2002 BMW F 650 GS Dakar Complete Engine Assembly | 9-Dec-2009
Channel: Junta Janardhan
Date: 29/06/2015

A recording of the steps involved in assembling the engine of a 2002 BMW F 650 GS Dakar (single-spark), but applicable to all bikes using the Rotax 650 cc single-cylinder motor. More information about the bike can be found here: http://faq.f650.com/FAQs/F650HistoryDifferences.htm

This is less of a tutorial and more of a "guideline" as to how to go about things - especially of what NOT to do while assembling an engine. Hopefully, you will learn from the mistakes made here and do a better job yourself. :-)

Many thanks to the amazing people of the Chain Gang (the F650.com forums), especially to Flash for his remarkable maintenance DVDs, and to the late, great Haakon for his sagely wisdom and guidance. You will be sorely missed, old friend.

The video was shot using a Canon PowerShot A460, so apologies for being too poor to afford a decent quality camera. :-P

0:00:00 - Installing The Gear Shifter
0:02:50 - Installing Gear Shifter Drum & Transmission Gears
0:06:20 - Installing The Transmission Gears & Selector Forks
0:09:55 - Checking The Gears & The Crankshaft Oil Line
0:13:15 - Installing The Crankshaft & Counterbalance Shaft
0:16:15 - Installing The Crankcase Gasket
0:19:45 - Crankcase Installed
0:22:10 - Cleaning The RHS Gasket Mating Surface
0:27:15 - Installing The Crankshaft Double-Drive Gear
0:30:55 - Tightening The Double-Drive Gear Nut
0:34:35 - Tightening The Clutch Cage Nut
0:38:25 - Bending The Clutch Cage Nut's Tab Washer
0:40:55 - Installing The Clutch Plates
0:43:50 - Installing The Clutch Cover Using ThreeBond
0:48:40 - Installing The Piston
0:52:35 - Installing The Cylinder Block
0:57:30 - Installing The Head
0:59:45 - Installing The Head Fasteners
1:04:05 - Installing The Shim Buckets & Lower Cam Carrier
1:08:10 - Installing The Upper Cam Carrier
1:12:55 - Installing The Valve Cover & Starter Motor
1:15:45 - Placing The Engine Into Position
1:19:15 - Installing The Front Engine Mount Bolts
1:22:05 - Aligning The Swingarm Bolt Holes
1:25:05 - Installing The Swingarm Bolt
1:29:10 - Tightening The Swingarm Bolt

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