 mm (32.3 in) Height Seat: 800 mm (31.5 in) Wheelbase: 1490 mm (58.7 in) Weights Dry Weight: 182 kg (401 lbs) Curb Weight: 198 kg (437 lbs) (fully fueled) Max Payload: Not specified, but typically around 200 kg for this class. 🛡️ Safety Features Ratings Crash Test Results: Not applicable to motorcycles in the same way as cars. Focus is on rider protection and vehicle stability. Active Features Braking: Disc brakes front and rear. Optional ABS available on some models. Suspension: Stable chassis and well-tuned suspension contribute to predictable handling. Passive Features Lighting: Halogen headlamp, integrated turn signals. Ergonomics: Designed for rider comfort and control. 💡 Technology Features Infotainment Instrumentation: Analog speedometer and tachometer, LCD display for odometer, trip meter, clock, and basic warning lights. Often features a fuel gauge. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on some configurations, enhancing safety. Connectivity Diagnostics: Diagnostic port for connection to BMW's diagnostic tools (e.g., GT1, DIS) for advanced troubleshooting and ECU programming. 🔧 Maintenance Service Intervals Oil Change: 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 Maintenance: Inspect every 10,000 km (6,000 miles), clean or replace as needed. Spark Plug Replacement: Every 20,000 km (12,000 miles). Coolant Replacement: Every 2 years or 30,000 km (18,000 miles). Brake Fluid Flush: Every 2 years. Valve Clearance Check: Every 20,000 km (12,000 miles). Fluid Specifications Engine Oil: SAE 10W-40 or 15W-50, API SG or higher, JASO MA compliant (synthetic or semi-synthetic recommended). Engine Oil Capacity: Approx. 2.3 Liters (2.4 US quarts) with filter change. Coolant: BMW approved ethylene glycol based coolant with corrosion inhibitors (50% mix with distilled water). Brake Fluid: DOT 4 Clutch Fluid: DOT 4 (shared with brake system if hydraulic) Known Issues Fuel Pump: Early models could experience premature fuel pump failure, often indicated...
Riders seeking a reliable, comfortable, and versatile motorcycle for daily commuting and light touring, with a premium feel associated with the BMW brand.
Competitive Analysis
Competitors:
Honda VFR800, Yamaha FZ6, Ducati ST2, Suzuki SV650S (depending on specific market positioning and rider priorities).
High-resolution scans, suitable for printing individual pages or the entire manual
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, parallel-twin
Displacement:
652 cc
Bore X Stroke:
100 mm x 83 mm
Compression Ratio:
10.1:1
Valvetrain:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Power Output Hp:
50 hp (approx. at 6500 rpm)
Torque Nm:
63 Nm (approx. at 5000 rpm)
Engine Management:
Electronic Fuel Injection (EFI) with Motronic MA 2.4
Fuel System
Fuel Type:
Unleaded gasoline (95 RON recommended)
Fuel Tank Capacity:
17 Liters (4.5 US gallons)
🔧 Transmission
Standard
Type:
5-speed manual
Clutch:
Wet multi-disc, cable-actuated
Final Drive:
O-ring sealed chain drive
📐 Dimensions
Exterior
Length:
2105 mm (82.9 in)
Width Handlebar:
820 mm (32.3 in)
Height Seat:
800 mm (31.5 in)
Wheelbase:
1490 mm (58.7 in)
Weights
Dry Weight:
182 kg (401 lbs)
Curb Weight:
198 kg (437 lbs) (fully fueled)
Max Payload:
Not specified, but typically around 200 kg for this class.
🛡️ Safety Features
Ratings
Crash Test Results:
Not applicable to motorcycles in the same way as cars. Focus is on rider protection and vehicle stability.
Active Features
Braking:
Disc brakes front and rear. Optional ABS available on some models.
Suspension:
Stable chassis and well-tuned suspension contribute to predictable handling.
Passive Features
Lighting:
Halogen headlamp, integrated turn signals.
Ergonomics:
Designed for rider comfort and control.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer and tachometer, LCD display for odometer, trip meter, clock, and basic warning lights. Often features a fuel gauge.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on some configurations, enhancing safety.
Connectivity
Diagnostics:
Diagnostic port for connection to BMW's diagnostic tools (e.g., GT1, DIS) for advanced troubleshooting and ECU programming.
🔧 Maintenance
Service Intervals
Oil Change:
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 Maintenance:
Inspect every 10,000 km (6,000 miles), clean or replace as needed.
Spark Plug Replacement:
Every 20,000 km (12,000 miles).
Coolant Replacement:
Every 2 years or 30,000 km (18,000 miles).
Brake Fluid Flush:
Every 2 years.
Valve Clearance Check:
Every 20,000 km (12,000 miles).
Fluid Specifications
Engine Oil:
SAE 10W-40 or 15W-50, API SG or higher, JASO MA compliant (synthetic or semi-synthetic recommended).
Engine Oil Capacity:
Approx. 2.3 Liters (2.4 US quarts) with filter change.
Coolant:
BMW approved ethylene glycol based coolant with corrosion inhibitors (50% mix with distilled water).
Brake Fluid:
DOT 4
Clutch Fluid:
DOT 4 (shared with brake system if hydraulic)
Known Issues
Fuel Pump:
Early models could experience premature fuel pump failure, often indicated by intermittent starting or poor running.
Regulator Rectifier:
Overheating or failure of the regulator/rectifier can lead to battery charging issues.
Cam Chain Tensioner:
While not as prevalent as on some single-cylinder BMWs, proper tensioner function should be checked.
ABS System:
If equipped with ABS, sensor or modulator issues can occur, requiring specialized diagnosis.
📚 Vehicle History
Brand Heritage
Bmw Motorrad:
BMW Motorrad has a long and storied history dating back to the 1920s, known for engineering excellence, innovation, and robust motorcycles.
Model Evolution
F Series Heritage:
The F650 CS is part of BMW's F-series, which initially featured Rotax-engineered single-cylinder engines before moving to parallel twins. The CS ('City/Street') variant offered a more modern, stylish take on the F650 platform.
Production
Manufacturing:
Produced in collaboration with Aprilia in Italy by the then-owner of the BMW motorcycle brand, BMW Italia, for certain markets.
Production Run:
2001-2005 (with this specific engine configuration).
🏆 Awards & Recognition
Recognitions
Industry Reception:
The F650 CS was generally well-received for its unique styling, comfortable ride, and BMW's reputation for quality, though it occupied a niche market.
Ratings
Reliability Reputation:
Generally good, though like any motorcycle of this era, adherence to maintenance schedules is crucial. The parallel-twin engine proved more robust than some earlier single-cylinder F-series.
Certifications
Emissions:
Meets relevant European and US emissions standards for its production years.
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