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BMW F850 GS K81 Service Manual

The document is a repair guide for the BMW F850 GS motorcycle, detailing technical specifications, engine data, and maintenance information. It includes information on engine performance, fuel requirements, cooling system, clutch and gearbox specifications, and braking system details. The guide serves as a comprehensive resource for servicing and understanding the motorcycle's components and operational parameters.

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100% found this document useful (1 vote)

1K views959 pages

BMW F850 GS K81 Service Manual

Uploaded by

mniemiec0804

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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BMW

MOTORRAD

BMW F850 GS
K81
(0B09/0B19/0B29/0B39)

Repair Guide

BMW Motorrad
General Information

Repair Guide

BMW Motorrad
BMW-Motorrad - F 850 GS

Technical data - F 850 GS

11 - Engine

Designation Precondition Value Valid

CO2 emission according to WMTC 98 g/km
Running-in speed Odometer <6500 min-1
reading 0...1200 km
Odometer No full load
reading 0...1200 km
Maximum engine speed max 9000 min-1
Displacement 853 cm3
Piston stroke 77 mm
Idle speed Engine at regular 1250+50 min-1
operating temperature −50

Torque at engine 92 Nm
speed 6250 min-1
Press loss Engine at regular max 25 %
through valves or cylinder operating temperature

Engine design Water-cooled 2-cylinder four-stroke

engine with four valves per cylinder
operated via rocker arms, two
overhead camshafts and dry-sump
lubrication
Engine number location Top right of crankcase
Engine type A24A08B
Nominal capacity at engine 70 kW
speed 8250 min-1
Compression ratio 13.1:1
Maximum engine speed max 9000 min-1
Cylinder bore 84 mm
Engine oil, capacity with filter change approx. 3.0 l
without filter change 2.7 l
Fluids and lubricants
Viscosity class
Engine oil, capacity with filter change approx. 3.0 l
Specification (SAE 5W-40, API SL / JASO MA2, Additives (e.g. molybdenum-based) are
not permissible because they can attack coated components of the engine,
BMW Motorrad recommends BMW Motorrad ADVANTEC Ultimate oil.)
Engine oil, quantity for topping up Difference between MIN max 0.5 l
and MAX
Engine oil, specified level between MIN and MAX mark

11 12 - Cylinder head with cover

Wear limit, tilt clearance, valve to at valve lift 10+0.1 mm max 0.40 mm
valve guide −0.1

11 21 - Crankshaft with bearings

Colour codes of crankshaft bearing Crankcase 1 (yellow) / Bearing shells yellow
shells Crankshaft 1 (yellow)

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS
Crankcase 1 (yellow) / Bearing shell at top yellow, bearing
Crankshaft 2 (green) shell at bottom green
Crankcase 2 (green) / Bearing shell at top yellow, bearing
Crankshaft 1 (yellow) shell at bottom green
Crankcase 2 (green) / Bearing shells, green
Crankshaft 2 (green)
Radial play of crankshaft main When new 0.030...0.058 mm
bearing Wear limit max 0.07 mm
Mark on the crankcase for the centre column (arrow). Colour of crankshaft bearing shells
identification of the bearing shells L: Left C: Centre R: (main bearing): 1 (yellow)/2 (green)
Right (in direction of
travel, engine installed)

Assignment of the crankshaft main Left labelling 1/2 on Main bearing shell on the magnetic
bearing shell crank web wheel side
Centre labelling 1/2 on Main bearing shells of centre mount
crank web
Right labelling 1/2 on Main bearing shells on the timing
crank web chain side (Arrow)

Endplay of crankshaft When new 0.120...0.253 mm

Wear limit max 0.30 mm
ID marks of crankshaft baring Colour coding on outer Bearing shell, class 1
side yellow
Colour mark on outside Bearing shell, class 2
green

Marks on crankcase Table on upper section of crankcase

Classification of crankshaft bearing (magnetic wheel side)
shells (main bearing)

Mark for classification of the Labelling on crank web Crankshaft main bearing
crankshaft bearings on magnetic wheel side
for identifying the bearing shells 1/2
Labelling on crank web Connecting rod bearing
on magnetic wheel side
A/B

11 24 - Conrod with bearings

Conrod bearing, bore diameter Identification on A/red or B/blue
connecting rod bearing
cap

Conrod weight class 0 452...456.9 g

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Classification, conrod groups by Conrod weight class 1 457...461.9 g
weight Conrod weight class 2 462...466.9 g
Conrod weight class 3 467...471.9 g
Conrod endplay When new 0.130...0.312 mm
Wear limit max 0.312 mm
Colour codes, conrod bearings Connecting rod bore A Bearing shell red
Assignment, conrod/conrod cap (red) / crankshaft A (red)
Connecting rod bore A Bearing shell violet
(red) / crankshaft B
(blue)
Connecting rod bore B Bearing shell blue
(blue) / crankshaft B
(blue)
Connecting rod bore B Bearing shell violet
(blue) / crankshaft A
(red)
Mark for classification of the conrod Left labelling A/B on the Bearing shell on the magnet wheel
bearings crank web side: Class A/B
Right labelling A/B on Bearing shell on the timing chain
the crank web side: Class A/B

Overview of conrod marks A Weight class

B Hole diameter

11 25 - Piston with rings and bolts

Designation Precondition Value Valid

Type of final drive Chain drive
Type of rear suspension Double arm aluminium swinging arm
33 54 - Spring strut, mounting parts
Basic setting of spring preload, rear One-up without luggage Turn the adjuster knob counter-
clockwise as far as it will go.
One-up with luggage Turn the adjuster knob counter-
clockwise as far as it will go, then
back it off 20 turns in the clockwise
direction.
Two-up with luggage Turn the adjuster knob clockwise as
far as it will go.
Spring travel at rear wheel at rear wheel 215 mm
Basic setting of rear-suspension One-up without luggage Turn the adjusting screw as far as it
damping characteristic will go clockwise, then back it off 1.5
turns.
One-up with luggage Turn the adjusting screw as far as it
will go clockwise, then back it off 0.5
turns.
Two-up with luggage Turn the adjusting screw as far as it
will go clockwise, then back it off 0.25
turn.
Type of rear-wheel suspension Central spring strut with coil spring,
adjustable rebound stage damping
and spring preload
33 82 - Traction drive, chain pinion, belt pinion
Final drive, number of teeth 17/44
Pinion / sprocket
Secondary transmission ratio 2.588
33 83 - Traction drive, chain, belt
Chain deflection Motorcycle with no 40...50 mm
weight applied,
supported on its side
stand
Permissible chain length measured from the max 144 mm
centre of 10 rivets,
chain pulled taut

