BMW F650GS DAKAR F 650 GS Motorcycle Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: F650GS Dakar Model Code: E169 Product Type: Service Repair Workshop Manual Codes Chassis Code: E169 👋 Introduction Market Position Vehicle Segment: Dual-sport / Adventure Touring motorcycle. Target Audience: Riders seeking a capable and versatile motorcycle for both on-road commuting and off-road exploration. Competitive Analysis Key Competitors: KTM 640 Adventure, Honda Transalp, Suzuki DR650SE, Kawasaki KLR650. Key Features Unique Selling Points: Dakar variant offers increased suspension travel, larger fuel tank, and rugged styling for off-road bias compared to the standard F650GS. Reliability Focus: Known for its robust Rotax-derived engine and durable chassis, making it a reliable adventure platform. 📋 Manual Details Coverage Areas General Coverage: Complete service, repair, and maintenance for the BMW F650GS Dakar motorcycle. Page Count Estimated Page Count: 500+ Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine System: Engine disassembly, assembly, tuning, lubrication, cooling, and fuel systems. Transmission System: Clutch, gearbox, chain drive, maintenance, and repair procedures. Chassis System: Frame, suspension (front telescopic fork and rear monoshock), steering, and wheels. Braking System: Front and rear brake systems, including hydraulic components, pads, and discs. Electrical System: Ignition, lighting, charging system (alternator, battery), starter motor, and wiring diagrams. Fuel System: Fuel injection system (Rotax 99/86/01 engine variant), fuel pump, injectors, and filters. Exhaust System: Exhaust manifold, catalytic converter (if applicable), and muffler. Bodywork And Fairings: Removal, installation, and repair of body panels, seats, and luggage systems. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug service, and fluid checks. Troubleshooting Guides: Diagnostic procedures for common problems, symptom-based fault finding. Engine Rebuild: Detailed steps for complete engine disassembly, inspection, repair, and reassembly. Suspension Service: Fork seal replacement, shock absorber service, and linkage maintenance. Brake Overhaul: Brake caliper service, master cylinder rebuild, and bleeding procedures. Electrical Diagnostics: Wiring diagram interpretation, component testing, and fault diagnosis. Carburetor Or Injection Tuning: Fuel system adjustments, idle speed settings, and diagnostic checks. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic rider maintenance to full engine and chassis rebuilds. Diagnostic Capabilities: Detailed diagnostic flowcharts and component testing procedures for accurate fault identification. Special Tools: Identification and usage of BMW specific tools required for certain procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Printability: Printable pages for on-site workshop use. Print Quality Image Resolution: High-resolution illustrations and diagrams for clarity. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled. Engine Code: Rotax 99/86/01 Displacement: 652 cc Bore X Stroke: 100 mm x 83 mm Compression Ratio: 10.0:1 Performance Horsepower: 50 hp @ 6,500 rpm Torque: 62 Nm (45.7 lb-ft) @ 5,200 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Bosch Motronic MA 2.4. Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2. Fuel Tank Capacity: 17.3 Liters (4.57 US gal) / 23 Liters (6.08 US gal) with optional auxiliary tank. 🔧 Transmission Standard Transmission Type: 5-speed, constant mesh manual transmission. Optional Optional Transmission: N/A (Standard 5-speed) Features Clutch Type: Wet multi-plate clutch, hydraulically actuated. Final Drive: Endless O-ring chain, 525 pitch. 📐 Dimensions Exterior Length: 2,245 mm (88.4 in) Width: 915 mm (36.0 in) Height: 1,420 mm (55.9 in) Wheelbase: 1,483 mm (58.4 in) Ground Clearance: 225 mm (8.9 in) Weights Dry Weight: 174 kg (383.6 lbs) Wet Weight: 199 kg (438.7 lbs) Max Payload: 200 kg (441 lbs) 🛡️ Safety Features Ratings Safety Certification: Not applicable in traditional automotive crash ratings; focus on component integrity and rider protection. Active Features Braking System Type: Dual disc front brake, single disc rear brake with ABS (optional on some models/years). ABS System: Optional Bosch ABS (anti-lock braking system) available on certain production runs and markets. Passive Features Lighting System: Halogen headlamp, LED taillight, turn signals. Chassis Design: Steel tube frame for rigidity and impact absorption. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature display, fuel level indicator, and warning lights. Driver Assistance ABS Availability: Optional ABS system, which can be a significant safety feature for a dual-sport motorcycle. Connectivity Accessory Power: 12V accessory socket for charging GPS devices or other electronics. Lighting Technology Headlight Type: 12V 60/55W Halogen headlight with integrated position light. 🔧 Maintenance Service Intervals Oil Change Interval: Every 10,000 km (6,200 miles) or annually, whichever comes first. Spark Plug Replacement: Every 20,000 km (12,500 miles). Air Filter Cleaning: Every 10,000 km (6,200 miles) or as needed based on operating conditions. Valve Clearance Check: Every 20,000 km (12,500 miles). Fluid Specifications Engine Oil Type: SAE 15W-50, API SG or higher (or specified BMW motorcycle oil). Engine Oil Capacity: Approx. 2.3 liters (2.4 US qt) with filter change. Coolant Type: BMW Motorrad coolant...
