Brake system of motorcycle BMW F650GS (2000-2007)

Technical data of brake system
Brakes Brake fluidDOT 4 Brake actuationHydraulic Front wheel Front brake2-piston floating calliper with rigidly mounted disc Brake disc dia.mm (in)300 (11.81) Brake-disc thickness Minimum thicknessmm (in) mm (in)5 (0.20) 4.5 (0.18) Permissible...

Removing and installing front brake calliper
Caution! Refer to notes on the hazards involved in handling brake fluid. Press the brake calliper against the brake disc in order to force the pistons back. Release brake line (3) at brake calliper and seal the line. Loosen retaining screws (4) for...

Removing and installing front brake pistons
Remove front brake calliper. Remove the split-pin keeper (1) from retaining pin (2). Drive the retaining pin out towards the wheel side. Pull the brake pads (6) down to remove. Hold a cloth over the brake calliper. Caution! Do not insert your...

Removing and installing front brake disc
Caution! Do not operate the brake with the wheel removed. Remove front wheel. See Group 36. Note: Retaining screws (1) are secured with Loctite 243 and should be heated if necessary before removal. Remove retaining screws (1) with brake disc. [ABS]...

Checking front brake disc for lateral runout
Caution! Do not operate the brake with the wheel removed. Remove front wheel. See Group 36. Mount front wheel on balancing stand, BMW # 36 3 617, with balancing shaft, BMW # 36 3 600. Using dial gauge, BMW # 00 2 510, measure lateral runout. Lateral...

Removing and installing rear brake calliper
Caution! Refer to notes on the hazards involved in handling brake fluid. Remove wheel cover together with chain cover. Press the brake calliper against the brake disc in order to force the pistons back. Cut through cable tie (1). [ABS] Remove...

Removing and installing rear brake piston
Remove rear brake calliper. Remove the split-pin keeper (1) from retaining pin (2). Drive the retaining pin out towards the wheel side. Remove brake pads (6). Hold a cloth over the brake calliper. Caution! Do not insert your fingers between the...

Removing and installing rear brake disc
Caution! Do not operate the brake with the wheel removed. Remove rear wheel. See Group 36. Note: Retaining screws (1) are secured with Loctite 243 and should be heated if necessary before removal. Remove retaining screws (1) with brake disc. Remove...

Checking rear brake disc for lateral runout
Place motorcycle on its centre stand. Remove wheel cover together with chain cover. Attach dial gauge holder, BMW # 00 2 500, to the rear swinging arm. Using dial gauge, BMW # 00 2 510, measure lateral runout. Lateral runout: max. 0.25 mm (0.010 in).

Removing and installing front brake master cylinder
Place the motorcycle on its main (centre) stand. Caution! Refer to notes on the hazards involved in handling brake fluid. Drain the brake system. Remove brake microswitch. Disconnect brake hose (1) from the brake master cylinder. Remove screws...

Removing and installing rear brake master cylinder
Place the motorcycle on its main (centre) stand. Caution! Refer to notes on the hazards involved in handling brake fluid. Do not operate the brake when dismantled. Drain the brake system. Disengage piston thrust rod (3). Disconnect brake line (5)....

Removing and installing footbrake lever
Remove footrest plate (1). Disengage piston thrust rod (4). Remove hexagon fit bolt (2). Remove brake pedal (3), leaving torsion spring (5) on the frame. Installation is the reverse of the removal procedure: pay particular attention to the...

Checking play at piston thrust rod, adjusting if necessary
Checking play at piston thrust rod With no load applied to the brake pedal, i.e. lug of lever against stop on frame (arrow), play must be perceptible at piston thrust rod (7). Note: Adjust the piston thrust rod if no play is perceptible. Adjusting...

Removing and installing front ABS sensor
Place the motorcycle on its main (centre) stand. Remove seat. Remove left cover. Remove the fastener securing ABS sensor (4) to the front fork. Disconnect ABS plug (5). Press ABS plug (6) to the rear and out of its holder. Cut the cable ties on the...

Removing front ABS sensor ring
Caution! Do not operate the brake with the wheel removed. Note: Retaining screws (1) are secured with Loctite 243 and should be heated if necessary before removal. Remove retaining screws (1) from brake disc. Remove sensor ring (2). Installation is...

Removing and installing rear ABS sensor
Place motorcycle on its centre stand. Remove seat. Remove wheel cover together with chain cover. Cut through cable tie (3). Remove fastener securing ABS sensor (4) and remove ABS sensor. Disconnect ABS sensor plug (5) and unclip the plug from the...

Removing and installing rear ABS sensor ring
Caution! Do not operate the brake with the wheel removed. Remove rear wheel. See Group 36. Note: Retaining screws (1) are secured with Loctite 243 and should be heated if necessary before removal. Remove securing screws (1) from sensor ring. Remove...

Removing and installing ABS control unit
Caution! All work on the ABS control unit must be carried out by an authorised BMW workshop. Remove the rear frame. See Group 46. Remove front brake lines. Caution! If brake fluid escapes, it may damage paint. Line connections must be protected...

Removing and installing front brake lines/hoses (with ABS)
Removing and installing brake lines Place the motorcycle on its main (centre) stand. Remove seat. Remove left cover. Drain the brake system. Disconnect the expansion tank and pull it to one side. Disconnect brake line to brake calliper (1) and brake...

Removing and installing rear brake lines/hoses (with ABS)
Removing and installing brake lines Place the motorcycle on its main (centre) stand. Remove seat. Drain the rear brake system. Disconnect brake line from brake master cylinder. Raise the rear frame. See Group 46. Release the brake line from the...

Checking/adjusting front ABS sensor gap
Caution! Always check the ABS sensor gap after replacement of ABS sensor, sensor ring, wheel bearing, front wheel, front forks, spacer, quick-release axle or brake disc. Lift front wheel clear of the ground. Using a feeler gauge, measure the gap...

Checking/adjusting rear speed/ABS sensor gap
Caution! Always check the speed/ABS sensor gap after replacement of ABS sensor, sensor ring, brake-calliper bracket, spacer sleeve, rear wheel or wheel bearing. Lift rear wheel clear of the ground. Remove wheel cover and chain cover. Using a feeler...