052021 1/1
BMW-Motorrad - F 850 GS

Technical data - F 850 GS

34 - Brakes

Designation Precondition Value Valid

Brake fluid level, front Brake-fluid reservoir The brake fluid level may not drop
horizontal, motorcycle below the MIN mark.
upright

Hydraulic fluid (Brake fluid, DOT4)

Brake fluid level, rear (visual The brake fluid level may not drop
inspection) below the MIN mark.

Technical data - F 850 GS

Equipment trim-level variant:

Rear softbagOA

Tank bagOA

71 - Parts and accessories for engine and frame and suspension

Designation Precondition Value Valid

71 54 - Accessories for luggage carrier
Payload of rear softbag max 1.5 kg
Payload of tank rucksack max 5 kg

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

Technical data - F 850 GS

77 - Optional accessories, motorcycle

Designation Precondition Value Valid

77 40 - Luggage system
Maximum permissible speed for max 130 km/h
riding with softbag for rear seat fitted
to the vehicle
Volume of the softbag for rear seat 2.5...8 l
Payload of the softbag for rear seat max 5 kg
77 41 - Case, liner
Maximum permissible speed for max 160 km/h
riding with cases fitted to the
motorcycle
Capacity, left case 25...35 l
Capacity, right case 15...23 l
Payload per case max 8 kg
77 43 - Topcase, liner
Maximum speed for riding with a max 160 km/h
loaded topcase
Payload of topcase max 5 kg
77 45 - Tank rucksack
Tank rucksack volume without capacity approx. 10 l
extension
Capacity extension approx. 4 l
Payload of tank rucksack max 5 kg

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

Tightening torques - F 850 GS

Retaining panel for centre stand to left footrest plate

Microswitch to clutch lever fitting

M2 x 22, Replace screw 0.3 Nm
Micro-encapsulated, Thread-locking compound (micro-
encapsulated)

61 33 - Emergency power siren, horn

Retaining bracket to crankcase
M8 x 16 19 Nm
Horn to bracket
M8 x 16 19 Nm

BMW-Motorrad - F 850 GS

Tightening torques - F 850 GS

77 - Optional accessories, motorcycle Value Valid

77 11 - Exhaust system
Sports silencer to rear frame
M8 x 40 19 Nm
Silencer to front silencer
M8 19 Nm
77 14 - Engine guard, crash bars
Crash bar, left, to engine protection bar, right
M5 x 14 6 Nm
Thread-locking compound (micro-encapsulated)
Engine guard to bracket
M6 x 25 9 Nm
Engine protection bar on engine block
M8 x 35 19 Nm
Thread-locking compound (micro-encapsulated)
Engine protection bar on side stand bearing support and engine
M8 x 25 19 Nm
Thread-locking compound (micro-encapsulated)
Crash bar to crankcase
M10 x 30 56 Nm
Thread-locking compound (micro-encapsulated)
77 25 - Frame, footrests, mounted parts
Case holder bracket (aluminium) with rear footrest bracket to rear frame
M8 x 30 - 10.9 28 Nm
Thread-locking compound (micro-encapsulated)
Left footrest plate to crankcase
M8 x 40 - 10.9 28 Nm
77 32 - Bow-shaped hand guard
Hand protector with handlebar weight to handlebar
M10 x 50 38 Nm
Thread-locking compound (Loctite 243, Medium strength)
77 42 - Mounted parts, cases
Case carrier to rear frame
top front, M8 x 50 19 Nm
Thread-locking compound (micro-encapsulated)
top rear, M8 x 35 19 Nm
Thread-locking compound (micro-encapsulated)
front, M8 x 20 19 Nm
Thread-locking compound (micro-encapsulated)
Cross-member to case holder/number plate carrier
M8 x 20 19 Nm
Thread-locking compound (micro-encapsulated)
M5 x 14 4 Nm
77 44 - Mounted parts, topcase, luggage carrier
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Luggage carrier to rear frame
M8 x 40 19 Nm
Thread-locking compound (micro-encapsulated)
Luggage carrier to rear frame
M8 x 30 19 Nm
Thread-locking compound (micro-encapsulated)
77 49 - Other luggage system
Tighten adapter plate
M6 x 40 8 Nm
77 51 - Lights
Bracket for additional LED headlight to front panel carrier
M6 x 25 8 Nm
Micro-encapsulated, Thread-locking compound (micro-
encapsulated)
Additional LED headlight to bracket
M6 x 40 6 Nm
77 52 - Audio, navigation, information system
Cross-member to upper section of bracket
M5 x 12 5 Nm
Securing screw to handlebar clamping block
M8 x 30 - 10.9 Tightening sequence: in the
Lubricate screw, Lubricant (MP 3 paste) forward direction of travel, tighten
until seated
25 Nm
Bracket to screws for handlebar clamp
M5 x 20, Replace screw 5 Nm
Thread-locking compound (mechanical)
Holder for navigation system with windscreen adjuster to front panel carrier
M6 x 40 5 Nm
Smartphone Cradle to bracket
M4 x 30 1.3 Nm
Socket or USB charging socket to trim panel
M18 x 1 3 Nm
77 53 - Switches, small items, control unit
Additional switch to clamping block
M5 x 12 2 Nm

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

Service data - F 850 GS

Designation Precondition Value Valid

11 - Engine
Running-in speed Odometer <6500 min-1
reading 0...1200 km
Odometer No full load
reading 0...1200 km
Engine oil, capacity with filter change approx. 3.0 l
without filter change 2.7 l
Fluids and lubricants
Viscosity class
Engine oil, quantity for topping up Difference between MIN max 0.5 l
and MAX
Engine oil, specified level between MIN and MAX mark

