Motorcycle engine repair BMW F650GS (2000-2007)

Technical data of engine motorcycle
Engine, general TypeSingle-cylinder four-stroke, double overhead camshafts driven by roller chain, 4 valves operated by bucket tappets, balancing shaft, liquid-cooled cylinder and cylinder head, integral water pump, 5-speed gearbox and dry sump...

Engine design of motorcycle
Sectional view of engine Engine oil circuit: 1. Delivery pump; 2. Oil tank; 3. Check valve; 4. Oil filter; 5. Control valve; 6. Low-pressure line (gearbox); 7. Low-pressure line (clutch); 8. High-pressure line (crankshaft); 9. High-pressure line...

Removing and installing cylinder head, engine installed
Note: If an engine failure occurs, the oil tank and oil lines must be cleaned with the material used for this purpose in the workshop, and then blown through with compressed air. Preparatory work Remove left, right and centre covers. See Group 46....

Removing cylinder, engine installed
Remove cylinder head. Use pliers, BMW # 17 5 500, to open the clamp securing the coolant hose to the water pump (arrow) and disconnect the hose. Disconnect ground cable (arrow) from cylinder. Remove cylinder base screws. Push the rear chain guide...

Removing engine
Preparatory work Drain coolant. See Group 00. Place motorcycle on its centre stand. Secure front wheel in position. Remove seat. Remove intake air silencer. See Group 13. Disconnect battery negative terminal. Remove engine guard. Drain engine oil....

Lowering engine
Preparatory work Drain coolant. See Group 00. Place motorcycle on its centre stand. Secure front wheel in position. Remove seat. Remove intake air silencer. See Group 13. Disconnect battery negative terminal. Remove engine guard. Drain engine oil....

Removing cylinder head
Caution! If there is any mechanical damage, the oil tank and the oil lines must be cleaned. Remove starter motor. See Group 12. Remove oil lines. Remove valve cover (1). Remove spark plug. Remove centre screw plug on right in engine block. Turn...

Disassembling and assembling cylinder head
1. Valve; 2. Lower valve spring plate; 3. Valve stem seal; 4. Valvespring; 5. Upper valve spring plate; 6. Valve collets Removing valves Use suction device, BMW # 113251, to pull out the bucket-type tappets. Check that bucket tappets and guides are...

Removing and checking cylinder
Removing cylinder Remove cylinder. Separate the cylinder base from the engine block. Caution! When removing cylinder, make sure that the piston does not strike the engine block. Checking cylinder Check cylinder face and sealing faces for damage and...

Removing and checking piston
Removing piston Remove piston pin circlips. Press out piston pin with drift, BMWNo. 116581. Note: Mark exhaust-valve side on piston crown. Disassembling piston Remove piston rings with piston ring pliers. Carefully clean piston. Check piston for...

Removing ignition magnet
Remove retainer on right engine housing cover. Remove the central plug and install handle, BMW # 12 5 500. Remove the cover, noting the thrust washer (arrow). If necessary, remove ignition trigger (4). Unscrew hex nut. Heat hub to 80°C (176°F)....

Removing countershaft for starter
Remove thrust washer (1) and spacer sleeve (2). Remove double gear (4). Pull off idler gear (3). Remove freewheel gear (5).

Disassembling and assembling freewheel
Disassembling freewheel 1. Machine screw 2. Magnet rotor 3. Freewheel 4. Lock ring 5. Freewheel housing 6. Freewheel gear Warning: Securing screws (1) are secured with Loctite 648 and considerable torque is required to release them. Release...

Removing clutch
Turn engine round in assembly fixture. Remove left retaining for engine housing cover and remove cover. Removing pressure plate Remove hex screws (2) in diagonally opposite sequence. Lift off complete pressure plate (1). Removing clutch plates...

Removing and installing oil pump
Removing oil pump Remove circlip (1) from idler gear. Remove the retaining rings of the oil-pump gears (2) and disengage the oil-pump gears. Remove idler gear (3). Remove needle rollers (4). Remove thrust washers (5). Remove countersunk screws from...

Removing double drive gear
Note: Retaining screw (arrow) must be installed. Remove hex nut (1). Press chain guide (2) to rear of engine block. Pull off double drive gear with timing chain.

Removing crankshaft and balancing shaft
• Lever out water-pump drive gear (3) with a screwdriver. Remove needle roller. Swivel engine in assembly fixture so that magnet side is uppermost. Remove all threaded fasteners for engine housing. Remove oil filter and unfasten two fasteners on...

