Repair of handlebar of motorcycle BMW F650GS (2000-2007)

Technical data of handlebar
Steering Type One-part tubular handlebar with cross-tie Steering lock angle ° 40 Steering tube diameter mm (in) 22 (0.87) Width across handlebars (handlebar only, without grips) mm (in) 770 (30.3)

Removing and installing left handlebar fitting
Note: To avoid damage, use a protective apron for the tank, BMW No. 16 1 600. Place motorcycle on its centre stand. Remove seat. Remove left, right and centre covers. Cut the cable tie at the handlebar. Remove cover (3) from housing (2). Remove...

Removing and installing clutch switch
Place motorcycle on its centre stand. Remove seat. Remove left, right and centre covers. Release clutch switch on handlebar fitting. Cut through the cable ties securing the cables at the handlebar and the multi-function switch. Cut through the cable...

Removing and installing right handlebar fitting
Place motorcycle on its centre stand. Remove seat. Remove left, right and centre covers. Cut the cable tie at the handlebar. Caution! Refer to notes on the hazards involved in handling brake fluid. Disconnect and seal brake hose (1). Remove brake...

Removing and installing handlebar
Remove left handlebar fitting. Remove right handlebar fitting. Remove impact pad (1). Loosen clamping screws (2). Remove handlebar (4) together with clamping blocks (3). Installation is the reverse of the removal procedure: pay particular attention...

Removing and installing clutch cable
Disengage clutch cable (5) from release lever. Pull cable out of holder (4). Remove rubber grommet (1) from clutch lever. Make sure that slots in adjusting screw, locknut and lever fitting (arrow) are in line. Pull back cable shroud (2). Pull the...

Removing and installing throttle cable
Remove seat. Remove left cover. Disengage throttle cable from adapter (arrow). Remove circlip (5) from throttle-cable holder and disengage throttle cable. Pull the cable out toward the handlebar. Remove cover (4). Remove fastener for throttle cable...

Checking steering head bearing play
Lift front wheel clear of the ground. Move fixed fork tubes forward (arrows). Adjust the steering head bearing if play is perceptible.

Adjusting steering head bearing play
Caution! Cover or mask off the instrument cluster and trim to prevent scratches. Remove impact pad (2). Remove clamp blocks (1). Remove the handlebar and place it in front of the instrument cluster. Unscrew hex nut (5). Release clamping screws (3)...

Removing and installing left and right handlebar levers
Removing and installing left handlebar lever Disengage clutch cable (1) from release lever. Pull cable out of holder (2). Remove the rubber grommet from the clutch lever. Make sure that slots in adjusting screw, locknut and lever fitting (arrow) are...