1134 - Valves with springs

Exhaust valve clearance Engine cold max 35 °C 0.30...0.35 mm
Inlet valve clearance Engine cold max 35 °C 0.11...0.20 mm
1212 - Ignition lead, spark plugs
Spark plugs, manufacturer and NGK LMAR9J-9E
designation
13 - Fuel preparation and control
Recommended fuel grade Premium unleaded maximum 15%
ethanol, E15
95 ROZ/RON
90 AKI
16 - Fuel supply
Usable fuel capacity approx. 15 l
Reserve fuel approx. 3.5 l
17 - Cooling
Cooling system test pressure Test pressure must 1.2 bar
remain
unchanged: 5 min
Coolant, specified level Engine cold Between MIN and MAX mark on the
expansion tank

31 - Front axle, front-wheel steering

Fork oil, capacity of left fork leg approx. 660 ml
Telescopic fork oil (Telescopic fork oil, type 4)
Fork oil, capacity of right fork leg approx. 557 ml
Telescopic fork oil (Telescopic fork oil, type 4)
Level of fork oil in left fork leg (air Fork fully compressed, 140 mm
chamber) compression spring and
spacer removed
052021 1/7
BMW-Motorrad - F 850 GS
Telescopic fork oil (Telescopic fork oil, type 4)
Level of fork oil in right fork leg (air Forks fully compressed 132 mm
chamber) and damper unit bled,
compression spring
removed
Telescopic fork oil (Telescopic fork oil, type 4)
3142 - Telescopic forks
Projection of fork tube in fork bridge, Groove flush with top edge of fork
top bridge
3273 - Bowden cables
Clutch cable play at the outer end of the 3...5 mm
handlebar lever,
handlebars in straight-
ahead position, engine
cold
3383 - Traction drive, chain, belt
Chain deflection Motorcycle with no 40...50 mm
weight applied,
supported on its side
stand
Permissible chain length measured from the max 144 mm
centre of 10 rivets,
chain pulled taut
34 - Brakes
Brake fluid level, front Brake-fluid reservoir The brake fluid level may not drop
horizontal, motorcycle below the MIN mark.
upright
Hydraulic fluid (Brake fluid, DOT4)

Brake fluid level, rear (visual The brake fluid level may not drop
inspection) below the MIN mark.
Hydraulic fluid (Brake fluid, DOT4)

3411 - Front wheel brakes

Brake-pad wear limit, front Friction pad only, min 1.0 mm
without backing plate.
The wear indicators, i.e.
the grooves, must be
clearly visible.

Brake disc lateral runout, front removed, at outer max 0.10 mm

diameter, components
cooled down
installed, at outside max 0.15 mm
circumference,
components cooled
Brake disc thickness, front When new 4.5 mm
Wear limit min 4.0 mm
3421 - Rear wheel brakes
Brake-pad wear limit, rear Friction pad only, min 1.0 mm
without backing plate.
Brake disc lateral runout, rear installed, at outside max 0.15 mm
circumference,
component cooled
max 0.10 mm

052021 BMW Motorrad, UX-VA-4 2/7

BMW-Motorrad - F 850 GS
removed, at outside
circumference,
component cooled
Brake disc thickness, rear When new 5.0 mm
Wear limit min 4.5 mm
3631 - Wheels with bearings
Vertical runout, rear wheel max 2 mm
Lateral runout, rear wheel max 2 mm
Vertical runout, front wheel max 2 mm
Lateral runout, front wheel max 2 mm
3632 - Tyres
Wheel valve test pressure 4 bar
Tyre pressure, rear One-up, tyre cold 2.5 bar
Two-up and/or with 2.9 bar
luggage, tyre cold
Tyre pressure, front One-up, tyre cold 2.2 bar
Two-up and/or with 2.5 bar
luggage, tyre cold
Tyre tread depth, front and rear Wear limit, for Germany min 1.6 mm
only
Wear limit, outside Country-specific legal requirements
Germany
6312 - Headlight
Distance between headlight and 5m
vertical surface
For headlight adjustment
Distance from light/dark limit to upper Suspension set to basic 5 cm
edge of low-beam headlight light- setting and vehicle
emitting surface loaded with 85 kg
6575 - Anti-theft alarm
Battery type CR 123 A
11 12 - Cylinder head with cover
Cylinder head cover to cylinder head
M6 x 20 10 Nm
Slide rail to bearing bracket
M6 x 12 10 Nm
Camshaft bearing cap to cylinder head
M7 x 38 Tightening sequence: See repair
manual
1st tightening torque, 5 Nm
2nd tightening torque, 15 Nm
11 13 - Oil sump
Bracket for overheating protection on oil sump
M6 x 16 8 Nm
Oil drain plug in oil sump
M16 x 1.5 25 Nm
Screw plug in dry sump
M10 x 1 8 Nm
11 14 - Housing cover
Screw plug (crankshaft) in crankcase
M24 x 1.5 10 Nm

052021 BMW Motorrad, UX-VA-4 3/7

BMW-Motorrad - F 850 GS
11 31 - Camshaft
Timing-chain tensioner to cylinder head
M24 x 1.5 15 Nm
11 42 - Oil filter and lines
Oil filter to crankcase 11 Nm
12 12 - Ignition lead, spark plugs
Spark plug to cylinder head
M10 x 1 12 Nm
13 71 - Intake air silencer
Intake air silencer to frame
M6 x 25 8 Nm
16 11 - Fuel tank with filler neck
Fuel tank to holder for fuel tank
M8 x 45 19 Nm
17 11 - Radiator with fasteners
Radiator to bracket
M6 x 25 8 Nm
23 00 - Gearbox
Pinion to gearbox output shaft
M10 x 35 50 Nm
Thread-locking compound (Loctite 243, Medium strength)
31 42 - Telescopic forks
Damper unit to forkleg
M8 x 22 20 Nm
Thread-locking compound (Loctite 243, Medium strength)
Cover to fixed fork tube 35 Nm
Adjustment specification, steering-head bearing
top slotted nut, M35 x 1 Tightening torque, 1 Nm
Secure with circlip turn further until circlip can be
installed
Adjustment specification, steering-head bearing
bottom slotted nut, M35 x 1 Tightening torque, 40 Nm
Swing the forks 3x to left/right through
full arc of travel
slacken (forks turned fully to the left),
80°
Tightening torque (forks turned fully to
right), 15 Nm
Fork bridge, bottom, to fork fixed tube