Removing compensating gear
Press off compensating gear with pressure pad, BMW # 11 0 561. Installation is the reverse of the removal procedure: pay particular attention to the following. Note: Coat the bearing seat for the expander gear on the compensating gear with Optimoly...

Removing and installing crankshaft gear
Clamp crankshaft into vise with protective jaws. Use yoke, BMW # 11 6 501, spindle, BMW # 11 6 502, and pressure pad, BMW # 11 6 503, to pull off the crankshaft gear. Installation is the reverse of the removal procedure: pay particular attention to...

Removing and installing gearbox mainshaft bearings
Note: To protect the gasket surfaces of the engine block, place the old gasket under the bearing puller. Always renew the mainshaft sealing ring. Heat the left of the engine block to 80-100°C (176-212°F). Using bearing puller plate, BMW # 11 6 561,...

Removing and installing gearbox compensating shaft bearings
Note: To protect the gasket surfaces of the engine block, place the old gasket under the bearing puller. Always renew the mainshaft sealing ring. Heat the left of the engine block to 80-100°C (176-212°F). Using bearing puller plate, BMW # 11 6 561,...

Removing and installing grooved ball bearings of gearbox compensating shaft
Note: To protect the gasket surfaces of the engine block, place the old gasket under the bearing puller. Always renew the mainshaft sealing ring. Heat the left of the engine block to 80-100°C (176-212°F). Using bearing puller plate, BMW # 11 6 561,...

Removing and installing main bearings
Check main bearings for signs of damage and wear. Removal Heat the engine housing to 100°C (212°F). Drive out the bearing bushings with drift, BMW # 11 0 541, and drift, BMW # 00 5 500. Installation Mark the position of the oil hole in the bearing...

Installing crankshaft and balancing shaft
Secure right side of engine housing in engine bracket with magnet side facing downwards. Install balancing shaft in engine housing; marking (1) must be aligned with marking (3) on housing. Coat 1.0 mm (0.04 in) thrust washer with oil and install on...

Installing double drive gear
Lock the crankshaft in the TDC position with locating screw, BMW # 11 6 570. Insert chain through chain aperture and loop it around crankshaft. Slide double drive gear (2) on to crankshaft. Engage chain. Install snap ring. Clean threads of...

Installing oil pump gears
Install idler gear (1) with washer and circlip. Install washers (4) of oil pump gears and slide needle rollers (5) into position. Install oil pump gears (3) and install the circlips (2).

Installing clutch
Installing clutch cage Place thrust washer (1) on compensating shaft. Coat needle sleeves (3, 5) with oil and install, with the small sleeve (5) down. Insert O-ring (2) into groove under splines. Install clutch cage (4); gears must all be in mesh....

Installing countershaft for starter motor
Turn engine in assembly fixture so that magnet side is uppermost. Note: Oil the bearing bushing for freewheel gear (6) and the straight pins. Slide freewheel gear (6) with the press-fit bearing bushing, onto the crankshaft. Push intermediate starter...

Installing magnetic ignition trigger
Caution! Tapers on crankshaft and magnet hub and hex nut must be clean and free of grease. Apply a thin coat of Loctite 648 to the magnet hub taper. Oil freewheel in freewheel housing. Slide magnet wheel (1) onto crankshaft: woodruff key and keyway...

Installing piston
Coat the small end bore and the piston pin bore in the piston with Optimoly MP 3. Caution! Note the mark on the exhaust side of the crown applied on disassembly. Install the piston. Press the piston pin in with drift, BMW # 11 6 581. Install piston...

Installing cylinder
Fit cylinder base gasket on engine housing: oil bore must be clear. Oil the piston rings and press the sliding piston ring sleeve, BMW # 11 6 510, over the piston rings from above so that the piston projects from the sliding sleeve by about 2 mm...

Installing cylinder head
Note: Install a new cylinder head gasket. Install the cylinder head gasket. Use a wire hook to pull the timing chain through the cavity in the cylinder head. Fit cylinder head with valves installed to cylinder. Secure the cylinder head and cylinder...

Installing camshaft and adjusting valves
Oil outside of bucket tappets and reinstall on original valves. Measure thickness of shims with micrometer and note down dimension. Place lower part of camshaft carrier (1) on cylinder head. Fit camshafts with cam lobes facing upwards, press down by...

Installing engine
Installation is the reverse of the removal procedure: pay particular attention to the following. Working from the right, manoeuvre the engine on the lifter into position below the motorcycle. Raise the engine and tilt it to the rear. Manoeuvre the...