BMW F650, F650 ST Funduro and ST (Strada) 1994–2000 OEM Service Manual (P/N 0-89287-802-9)

Clymer M309 covers the Rotax-built, liquid-cooled, DOHC four-valve single-cylinder engine used in BMW’s carbureted F650 range. This 384-page PDF scan contains the 2002 first edition of the repair manual, ISBN 0-89287-802-9. It is suited to home mechanics comfortable with tools: measurement basics are explained, while selected operations call for specialist equipment or dealer service.

• 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.

Model and Market Coverage

The manual identifies these specific combinations:

Build differences extend beyond bodywork. Oil-pump driven gears have no retaining snap rings through engine 398 297; engines 398 298 onward use snap rings. Separate fork-oil data distinguish regular and lowered suspension. Emissions coverage includes California charcoal-canister replacement; secondary-air coverage for U.S. and Swiss models is limited to pipe and fitting inspections.

Repair Procedures and Service Limits

The 15 technical chapters are organized by vehicle system, followed by an index and wiring diagrams. 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 likewise receives adjustment, inspection and replacement coverage, without internal rebuilding.

Electrical coverage has a similar boundary: ignition-control-unit and regulator/rectifier diagnosis relies on dealer substitution with known-good units, rather than component bench-test procedures.

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 address specific damage risks: incorrect clutch-housing engagement can damage the plastic oil-pump gears, and incorrect crankshaft-to-balancer alignment can cause severe vibration and internal engine damage.

Technical Specifications and Reference Data

Maintenance schedules are paired with fluid capacities, intake and exhaust valve-clearance data, wear limits, electrical test values and component-specific torque specifications. Standard metric fastener tables provide general reference data. Battery information includes a specific-gravity versus state-of-charge chart.

Scan condition: Printed page 26 is missing, and some pages have cropped text, including printed page 124.

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.