M8 x 35 Tightening sequence: Tighten

screws six times in alternate
sequence
052021 BMW Motorrad, UX-VA-4 4/7
BMW-Motorrad - F 850 GS
19 Nm
Fork bridge, top, to fork fixed tube
M8 x 35 19 Nm
Clamp of quick-release axle

M8 x 35 Tightening sequence: Tighten

screws six times in alternate
sequence
19 Nm
Locknut to cover 20 Nm
Adjusting steering-head bearing (for maintenance)
Bottom slotted nut, M35 x 1 (forks turned fully to right), 15 Nm
Rubber washer
Top slotted nut, M35 x 1 Tightening torque, 1 Nm
Secure with circlip turn further until circlip can be
installed
Fork bridge, top, to steering tube
M28 x 1.5 130 Nm
Secure thread in the lower area, Thread-locking compound
(Loctite 243, Medium strength)
Lubricate at the bottom of the head lightly , Lubricant
(Klüberplex Fluoropan T PTFE)
32 71 - Motorcycle handlebars
Handlebar weight to handlebars
M10 x 50 38 Nm
32 76 - Steering damper
Steering damper to fork bridge
M8 x 35, Renew screw 19 Nm
Thread-locking compound (micro-encapsulated)
Steering damper to frame
M8 x 55, Replace screw 24 Nm
Thread-locking compound (micro-encapsulated)
33 35 - Rear wheel swinging arm with pivot mount, link
Rear wheel swinging arm to frame
M20 x 1.5, Replace screw 200 Nm
33 84 - Traction drive, chainwheel, belt wheel
Chain sprocket to chain-sprocket carrier
M12 x 1.5 110 Nm
Thread-locking compound (mechanical)
33 85 - Mounted parts, traction drivetrain
Chain slide rail to rear wheel swinging arm
M6 x 14.5 8 Nm
Chain guard to swinging arm

052021 BMW Motorrad, UX-VA-4 5/7

BMW-Motorrad - F 850 GS
M6 x 16, Replace screw 3 Nm
Thread-locking compound (micro-encapsulated)
34 11 - Front wheel brakes
Brake caliper to telescopic fork
M10 x 45 38 Nm
Brake disc to front wheel
M8 x 27 - 10.9, Replace screw Tightening sequence: tighten in
Thread-locking compound (micro-encapsulated) diagonally opposite sequence
19 Nm
Bleed screw to brake caliper, front 14 Nm
34 21 - Rear wheel brakes
Brake fluid tank to side cover
M6 x 16, Replace screw 2.4 Nm
Thread-locking compound (mechanical)
Brake disc to rear wheel
M8 x 15.5, Replace screw Tightening sequence: tighten by
Thread-locking compound (micro-encapsulated) stages in diagonally opposite
sequence
30 Nm
Bleed screw to brake caliper, rear 14 Nm
34 32 - Brake lines
Brake-hose distributor to fork clamp
M6 x 16 8 Nm
36 23 - Electronic components
Wheel-speed sensor, front, to fork leg
M6 x 16, Replace screw 8 Nm
Thread-locking compound (micro-encapsulated)
36 31 - Wheels with bearings
Nipple on spoke
M4.5 x 0.75 3.5 Nm

Thread locking compound for spoke nipples

Grubscrew, M4 2 Nm
Axle screw in front quick-release axle
M20 x 1.5 50 Nm
Rear quick-release axle in swinging arm
M24 x 1.5 100 Nm
Thread-locking compound (mechanical)
46 52 - Centre stand

Retaining panel for centre stand to left footrest plate

M10 x 35 38 Nm
46 53 - Side stand
Side stand to pivot mount
M10 x 1 41 Nm
Thread-locking compound (micro-encapsulated)
or, Thread-locking compound (Loctite 243, Medium strength)

052021 BMW Motorrad, UX-VA-4 6/7

BMW-Motorrad - F 850 GS
46 61 - Front-wheel cover
Fork partition to bottom fork bridge
M6 x 16, Replace screw 3 Nm
Thread-locking compound (micro-encapsulated)
Front-wheel cover to telescopic fork
M6 x 16, Replace screw 3 Nm
Thread-locking compound (micro-encapsulated)
46 63 - Motorcycle fairing, windscreen
Engine guard to bracket
M6 x 25 8 Nm
Windscreen to windscreen holder
M5 x 20 4 Nm
Windscreen holder to front panel carrier
M6 x 20 5 Nm
Windscreen adjuster to front panel carrier
M6 x 40 5 Nm
46 71 - Engine fasteners, footrests
Left footrest plate to crankcase
M8 x 45 - 10.9 28 Nm
Footrest plate with side-stand bearing support on crankcase
M10 x 50 38 Nm
51 16 - Mirrors, covers, ashtrays, stowage compartments
Adapter to clamping block
M10 x 14 - 4.8 25 Nm
Mirror (locknut) to clamping piece
M10 x 1.25 Left-hand thread, 22 Nm
61 21 - Battery with holder
Wiring harness to battery
M6 x 13.5 5 Nm
63 17 - Foglights, additional lights
Auxiliary headlight to bracket
M6 x 40 6 Nm

052021 BMW Motorrad, UX-VA-4 7/7

Engine

Repair Guide

BMW Motorrad
BMW-Motorrad - F 850 GS

11 00 050 Removing/installing engine

+ 11 00 541

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Preparatory work
Placing motorcycle on rear-wheel stand
Support rear wheel with wedges
Draining engine oil
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Remove the intake aisilencer
Removing throttle-valve assembly
Removing battery
Draining coolant
Draining coolant expansion tank
Disconnecting plug connection(s) for oxygen sensor
Removing radiator
Releasing exhaust duct
Removing complete exhaust system
Installing engine lifter
Removing the cover for wiring harness
Disengaging clutch cable
Disengaging gearshift rod
Removing left side cap
Removing front left footrest plate
Releasing pinion
Relieving chain tension
Removing chain guard
Remove pinion with drive chain
Remove the chain slide rail
Releasing right side cap with brake fluid expansion tank
Release support for seat bench
Removing bracket for fuel tank

052021 BMW Motorrad, UX-VA-4 1/7

BMW-Motorrad - F 850 GS
Removing cover for voltage regulator with spray guard
Releasing wiring harness
Releasing footbrake cylinder
Releasing right footrest plate

Core activity
(-) Remove the engine

.-NOTICE
So that the swinging arm can remain installed while removing the engine, the
swinging arm axle can/must/may not be completely removed. On the opposite
side, support must be provided with a suitable pipe.

