BMW F 650 CS Repair Manual 2001–2005 (ABS & Non-ABS)

This BMW Motorrad F 650 CS repair manual, printed 06/01, covers maintenance and component repair for machines in standard condition or fitted with genuine BMW accessories. ABS-specific work and equipment-dependent procedures are identified within the relevant sections.

Searchable Text and Bookmarked Procedures

Text search and navigation: The maintenance and repair text is searchable, and embedded PDF bookmarks lead to construction groups and individual procedures.

One printable, English-language PDF contains 352 pages, including nine preliminary pages and 40 mostly blank pages carrying chapter icons and page numbers. The preliminary material includes the cover, publication information, introductory guidance, service sheets, and general contents.

Engine Overhaul, Belt Drive, and Chassis Service

The following selected repair topics show the manual’s scope. Other included subjects cover lock-barrel replacement and headlight beam adjustment.

• Engine overhaul: Engine removal, cylinder-head rebuilding, piston and cylinder inspection, crankshaft and balancing-shaft work, centrifugal decompressor service, and reassembly.

• Maintenance and lubrication: Inspection schedules, valve-clearance adjustment, engine and oil-tank servicing, frame-strainer cleaning, and engine oil-circuit bleeding.

• Fuel and cooling systems: Fuel-pressure checks, injector and throttle-component replacement, fuel-pump service, coolant-pump repair, cooling-system pressure testing, and thermostat replacement.

• Clutch and gearbox: Multi-plate clutch inspection, release-mechanism repair, gearbox-shaft disassembly, selector inspection, bearing replacement, and assembled gearbox checks.

• Belt drive and suspension: Poly Chain GT belt replacement and tension adjustment, drive-damper service, single-arm swingarm bearings, telescopic-fork overhaul, and steering-head bearing replacement.

• Brakes and ABS: Caliper and master-cylinder service, brake-disc inspection, hydraulic bleeding, ABS sensor replacement, and ABS-specific brake-line procedures.

• Electrical equipment: Starter-motor disassembly, ignition-component replacement, resistance specifications, wiring-harness routing views, and relay and connector location illustrations.

The manual is intended for workshop personnel with theoretical and practical BMW training, with special tools and diagnostic equipment specified for relevant operations.

Internal Engine Inspection and Dry-Sump Lubrication

Component-specific wear limits let technicians compare measured parts with factory inspection criteria before deciding what needs replacement. The engine chapter distinguishes cylinder and piston size groups and documents bearing clearances, crankshaft shimming, valve-guide work, and camshaft timing.

The dry-sump cleaning procedure addresses contamination that could damage a rebuilt engine and specifies BMW flushing hose 11 7 671 for the frame-integrated oil tank. Engine reassembly also includes a dedicated oil-circuit bleeding procedure before startup.

Fuel Delivery and Cooling-System Work

The fuel chapter covers BMS control-unit removal, injector replacement, throttle-valve actuator service, and the self-teaching throttle-position potentiometer. U.S.-version fuel-evaporation control-valve and activated-charcoal-filter procedures are identified separately.

Cooling-system coverage extends to pump shaft and seal replacement, coolant filling and bleeding, leak testing, and radiator and fan removal.

Fork Rebuilding and Rear-Drive Adjustment

Step-by-step instructions cover telescopic-fork disassembly and reassembly, steering-head bearing replacement, and toothed-belt tension adjustment through the eccentric clamp. Belt setup distinguishes new and used belts, while pulley replacement is linked to runout measurement.

The fork assembly instructions identify a specific damage risk: installing the spring backward can damage the sliding surface inside the fixed tube. Rear-drive sections also cover eccentric bearings, the drive shaft, suspension linkage, and drive-damper components.

Electrical Illustrations and Workshop References

Visual references include the engine cutaway, engine oil circuit, coolant circuit, gearbox-shaft component view, left and right wiring-harness views, and wheel-track-offset measurement record. Electrical coverage uses routing illustrations and component-location photographs rather than a full system wiring-diagram set.

Construction-group specifications supply tightening torques, operating-fluid requirements, wear limits, and electrical resistance data. BMW MoDiTeC is specified for reading fault memory.

ABS Bleeding and Service Requirements

For ABS-equipped machines, the manual calls for BMW MoDiTeC’s Control Units/Toolbox ABS routine in addition to the printed bleeding procedure. It warns that residual air may remain in the ABS control circuits without this supplementary routine.

ABS control-unit work is reserved for authorized BMW workshops. Ensure your workspace is fully prepared and follow the manual’s safety precautions before component teardown.

A Preview of Valve-Clearance and Fuel-Pressure Data

For valve-clearance checks with the engine cold, at a maximum of 35°C/95°F, the manual specifies 0.03–0.11 mm for the intake valves and 0.25–0.33 mm for the exhaust valves.

The fuel-pressure test specifies 3.5 ± 0.2 bar with the engine running in neutral. Its accompanying fault-isolation note directs attention to the pump, filter, pressure regulator, and lines when pressure falls outside specification.