BMW F 650 GS / GS Dakar Repair Manual, 1993–2007

This BMW Motorrad After Sales repair manual covers the F 650 GS and F 650 GS Dakar configurations documented with the included service sheets dated 02/00. Procedures apply to standard motorcycles and machines fitted with genuine BMW accessories. This is not a blanket 1993–2007 model-year manual or a guide to motorcycles modified from factory specification.

Searchable PDF and Chapter Bookmarks

Text search and navigation: The PDF has searchable text and embedded bookmarks for chapters and individual procedures. Electrical illustrations show harness routing, component locations, and connectors; complete circuit wiring diagrams are not included.

One printable English PDF with 334 pages, including the cover, two introductory pages, three single-page factory service sheets, and 40 largely blank chapter pages.

Engine Overhaul, Chassis Repair, and System Testing

The following selected coverage highlights outline the main workshop content. Additional topics include lock-barrel replacement and headlight-beam adjustment.

• Engine repair: Cylinder-head removal with the engine installed, complete engine disassembly, camshaft and timing-chain work, valve-guide and seat inspection, piston measurement, and crankshaft service.

• Fuel and emissions: BMS control-unit replacement, injector and throttle-component service, fuel-pressure testing, tank and pump removal, and USA-version evaporative-emissions equipment.

• Cooling and exhaust: Cooling-system leak testing, water-pump shaft and seal replacement, thermostat and radiator removal, and oxygen-sensor and catalytic-exhaust service.

• Clutch and gearbox: Step-by-step clutch disassembly and reassembly, release-shaft service, gearbox-shaft teardown, bearing replacement, and selector-mechanism inspection and assembly.

• Suspension and wheels: Fork disassembly and alignment checks, steering-head and rear-linkage bearings, drive-chain service, wheel bearings, spoke replacement, rim truing, and static balancing.

• Brakes and ABS: Caliper-piston and master-cylinder repair, brake-line replacement, ABS sensor and ring service, sensor-gap adjustment, and MoDiTeC-assisted bleeding requirements.

• Electrical equipment: Starter-motor overhaul, ignition-trigger and stator replacement, voltage-regulator service, relay and connector identification, switches, instruments, and lighting.

BMW describes this as a workshop reference that builds on theoretical and practical training. It is suited to trained technicians and highly experienced owners with motorcycle-repair knowledge, measuring equipment, and the required service tools.

Scheduled Service and Factory Reference Sheets

The opening material covers pre-delivery setup, inspection routines, annual service, MoDiTeC fault-memory checks, valve-clearance adjustment, engine-oil and Dakar fork-oil changes, coolant and brake-fluid service, chain and spoke checks, and final road-safety checks.

The maintenance schedule and pre-delivery checklist carry BMW Order No. 01 71 0 021 836. The service-data sheet carries Order No. 01 71 0 021 845; all three sheets are marked UX-VS-2, 02/00.

Component-specific torque tables, operating-fluid information, capacities, wear limits, clearances, adjustment data, and electrical specifications accompany the repair chapters. These references support inspection and reassembly rather than stopping at routine maintenance.

Internal Engine Work and Workshop Tools

The engine chapter covers the liquid-cooled DOHC single, dry-sump lubrication, and twin trochoid oil pumps. Inspection procedures address the centrifugal decompressor, camshaft bearing clearance, cylinder and piston measurements, and crankshaft and balancer shimming.

Separate in-frame cylinder-head procedures and complete bench-overhaul instructions help establish the access and equipment needed for the planned repair. Tool references include engine lifter BMW 00 1 540 with adapter 11 0 591, piston-ring sleeve 11 6 510, and gearbox circlip pliers 23 4 500.

BMW specifically warns against starting a rebuilt engine before the oil circuit has been bled. The manual includes the corresponding oil-circuit bleeding procedure.

Dakar Differences and Chassis Work

Procedures restricted to the Dakar are tagged [Dakar]. Fork-fluid specifications distinguish standard GS, lowered GS, and Dakar configurations. Other differences include rear-suspension specifications, front-wheel size, hand protectors, harness routing, and voltage-regulator location.

Steering and wheel procedures identify pin-wrench adapter BMW 31 6 521 and wheel-balancing unit 36 3 600. The fork assembly instructions warn that incorrect coil-spring orientation can damage the sliding surface inside the fixed tube.

Fuel-System Diagnosis and ABS Requirements

BMS mapped ignition and manifold fuel injection are covered alongside throttle-valve actuator and potentiometer replacement. The potentiometer uses a self-teaching system. Fuel-pressure testing includes guidance on checking the pump, filter, regulator, and lines when pressure falls outside specification.

The tank chapter treats the rollover valve, fuel pump, and strainer separately from the USA-version fuel-evaporation valve and activated-charcoal filter.

For ABS-equipped motorcycles, BMW specifies the MoDiTeC Control Units/Toolbox ABS routine in addition to manual bleeding because residual air can remain in the control circuits. Brake procedures identify resetting tool BMW 34 1 500. BMW reserves all work on the ABS control unit for an authorized BMW workshop.

Fuel lines are pressurized, and brake, ABS, steering, and suspension work directly affects road safety. Follow the BMW cautions and use qualified service support for repairs beyond your training or equipment.

Illustrations and Electrical Scope

Reference illustrations include the engine cutaway, engine oil circuit, ignition-magneto components, coolant circuit, gearbox-shaft components, and telescopic-fork component view.

The electrical chapter adds left- and right-side harness-routing views, Dakar-specific views, equipment-box relay locations, and connector identification. Fault-memory access requires the diagnostic equipment described in the manual; a fault-code interpretation chart is not included.

Examples of Fuel and Cooling Test Data

Fuel-pressure testing: The specified pressure is 3.5 ± 0.2 bar with the engine running in neutral. The test section connects an out-of-range result with checks of the fuel pump, filter, pressure regulator, and lines.

Cooling-system leak testing: The specified test pressure is 1.5 bar, which must remain unchanged for at least five minutes. This accompanies the pressure-test procedure and its factory-tool references.