• Pull out hose (1) and (2) from chain failure protection (3) .
• Pull out hose (2) from holder (4) .

• Measure dimension (A) of a suitable pipe (with diameter (B)) (1) and mark

I
(arrow).

!} Technical data
Dimension A 58 mm
(distance of swinging
arm at outer edge
from frame at inner
edge)
Dimension B 24 mm
(diameter of suitable
pipe/swinging arm
K81_R 11033b
axle)

• Pull out swinging arm axle (1) with footrest plate (2) from swinging arm (3)
and frame (4) up to the desired dimension (C) , sliding pipe (5) with the mark

D
from the other side until the mark is reached (arrow) .

I Technical data
Dimension C 231 mm
(distance of swinging
arm at outer edge
from footrest plate at
inner edge)

• Remove screws (1).

052021 BMW Motorrad, UX-VA-4 2/7

BMW-Motorrad - F 850 GS

• Remove screws (1).

• Slacken collar nuts (2) .
• Unscrew threaded bushes (3) slightly.

• Remove screws (1).

• Slowly lower engine (1) with the engine lifter while avoiding collisions
between engine (1) and frame (2) .
• Remove engine (1) to the side.

(-) Installing engine

• Position engine (1) under frame (2).

• Slowly raise engine (1) with engine lifter and align it in the frame (2).

052021 BMW Motorrad, UX-VA-4 3/7

BMW-Motorrad - F 850 GS

• Install bolts (1), but do not tighten.

• Install bolts (1), but d not tighten.

• Tighten screws (1).

�Tightening torques
Frame to engine
M12 x 40 - 10.9 1100 Nm
I

• Lubricate threaded bushes (3).

Lubricant
Optimoly TA I1a 21 9 062 599

052021 BMW Motorrad, UX-VA-4 4/7

BMW-Motorrad - F 850 GS
Align threaded bushes (3) and collar nuts (2) with cylinder head with a
suitable tool.
• Tighten threaded bushes (3) and collar nuts (2), install bolts (1).

,,�Tightening torques
Cylinder head, right, to frame
Threaded bush M24 x 1.25-10.9 Tightening
Lubricate thread, Lubricant (Optimoly sequence: 1 rst step,
TA) tighten repeatedly
3 Nm
Collared nut, M24 x 1.25 Tightening
sequence: 2nd step
100 Nm
M12 x 100 x 50-10.9 Tightening
sequence: 3rd step
100 Nm

• Tighten screws (1).

"'°"!Tightening torques
Frame to engine
M12 x 40-10.9 1100 Nm
I

• Install swinging arm axle (1) with footrest plate (2), pulling out pipe (3).

• Feed hose (2) in holder (4).

• Feed hoses (1) and (2) in chain failure protection (3).

Follow-up work

052021 BMW Motorrad, UX-VA-4 5/7

BMW-Motorrad - F 850 GS
Secure the right footrest plate
Securing footbrake cylinder
Securing wiring harness
Installing cover for voltage regulator with spray guard
Installing bracket for fuel tank
Secure support for seat bench
Securing right side cap with brake fluid expansion tank
Installing chain slide rail
Installing pinion with drive chain
Installing chain guard
Installing front left footrest plate
Installing left side cap
Securing selector rod
Secure the clutch cable
Checking/adjusting clutch play
Installing the cover for wiring harness
Removing engine lifter
Install the complete exhaust system
Securing exhaust duct
Installing radiator
Connecting plug connection(s) for oxygen sensor
Installing battery
Installing throttle-valve assembly
Install the intake air silencer
Installing fuel tank
Filling cooling system
Securing coolant expansion tank
Fill up the coolant expansion tank
Checking coolant level
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Performing vehicle test with BMW Motorrad diagnostic system and
resetting the adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Pouring engine oil into engine
Checking engine oil level
Remove wedges below rear wheel

052021 BMW Motorrad, UX-VA-4 6/7

BMW-Motorrad - F 850 GS
Removing motorcycle from rear-wheel stand
Adjust chain sag
Final check of work performed

052021 BMW Motorrad, UX-VA-4 7/7

BMW-Motorrad - F 850 GS

11 00 209 Oil change, engine, with filter

+ 11 00 611

ATTENTION
Engine damage due to excess oil
Engine damage
Do not operate the engine with the oil level above maximum.
Correct the oil level if necessary (draw off the oil).

NOTICE
Change the oil at operating temperature:
Make sure the temperature is as specified in the repair instructions.
Or, alternatively, check whether the oil/coolant radiator is hot (risk of burning!).

Draining engine oil

Remove oil drain plug (1) and drain the oil.
Remove sealing ring (2).

Remove the oil filler plug (1) using a long 5 mm hexagon socket and drain
the oil.

Removing oil filter

Remove oil filter (1) using oil filter wrench (No. 11 4 650) and while doing so,
note the oil exiting at the exhaust manifold.
Catching the escaping oil.

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

◄
► Installing oil filter
• Clean the sealing face (arrow) and lubricate it with engine oil.
• Install new oil filter (1), using oil filter wrench (No.11 4 650).

""""Tightening torques
Oil filter to crankcase
Lubricate sealing ring with engine oil 111 Nm
I

◄
► Pouring engine oil into engine
" Install screw plug (1) with long 5 mm hexagon socket.
I"�

�Tightening torques
Screw plug in dry sump
M10 x 1 la Nm I

• Install oil drain plug (1) with new sealing ring (2).

