BMW F650GS Motorcycle Complete Workshop Service Repair Manual 2000 2001 2002 2003 2004 2005 2006 2007
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🏷️ Basic Information Identification Make: BMW Model: F650GS Product Type: Workshop Service Repair Manual Codes Platform Code: F650GS (Single Cylinder) 👋 Introduction Market Position Segment: Adventure Touring / Dual-Sport Motorcycle Target Audience: BMW F650GS owners, independent repair shops, motorcycle enthusiasts. Competitive Analysis Class Competitors: Honda Transalp, Kawasaki KLR650, Suzuki DR650, Yamaha XT660R. Key Features Vehicle Appeal: Versatile, reliable, fuel-efficient, suitable for both on-road touring and light off-road use. Manual Value Proposition: Empowers owners and technicians with the knowledge to perform all necessary maintenance and repairs, saving time and money, and ensuring optimal performance and longevity of the motorcycle. 📋 Manual Details Coverage Areas Covered Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Page Count Estimated Pages: 500+ Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, including disassembly, inspection, repair, and reassembly of all internal components (pistons, rings, valves, camshafts, crankshaft, etc.), cooling system, lubrication system. Fuel System: Fuel injection system (EFI) diagnosis and repair, fuel pump, injectors, throttle body, fuel pressure regulator, fuel filter replacement. Ignition System: Spark plugs, ignition coils, ECU (Engine Control Unit) diagnosis and troubleshooting. Transmission: Gearbox inspection, maintenance, repair, clutch system (friction plates, springs, hydraulic actuation), shift mechanism. Chassis And Frame: Frame inspection, steering head bearings, swingarm bearings, suspension components (forks, rear shock absorber), wheel bearings. Brakes: Brake fluid change, brake pad replacement, brake caliper overhaul, brake disc inspection and replacement, ABS (Anti-lock Braking System) diagnosis (if equipped). Electrical System: Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier), starter motor, lighting system, fuses, relays, switches, instrument cluster. Exhaust System: Exhaust pipe inspection, muffler maintenance, gasket replacement. Cooling System: Coolant type and capacity, radiator maintenance, fan operation, thermostat replacement. Bodywork And Trim: Fairing removal and installation, seat, fuel tank, fenders, luggage system mounting. Procedures Included Maintenance: Scheduled maintenance tasks, oil and filter changes, air filter replacement, spark plug replacement, chain adjustment and lubrication, brake bleeding, coolant flush. Troubleshooting: Diagnostic procedures for common problems, fault codes, symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major components and systems, including torque specifications. Disassembly Reassembly: Detailed procedures for removing and reinstalling all parts and assemblies. Torque Specifications: Comprehensive list of all critical torque values for engine, chassis, and brake components. Technical Depth Depth: Comprehensive; covers everything from basic routine maintenance to complete engine and transmission rebuilds, including electrical diagnostics and troubleshooting. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchable: Yes, fully text-searchable for quick information retrieval. Print Quality Quality: High-resolution, clear text and diagrams for easy reading and printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement: 652 cc Bore X Stroke: 100 mm x 83 mm Compression Ratio: 10.0:1 Valve Train: DOHC, 4 valves per cylinder Performance Horsepower Output: Approx. 48 hp @ 6500 rpm Torque Output: Approx. 63 Nm @ 5000 rpm Fuel System Induction: Bosch Motronic Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) Fuel Tank Capacity: 17.3 liters (4.57 US gal) 🔧 Transmission Standard Type: 5-speed manual gearbox Optional Type: None Features Clutch: Wet multi-plate clutch, hydraulically operated Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2180 mm (85.8 in) Width At Handlebars: Approx. 880 mm (34.6 in) Height At Seat: Approx. 800-820 mm (31.5-32.3 in) - depending on seat variant Wheelbase: Approx. 1493 mm (58.8 in) Weights Dry Weight: Approx. 196 kg (432 lbs) Wet Weight: Approx. 207 kg (456 lbs) - fully fueled Gross Vehicle Weight Rating: Approx. 410 kg (904 lbs) 🛡️ Safety Features Ratings ABS: Optional ABS (Anti-lock Braking System) available on some models/years. Active Features Braking System: Dual disc front brakes with twin-piston calipers, single disc rear brake with single-piston caliper. Lighting: Halogen headlamp, LED taillight. Passive Features Frame Construction: Steel tubular frame for durability and torsional rigidity. Handguards: Standard handguards for protection against wind and debris. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature gauge, hazard warning light switch. Driver Assistance ABS Availability: Optional ABS system, providing enhanced braking control, especially on slippery surfaces. Connectivity Diagnostic Port: Diagnostic port for connecting to BMW's diagnostic software for advanced fault finding and system checks. 🔧 Maintenance Service Intervals Oil Change: Every 10,000 km (6,000 miles) or annually Air Filter Check: Every 10,000 km (6,000 miles) Spark Plug Replacement: Every 20,000 km (12,000 miles) Valve Clearance Check: Every 20,000 km (12,000 miles) Brake Fluid Change: Every 2 years Coolant Flush: Every 2 years Fluid Specifications Engine Oil: SAE 15W-50, API SG/SH or higher, BMW Motorrad Special (or equivalent) Engine Oil Capacity: Approx. 2.7 liters (2.9 US qt) with filter change Coolant: BMW Motorrad Coolant (or equivalent ethylene glycol based coolant with...
Versatile, reliable, fuel-efficient, suitable for both on-road touring and light off-road use.
Manual Value Proposition:
Empowers owners and technicians with the knowledge to perform all necessary maintenance and repairs, saving time and money, and ensuring optimal performance and longevity of the motorcycle.
