User manual BMW F 650 GS REPAIR MANUAL

[. . . ] Repair Manual F 650 GS BMW AG Motorcycle Division After Sales Introduction This repair manual will help you to perform all the main maintenance and repair work correctly and efficiently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and practical knowledge acquired at the BMW Training Centre. A new issue of this repair manual will be published if amendments or additions (supplements) are needed. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer's specification. · · The repair manual is structured in the logical sequence of the work to be performed: Removal, Disassembly, Repair, Assembly, Installation. [. . . ] Disengage throttle cable from adapter. · · · · · · 2 5 1 3 E130060 · · · · Disconnect plug of throttle-valve potentiometer (1). Installation is the reverse of the removal procedure. 4 E130060 · · · · · · Lnot necessary to adjust the throttle-valve potenNote: It is tiometer after installation (self-teaching system). X Tightening torque: Throttle-valve potentiometer to throttle flap stub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Nm Disconnect the plugs for fuel injector (2), throttlevalve potentiometer (4) and throttle-valve actuator (3). Slacken the hose clip securing the fuel line and disconnect the line from the throttle flap stub. If necessary, remove fuel-injector holder and fuel injector. 13. 8 · Installation is the reverse of the removal procedure. 13 60 505 Checking fuel pressure Tightening torques: Intake air silencer to retainer . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fasteners, cover/ trim panel for turn indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 X Nm Nm Nm Nm d Warning: ­ Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. Remove seat. 13 71 000 Removing and installing intake pipe ­ 16 1 500 · · Removing throttle stub pipe Release the two fasteners securing the intake pipe to the cylinder head and remove the intake pipe. Remember to clean the sealing faces before reinstalling. Tightening torques: Air intake pipe to cylinder head . . . . . . . . . . . . . . . . . . . . 5 Fasteners, cover/ trim panel for turn indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 X Nm Nm Nm Nm Nm E130110 · · Connect a test pressure gauge, BMW No. Start engine and allow to idle. Fuel pressure: Specification . . . . . . . . . . . . . . . . . . 3. 5±0. 2 bar (49. 8±2. 8 psi) L Note: If fuel pressure is lower or higher than specification, check the fuel pump, fuel filter, pressure regulator and lines. 13. 9 Removing and installing fuel hoses Removing and installing line to fuel injector 13 31 135 ­ ­ Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. d Warning: · Remove seat. 13 3 010, to close off the fuel feed line. Removing and installing feed and return lines ­ ­ Remove seat. Disengage the oil tank. 4 · · 5 E130120 1 3 2 E130101 · · · · Open hose clips (4, 5). Installation is the reverse of the removal procedure: pay particular attention to the following. 13 1 500. Removing and installing throttle cable 32 72 305 See Group 32 · · Remove the fastener securing the fuel filter (1) to the frame bow. Fuel escapes · · Disconnect fuel feed line (2) and fuel return line (3). Installation is the reverse of the removal procedure: pay particular attention to the following. e Caution: · Note the installed positions of fuel feed line (2) and fuel return line (3). 13 1 500. 13. 10 16 16 Fuel tank and lines Contents Page Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 M B Removing and installing fuel filler cap Removing and installing roll-over valve Replacing fuel filter W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 See Group 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removing and installing fuel pump Removing and installing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removing and installing fuel strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removing and installing warning-contact switch for fuel level Removing and installing fuel-evaporation control valve Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 [USA version] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 [USA version] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 16. 1 M B W 16. 2 16 Technical Data Fuel tank Type Tank capacity Type of fuel Fuel pump Type Operating voltage Fuel pressure Delivery rate F 650 GS Plastic tank with cover l (Imp. gal/ 17. 3 (3. 8/4. 6) US gal) (including 4 l (0. 88/1. 06) reserve) Super (premium), unleaded. 95 octane (RON) Peripheral-gear pump V 7 - 15 bar (psi) 3. 5 (49. 8) l/h (Imp. gal/h; US gal/h) 150 (33; 39. 6) at 13. 5V, 3. 5 bar (49. 8 psi) M B W 16. 3 M B W 16. 4 16 11 030 Removing and installing fuel tank e Caution: handling fuel. 16 11 030 Removing ­ ­ ­ a fuel tank 3 4 5 6 ­ ­ a · · Remove the seat and the toolkit. [. . . ] Remove 3 securing screws from the transparent instrument cover and remove the cover. Remove the bezel. · · · · Disconnect the plug for the warning lights (2). Installation is the reverse of the removal procedure: pay particular attention to the following. 4 Warning: After installing the windscreen, check and if necessary adjust the headlight setting. d E620020 · Remove the securing screws (arrows) and remove the cover (4). 62. 6 1 E620030 · · · Remove the 3 securing screws (1) from the rear of the housing. Press back the 4 snap locks (arrows) on the plug housing and press out the instrument panel. [. . . ]