,,�Tightening torques
Oil drain plug in oil sump
M16x 1.5 l2s Nm I

K81_R11001b

• Remove the oil dipstick (1).

• Fill the engine with engine oil.

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

!] Technical data
Engine oil, capacity with filter approx. 3.0 I
change
without filter 2.71
change
Fluids and lubricants
Viscosity class

• Install the oil dipstick (1).

(-) Checking engine oil level

•NOTICE
When checking the engine oil level, be sure to adhere to the specified waiting
period:
Let the fan motor run one min while idling.
Engine off, one min waiting period (engine oil collects in the oil sump).
The motorcycle must never be operated with an oil level above maximum.

• Park the motorcycle upright.

• Allow the engine to idle until the fan starts up, then allow it to idle one minute
longer.
• Switch off the engine and wait for one minute to allow the oil to collect.
• Wipe the area around the oil filler neck clean.
• Remove oil dipstick (1) and clean with a clean rag.
Check
• Insert the oil dipstick into the oil filler neck until the head rests on the
crankcase, and turn it backward through one full turn to make the level
easier to read.
• Remove the oil dipstick and check the oil level.

!] Technical data
Engine oil, specified level between MIN and
MAX mark
(MAX)
, �l- - - Jl
��"1J'lx_

(MIN)

Result:
• If the oil level is below the MIN mark:
Measure:
• Top up the engine oil.

!] Technical data
Engine oil, quantity max 0.51
for topping up

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Difference
I between MIN
and MAX

Result:
• If the oil level is above the MAX mark:
Measure:
• Correct the oil level.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

11 00 550 Replacing engine (engine removed)

NOTICE
Transfer the parts to the new component; replace as necessary.

Core activity
(-) Removing holder for front silencer

Remove screws (1).

Remove the bracket (2).

(-) Installing holder for front silencer

Position bracket (2).

Install screws (1).

Tightening torques
Holder for front silencer to engine
M8 x 20 19 Nm

(-) Removing hose retaining bracket

Remove bolt (1).

Remove retaining bracket (2).

(-) Installing hose retaining bracket

Position retaining bracket (2).

Install bolt (1).

052021 BMW Motorrad, UX-VA-4 1/7

BMW-Motorrad - F 850 GS

,,�Tightening torques
Retaining bracket to crankcase
M6 x 12 la Nm I

KB1 _R 16023b

(-) Installing the retaining bracket with the horn

• Position the retaining bracket(2) with the horn(3).

• Install bolt(1).

�Tightening torques
Retaining bracket to crankcase
M8 x 16 119 Nm
I

(-) Removing the retaining bracket with the horn

• Remove bolt(1).
• Remove the retaining bracket(2) with the horn(3).

(-) Removing strut for radiator

• Remove bolt(1).
• Remove strut(2).

(-) Installing strut for radiator

052021 BMW Motorrad, UX-VA-4 2/7
BMW-Motorrad - F 850 GS

• Position strut (1) between the retaining lugs (arrow).

• Install bolt (2).

�Tightening torques
Strut for radiator to crankcase
M6x25 la Nm I

(-) Removing the spacer bush

• Remove the spacer bush (1).

(-) Installing the spacer bush

• Install spacer bush (1).

(-) Removing engine guard

• Remove screws (1).

• Remove engine guard (2).

i i

ef K81_R46075b

052021 BMW Motorrad, UX-VA-4 3/7

BMW-Motorrad - F 850 GS
(-) Removing bracket for front engine guard

• Remove screws (1).

• Remove the bracket (2).

K81_R46078b

(-) Removing bracket for rear engine guard

• Remove screws (1).

• Remove the bracket (2).

(-) Installing bracket for rear engine guard

• Position bracket (2).

• Install screws (1).

""Tightening torques
Bracket for overheating protection on oil sump
M6 x 16 la Nm I

K81_R460nb

(-) Installing bracket for front engine guard

• Position bracket (2).

• Install screws (1).

"',Tightening torques
Bracket for overheating protection on oil sump
M6 x 16 la Nm I

K81_R46078b

052021 BMW Motorrad, UX-VA-4 4/7

BMW-Motorrad - F 850 GS
(-) Installing engine guard

• Position engine guard(2).

• Install screws(1).

•�Tightening torques
Engine guard to bracket
M6x25 la Nm I
i i

K81_R46075b

(-) Removing pivot mount with side stand

• Remove bolt(1).
• Remove bearing support(2) with side stand(3).

(-) Installing pivot mount with side stand

• Position bearing support(2) with side stand(3).

• Install bolt(1).

�Tightening torques
Bearing support for side stand to crankcase
G) M10x35 138 Nm
I

(-) Removing chain drop guard

• Remove bolt(1).
• Remove chain failure protection(2).

052021 BMW Motorrad, UX-VA-4 5/7

BMW-Motorrad - F 850 GS

(-) Installing chain drop guard

• Position chain failure protection(2).

• Install bolt(1).

�Tightening torques
Chain failure protection to crankcase
M6x45 la Nm I

(-) Removing gear selector lever

• Loosen bolt(1).
• Release gearshift lever(2) from gearshift shaft(3) and remove.

(-) Installing gear selector lever

• Push gearshift lever(1) on gearshift shaft(2).

» Mark(arrow) on gearshift shaft(2) is aligned with the gap of gearshift lever
(1).
• Tighten the screw(3).

•�Tightening torques
Selector lever to selector shaft
M6x25 la Nm I

(-) Remove the direct ignition coils

052021 BMW Motorrad, UX-VA-4 6/7
BMW-Motorrad - F 850 GS

• Clean the cylinder-head cover with compressed air prior to removal.

• Remove direct ignition coils(1) using puller (No. 12 3 621).

(-) Installing direct ignition coils

• Insert direct ignition coils(1) in the spark plug shaft, connect to the spark
plug and engage.

(-) Removing line for crankcase ventilation

" Remove bolt(1).

• Remove line (2) with the O-ring(arrow).

(-) Installing line for crankcase ventilation

• Check the O-ring (arrow) for damage; replace if necessary.