Diagnostic procedures for common problems, symptom-based fault finding.
Engine Rebuild:
Detailed steps for complete engine disassembly, inspection, repair, and reassembly.
Suspension Service:
Fork seal replacement, shock absorber service, and linkage maintenance.
Brake Overhaul:
Brake caliper service, master cylinder rebuild, and bleeding procedures.
Electrical Diagnostics:
Wiring diagram interpretation, component testing, and fault diagnosis.
Carburetor Or Injection Tuning:
Fuel system adjustments, idle speed settings, and diagnostic checks.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic rider maintenance to full engine and chassis rebuilds.
Diagnostic Capabilities:
Detailed diagnostic flowcharts and component testing procedures for accurate fault identification.
Special Tools:
Identification and usage of BMW specific tools required for certain procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval.
Printability:
Printable pages for on-site workshop use.
Print Quality
Image Resolution:
High-resolution illustrations and diagrams for clarity.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled.
Engine Code:
Rotax 99/86/01
Displacement:
652 cc
Bore X Stroke:
100 mm x 83 mm
Compression Ratio:
10.0:1
Performance
Horsepower:
50 hp @ 6,500 rpm
Torque:
62 Nm (45.7 lb-ft) @ 5,200 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic MA 2.4.
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2.
Fuel Tank Capacity:
17.3 Liters (4.57 US gal) / 23 Liters (6.08 US gal) with optional auxiliary tank.
🔧 Transmission
Standard
Transmission Type:
5-speed, constant mesh manual transmission.
Optional
Optional Transmission:
N/A (Standard 5-speed)
Features
Clutch Type:
Wet multi-plate clutch, hydraulically actuated.
Final Drive:
Endless O-ring chain, 525 pitch.
📐 Dimensions
Exterior
Length:
2,245 mm (88.4 in)
Width:
915 mm (36.0 in)
Height:
1,420 mm (55.9 in)
Wheelbase:
1,483 mm (58.4 in)
Ground Clearance:
225 mm (8.9 in)
Weights
Dry Weight:
174 kg (383.6 lbs)
Wet Weight:
199 kg (438.7 lbs)
Max Payload:
200 kg (441 lbs)
🛡️ Safety Features
Ratings
Safety Certification:
Not applicable in traditional automotive crash ratings; focus on component integrity and rider protection.
Active Features
Braking System Type:
Dual disc front brake, single disc rear brake with ABS (optional on some models/years).
ABS System:
Optional Bosch ABS (anti-lock braking system) available on certain production runs and markets.
Passive Features
Lighting System:
Halogen headlamp, LED taillight, turn signals.
Chassis Design:
Steel tube frame for rigidity and impact absorption.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature display, fuel level indicator, and warning lights.
Driver Assistance
ABS Availability:
Optional ABS system, which can be a significant safety feature for a dual-sport motorcycle.
Connectivity
Accessory Power:
12V accessory socket for charging GPS devices or other electronics.
Lighting Technology
Headlight Type:
12V 60/55W Halogen headlight with integrated position light.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,200 miles) or annually, whichever comes first.
Spark Plug Replacement:
Every 20,000 km (12,500 miles).
Air Filter Cleaning:
Every 10,000 km (6,200 miles) or as needed based on operating conditions.
Valve Clearance Check:
Every 20,000 km (12,500 miles).
Fluid Specifications
Engine Oil Type:
SAE 15W-50, API SG or higher (or specified BMW motorcycle oil).
Engine Oil Capacity:
Approx. 2.3 liters (2.4 US qt) with filter change.
Coolant Type:
BMW Motorrad coolant (blue) or equivalent ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 brake fluid.
Known Issues
Common Problems:
Oil leaks from the clutch slave cylinder, regulator/rectifier failures, fuel pump issues, stator failures, and occasional ABS sensor faults.
Maintenance Tips:
Regular chain lubrication and adjustment, monitoring oil levels, and keeping the electrical connections clean are crucial for longevity.
📚 Vehicle History
Brand Heritage
Bmw Motorcycle Legacy:
BMW has a long and storied history in motorcycle manufacturing, particularly in the adventure touring segment with models like the R80G/S and GS series.
Model Evolution
F Series Introduction:
The F650GS platform was introduced as BMW's entry-level dual-sport, targeting a broader market with a more accessible single-cylinder engine.
Dakar Variant Creation:
The Dakar model was a factory-modified version of the F650GS, featuring longer travel suspension, taller windscreen, and a larger fuel tank to enhance its off-road and long-distance touring capabilities, inspired by the Paris-Dakar Rally.
Production
Production Years:
Approximately 2000-2007.
Manufacturing Location:
Brazil (by Motos BMW S/A, motorcycle division of BMW do Brasil Ltda. or sometimes associated with Aprilia production during certain periods).
🏆 Awards & Recognition
Recognitions
Market Reputation:
Highly regarded as a reliable and capable entry-level adventure bike, particularly for its ability to handle mixed terrain.
Ratings
Adventure Capability Rating:
Excellent for its class, offering good off-road manners and touring comfort.
Certifications
Emissions Compliance:
Compliant with relevant emissions standards for its production era (e.g., Euro-2).
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