BMW F650 / F650 ST 1994–2000 Clymer Repair Manual (P/N M309)

Clymer’s 2002 first-edition repair manual (P/N M309; ISBN 0-89287-802-9) covers BMW’s carbureted F650 range and its Rotax-built, liquid-cooled, DOHC four-valve single-cylinder engine.

PDF Search, Page Navigation and Readability

Search, bookmarks and diagram detail: PDF text search is unavailable. Numbered bookmarks link to individual pages rather than named chapters. Small wiring labels are readable when enlarged. Printed page 26 is missing, and some page edges cut off text, notably printed page 124.

ZIP download containing one printable, 384-page PDF. The total includes covers and front matter, two catalog pages, one notes page and one maintenance-log page.

Engine Overhaul, System Diagnosis and Chassis Repair

The following selected workshop topics are part of the manual’s coverage. Other sections include spark plug condition illustrations and body-panel removal.

• Engine top end: Valve-clearance inspection and shim adjustment, cylinder-head overhaul, camshaft timing and centrifugal decompressor repair, supported by the Camshafts and Drive Chain exploded view.

• Lower end and lubrication: Engine removal, crankcase separation, main-bearing replacement and crankshaft endplay adjustment, with Oil Pump Assemblies drawings for feed and scavenge pump service.

• Clutch and transmission: Wet-clutch plate, basket and release-mechanism inspection, plus internal disassembly of the five-speed gearbox and its shift mechanism. The Transmission exploded view identifies the shaft components.

• Fuel and exhaust systems: Dual Mikuni BST 33-B-316 carburetor disassembly, cleaning and float-height adjustment, alongside throttle and enrichment-cable service, fuel-shutoff inspection and exhaust-system removal.

• Electrical diagnosis: Ignition-coil resistance checks, starter-motor inspection and battery-drain testing accompany the two-page All Models 1994–2000 wiring diagram and its wire-color key.

• Cooling system: Pressure testing, thermostat checks and pump shaft and seal inspection, with the Water Pump exploded view showing the serviceable components.

• Suspension and steering: Fork disassembly and seal replacement, steering-head bearing service and rear-linkage bearing replacement, supported by the Front Fork exploded view.

It is suited to home mechanics comfortable with tools: measurement basics are explained, while selected operations call for specialist equipment or dealer service.

Model and Market Coverage

The manual identifies these specific combinations:

Oil-pump procedures distinguish snap-ring-retained driven gears from earlier assemblies. Separate fork-oil data address regular and lowered suspension. These distinctions help match service information and replacement parts to the installed engine and suspension.

Engine Reassembly and Special Tools

Step-by-step instructions cover major engine disassembly and reassembly, including starter-clutch service and oil-circuit bleeding. The cylinder section specifies replacement when wear exceeds the service limit; an oversize piston is not available.

Special-tool references include BMW crankshaft locking screw 11 6 570 for timing work and rotor removal tool 12 5 510 for alternator service.

Assembly cautions explain how incorrect clutch-housing engagement can damage the plastic oil-pump gears. Incorrect crankshaft-to-balancer alignment can cause severe vibration and internal engine damage.

Fuel and Emission-Control Service

Emissions coverage includes California charcoal-canister replacement and crankcase-breather inspection. Secondary-air coverage for U.S. and Swiss models is limited to pipe and fitting inspections.

Electrical Troubleshooting and Diagnostic Limits

The current-draw test explains how to isolate a circuit responsible for battery discharge while parked, giving the mechanic a way to narrow the fault before replacing components. Charging-system troubleshooting also covers output checks and wiring connections.

Ignition-control-unit and regulator/rectifier diagnosis relies on dealer substitution with known-good units rather than component bench-test procedures.

Wheels, Brakes and Rear-Shock Limits

Wheel work extends to hub-bearing replacement, spoke adjustment and wheel truing. Chain replacement distinguishes the original endless chain, which requires swingarm removal, from a replacement using a riveted master link.

Brake repair coverage includes pad replacement, disc inspection, hose replacement, and both manual and Mityvac vacuum-assisted bleeding. Calipers and master cylinders are handled as replacement assemblies; their internal overhaul is outside the manual’s scope.

The rear shock receives adjustment, inspection and replacement coverage, without internal rebuilding.

Maintenance Schedules and Workshop References

The 15 chapters are followed by an index and wiring diagrams. Maintenance schedules are paired with fluid capacities, intake and exhaust valve-clearance data, wear limits and component-specific torque specifications.

Standard metric fastener tables provide general reference data. Battery information includes a specific-gravity versus state-of-charge chart.

A Preview of Ignition and Thermostat Test Data

For resistance tests at 68°F (20°C), the electrical tables list ignition-coil primary resistance of 0.2–0.5 ohm and secondary resistance of 6,000–13,000 ohms.

The cooling-system test data specify thermostat opening at 72–75°C (162–167°F), alongside the thermostat inspection and heated-water testing procedure.

Working on motorcycle engines, suspension and brakes carries inherent risks, so always ensure proper shop safety practices and verify exact vehicle requirements before turning a wrench.