• Lubricate the O-ring (arrow) with engine oil.
• Position line(2) with the O-ring(arrow).
• Install bolt(1).
,.,,.r.

"',Tightening torques
Vent hose on crankcase
M6x20 la Nm I

052021 BMW Motorrad, UX-VA-4 7/7

BMW-Motorrad - F 850 GS

11 00 609 Oil change in engine with filter (for maintenance)

ATTENTION
Engine damage due to excess oil
Engine damage
Do not operate the engine with the oil level above maximum.
Correct the oil level if necessary (draw off the oil).

Draining engine oil

Remove oil drain plug (1) and drain the oil.
Remove sealing ring (2).

Remove the oil filler plug (1) using a long 5 mm hexagon socket and drain
the oil.

Removing oil filter

Remove oil filter (1) using oil filter wrench (No. 11 4 650) and while doing so,
note the oil exiting at the exhaust manifold.
Catching the escaping oil.

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

◄
► Installing oil filter
• Clean the sealing face (arrow) and lubricate it with engine oil.
• Install new oil filter (1), using oil filter wrench (No.11 4 650).

""""Tightening torques
Oil filter to crankcase
Lubricate sealing ring with engine oil 111 Nm
I

◄
► Pouring engine oil into engine
" Install screw plug (1) with long 5 mm hexagon socket.
I"�

�Tightening torques
Screw plug in dry sump
M10 x 1 la Nm I

• Install oil drain plug (1) with new sealing ring (2).

,,�Tightening torques
Oil drain plug in oil sump
M16x 1.5 l2s Nm I

K81_R11001b

• Remove the oil dipstick (1).

• Fill the engine with engine oil.

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

!] Technical data
Engine oil, capacity with filter approx. 3.0 I
change
without filter 2.71
change
Fluids and lubricants
Viscosity class

• Install the oil dipstick (1).

(-) Checking engine oil level

• Park the motorcycle upright.

!] Technical data
Engine oil, specified level between MIN and
MAX mark
(MAX)
, �l- - - Jl
��"1J'lx_

(MIN)

Result:
• If the oil level is below the MIN mark:
Measure:
• Top up the engine oil.

!] Technical data
Engine oil, quantity max 0.51
for topping up

052021 BMW Motorrad, UX-VA-4 3/4

www.software-motor.com | Delivering your downloads anywhere, at any time
BMW-Motorrad - F 850 GS

11 00 646 Checking pressure loss with BMW diagnostic system (spark plug removed)

Preparatory work
Removing screw plug (crankshaft)
Removing screw for dowel hole
Lock the crankshaft in TDC position

Core activity
(-) Checking pressure loss

Check
Install diagnosis adapter (No. 11 7 843) with hose (No. 11 7 842) and
adapter for loss of pressure (No. 11 7 841) in spark plug thread.
Connect the MBOX and follow the instructions issued by the diagnostic
system.
Check pressure loss with the MBOX.

Technical data
Press loss Engine at max 25 %
through valves or regular
cylinder operating
temperature

Result:
Pressure loss greater than maximum permissible value.
Measure:
Pinpoint the cause of the fault.
Possible causes:
inlet valves
exhaust valves
piston and cylinder

Follow-up work
Releasing TDC locator
Installing screw in dowel hole
Installing threaded plug (crankshaft)
Connect the BMW Motorrad diagnostic system to the vehicle
Performing vehicle test with BMW Motorrad diagnostic system
Disconnecting BMW Motorrad diagnostic system from vehicle

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052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

11 11 514 Replace engine block (engine removed)

Construction status:

August 2020

NOTICE
Tooth backlash at the clutch basket must be adjusted in the following cases:
Replacing the clutch basket
Replace the crankshaft or the engine housing.
Replace the transmission or the differential cover.

NOTICE
Transfer the engine number (with leading "E") to the new part.

Preparatory work
Removing holder for front silencer
Removing hose retaining bracket
Removing the spacer bush
Securing engine to assembly stand
Removing engine guard
Removing bracket for front engine guard
Removing bracket for rear engine guard
Removing oil filter
Removing the retaining bracket with the horn
Removing starter
Removing pivot mount with side stand
Removing chain drop guard
Removing gear selector lever
Removing potentiometer for gear indicator
Removing coolant pump
Removing screw plug (crankshaft)
Removing right crankcase cover
Remove the pressure plate
Removing clutch pushrod
Removing lined plates
Removing clutch hub
Removing clutch basket
Removing release lever
Removing left crankcase cover
Removing rotor
Removing freewheel for starter motor
Removing reduction gear for starter
Remove the direct ignition coils
Removing spark plugs
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Removing cylinder head cover
Rotating camshafts for valve clearance measurement

052021 BMW Motorrad, UX-VA-4 1/22

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BMW-Motorrad - F 850 GS

11 11 514 Replace engine block (engine removed)

NOTICE
Transfer the engine number (with leading "E") to the new part.

Preparatory work
Removing holder for front silencer
Removing hose retaining bracket
Removing the spacer bush
Securing engine to assembly stand
Removing engine guard
Removing bracket for front engine guard
Removing bracket for rear engine guard
Removing oil filter
Removing the retaining bracket with the horn
Removing starter
Removing strut for radiator
Removing pivot mount with side stand
Removing chain drop guard
Removing gear selector lever
Removing potentiometer for gear indicator
Removing coolant pump
Removing screw plug (crankshaft)
Removing right crankcase cover
Remove the pressure plate
Removing clutch pushrod
Removing lined plates
Removing clutch hub
Removing clutch basket
Removing release lever
Removing left crankcase cover
Removing rotor
Removing freewheel for starter motor
Removing reduction gear for starter
Remove the direct ignition coils
Removing spark plugs

www.software-motor.com |Removing cylinder

Delivering yourhead cover
downloads anywhere, at any time
Rotating camshafts for valve clearance measurement
Checking valve clearance
052021 BMW Motorrad, UX-VA-4 1/22
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BMW-Motorrad - F 850 GS

11 12 081 Replacing sealing rings for camshaft bearing cap

+ 11 12 823

Core activity
(-) Removing camshaft bearing cap unit

Remove the bearing bracket only in the indicated camshaft position (arrows)
to prevent distortion of the camshafts.