📋 Manual Details
Coverage Areas
Covered Years:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Page Count
Estimated Pages:
500+
Manual Type
Type:
Complete Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, including disassembly, inspection, repair, and reassembly of all internal components (pistons, rings, valves, camshafts, crankshaft, etc.), cooling system, lubrication system.
Fuel System:
Fuel injection system (EFI) diagnosis and repair, fuel pump, injectors, throttle body, fuel pressure regulator, fuel filter replacement.
Ignition System:
Spark plugs, ignition coils, ECU (Engine Control Unit) diagnosis and troubleshooting.
Transmission:
Gearbox inspection, maintenance, repair, clutch system (friction plates, springs, hydraulic actuation), shift mechanism.
Coolant type and capacity, radiator maintenance, fan operation, thermostat replacement.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, fenders, luggage system mounting.
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil and filter changes, air filter replacement, spark plug replacement, chain adjustment and lubrication, brake bleeding, coolant flush.
Troubleshooting:
Diagnostic procedures for common problems, fault codes, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major components and systems, including torque specifications.
Disassembly Reassembly:
Detailed procedures for removing and reinstalling all parts and assemblies.
Torque Specifications:
Comprehensive list of all critical torque values for engine, chassis, and brake components.
Technical Depth
Depth:
Comprehensive; covers everything from basic routine maintenance to complete engine and transmission rebuilds, including electrical diagnostics and troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchable:
Yes, fully text-searchable for quick information retrieval.
Print Quality
Quality:
High-resolution, clear text and diagrams for easy reading and printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder, liquid-cooled
Displacement:
652 cc
Bore X Stroke:
100 mm x 83 mm
Compression Ratio:
10.0:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower Output:
Approx. 48 hp @ 6500 rpm
Torque Output:
Approx. 63 Nm @ 5000 rpm
Fuel System
Induction:
Bosch Motronic Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (95 RON recommended)
Fuel Tank Capacity:
17.3 liters (4.57 US gal)
🔧 Transmission
Standard
Type:
5-speed manual gearbox
Optional
Type:
None
Features
Clutch:
Wet multi-plate clutch, hydraulically operated
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2180 mm (85.8 in)
Width At Handlebars:
Approx. 880 mm (34.6 in)
Height At Seat:
Approx. 800-820 mm (31.5-32.3 in) - depending on seat variant
Wheelbase:
Approx. 1493 mm (58.8 in)
Weights
Dry Weight:
Approx. 196 kg (432 lbs)
Wet Weight:
Approx. 207 kg (456 lbs) - fully fueled
Gross Vehicle Weight Rating:
Approx. 410 kg (904 lbs)
🛡️ Safety Features
Ratings
ABS:
Optional ABS (Anti-lock Braking System) available on some models/years.
Active Features
Braking System:
Dual disc front brakes with twin-piston calipers, single disc rear brake with single-piston caliper.
Lighting:
Halogen headlamp, LED taillight.
Passive Features
Frame Construction:
Steel tubular frame for durability and torsional rigidity.
Handguards:
Standard handguards for protection against wind and debris.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature gauge, hazard warning light switch.
Driver Assistance
ABS Availability:
Optional ABS system, providing enhanced braking control, especially on slippery surfaces.
Connectivity
Diagnostic Port:
Diagnostic port for connecting to BMW's diagnostic software for advanced fault finding and system checks.
🔧 Maintenance
Service Intervals
Oil Change:
Every 10,000 km (6,000 miles) or annually
Air Filter Check:
Every 10,000 km (6,000 miles)
Spark Plug Replacement:
Every 20,000 km (12,000 miles)
Valve Clearance Check:
Every 20,000 km (12,000 miles)
Brake Fluid Change:
Every 2 years
Coolant Flush:
Every 2 years
Fluid Specifications
Engine Oil:
SAE 15W-50, API SG/SH or higher, BMW Motorrad Special (or equivalent)
Engine Oil Capacity:
Approx. 2.7 liters (2.9 US qt) with filter change
Coolant:
BMW Motorrad Coolant (or equivalent ethylene glycol based coolant with corrosion inhibitors), mixed 50/50 with distilled water
Brake Fluid:
DOT 4
Clutch Fluid:
DOT 4 (if hydraulically operated)
Known Issues
Regulator Rectifier:
Early models may experience failure of the regulator/rectifier unit, leading to charging system issues. Upgrade may be available.
Water Pump Seal:
Potential for water pump seal leaks over time. Regular inspection recommended.
Suspension Wear:
Like many bikes of this era, fork seals and rear shock absorbers may require servicing or replacement due to age and mileage.
ABS Sensor Issues:
If equipped with ABS, sensor rings or modules can become fouled or fail, causing ABS warning lights.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW)
Legacy:
BMW has a long history of producing robust and reliable motorcycles, particularly known for their engineering and touring capabilities.
Model Evolution
F Series Introduction:
The F650GS (single-cylinder) platform was introduced to offer a more accessible and lighter alternative to BMW's larger boxer-twin models, while maintaining adventure touring capabilities.
Predecessors:
Based on the F650 'Funduro' and 'Stratos' models.
Production
Manufacturing Location:
Italy (by Aprilia for BMW) for earlier models, later moved to BMW's Berlin plant for the F650GS Twin.
Key Distinction:
This generation is characterized by its single-cylinder Rotax-designed engine, making it distinct from the later twin-cylinder F650GS (which became the F700GS).
🏆 Awards & Recognition
Recognitions
General Reputation:
Praised for its versatility, fuel economy, and reliability, making it a popular choice for touring and commuting.
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