Remove screws (1) and remove slide rail (2).

Release screws (3) taking care to proceed uniformly crosswise.
Remove screws (3) and sealing washers (4).
Remove bearing bracket (5).

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052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Remove sealing rings (1).

(-) Installing camshaft bearing cap unit

Lubricate new sealing rings (1) with engine oil and install.
If necessary, install fitting sleeves (2) and needle rollers (3)

ATTENTION
Incorrectly positioned camshaft axial guide
Component damage
Before tightening down the fasteners of the bearing cap, make sure that the
camshaft axial guide is correctly positioned.

Lubricate bearing bracket (1) on sliding surfaces with engine oil and install,
checking the axial guidance.
Install bolts (2) and new sealing washers (3), following the tightening
sequence.

Tightening sequence for camshaft bearing cap unit

Tightening sequence for fasteners of camshaft bearing cap unit, see (1) to
www.software-motor.com | (12).
Delivering your downloads anywhere, at any time

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

Tightening torques
Camshaft bearing cap to cylinder head
M7 x 38 Tightening
sequence: See
repair manual
1st tightening torque,
5 Nm
2nd tightening torque,
15 Nm

Install slide rail (2) and bolts (1).

Tightening torques
Slide rail to bearing bracket
M6 x 12 10 Nm

Follow-up work
Releasing TDC locator
Crank the engine over and check the timing
Installing screw in dowel hole
Installing threaded plug (crankshaft)
Recheck the valve clearance
Installing cylinder head cover
Installing direct ignition coils
Securing the radiator with air duct and exhaust duct
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
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Delivering your downloads
right radiator cowl anywhere, at any time
Installing left fairing side panel with badge carrier

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

11 12 116 Removing/installing cylinder head or replacing cylinder-head gasket

+ 11 12 814
Construction status:

August 2020

ATTENTION
Risk of oil contamination or mixing of oil and coolant
Component damage
Change engine oil and oil filter.
Change contaminated coolant.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Draining coolant
Removing fuel tank
Remove the intake air silencer
Remove the direct ignition coils
Removing spark plugs
Removing screw plug (crankshaft)
Removing screw for dowel hole
Removing throttle-valve assembly
Removing radiator
Removing complete exhaust system
Removing bracket for radiator
Releasing wiring harnesses
Removing cylinder head cover
Rotating camshafts for valve clearance measurement
Checking valve clearance
Set engine to TDC and block it in position
Removing timing-chain tensioner
Removing camshaft bearing cap unit
Remove the camshafts
Releasing cable on cylinder head
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Removing line clip from cylinder head

052021 BMW Motorrad, UX-VA-4 1/6

BMW-Motorrad - F 850 GS
Core activity
(-) Removing cylinder head

Remove bolt (1) with support plate (2) and seal (3) , letting the timing chain
(4) slide into the chain cavity.

Remove screws with washers (1).

Slacken collar nuts (2) .
Turn off threaded bush (3) to the limit position.

Remove screws (1).

Slacken bolts (1) to (6) gradually in the specified sequence and then remove
them.
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052021 BMW Motorrad, UX-VA-4 2/6

11 12 256 Removing/installing and sealing or replacing cylinder-head cover

+ 11 12 821

Core activity
(-) Removing cylinder head cover

Disconnect connector (1) for fuel injectors.

Remove screws (2).
Remove cylinder head cover (3) with seal (4).

Remove seals (1) and replace them.

(-) Installing cylinder head cover

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Delivering your
new seals (1). downloads anywhere, at any time

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Seal new seal (1) in the areas shown (arrows).

Sealant
3 - Bond 1209 07 58 9 062 376

Install new seal (4).

Position cylinder head cover (3), checking that the seal (4) is seated
correctly.
Install screws (2).

Tightening torques
Cylinder head cover to cylinder head
M6 x 20 10 Nm

Connect connector (1) for fuel injectors.

Follow-up work
Installing direct ignition coils
Securing the radiator with air duct and exhaust duct
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
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Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 12 641 Replacing cylinder head (cylinder head removed)

ATTENTION
Installation of a camshaft bearing cap that has already been run-in a new
cylinder head
Component damage
Install a correct, new camshaft bearing cap.

Preparatory work
Removing valve shims
Removing thermostat housing
Remove bypass distributor
Removing both air intake stubs
Removing camshaft sensor

Core activity
(-) Removing cam followers

Remove screws (1) with sealing washers (2).

Remove needle rollers (1).

Remove rocker arm shafts (2) to the left.
Remove rocker arms (3) on the exhaust side.

Remove needle rollers (1).

Remove rocker arm shafts (2) to the left.
Remove rocker arms (3) on the intake side.

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052021 BMW Motorrad, UX-VA-4 1/5

BMW-Motorrad - F 850 GS

(-) Removing valves

Secure mount (No. 11 0 853) to valve spring compressor (No. 11 0 851).

Adjust the compression fixture (No. 11 0 852) on spring cup (1).
Secure thrust cage (No. 11 0 852) to valve spring compressor (No. 11 0
851).
Position the valve spring compressor (No. 11 0 851) and press down spring
cup (1).

Use a suitable tool to remove valve shims (1).

Turn back the special tool and remove it.

Remove spring cup (1).
Remove valve spring (2).
Remove exhaust valve (3).

Repeat the procedure for all the valves.

(-) Removing valve stem seals and spring retainers

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Remove valve stem seal (1) with the puller (No. 11 1 756).

052021 BMW Motorrad, UX-VA-4 2/5

BMW-Motorrad - F 850 GS
Remove spring cup (2).
Repeat the procedure for all the valve stem seals and spring cups.

(-) Installing valve stem seals and spring retainers

Install spring cup (1) with the smooth side facing down.
Install new valve stem seal (2) with the drift (No. 11 5 602) carefully up to the
limit position.
Repeat the procedure for all the valve stem seals and spring cups.

(-) Installing valves

Lubricate the valve stem with engine oil.

Install valve (1).
Install valve spring (2) with the smaller diameter (arrow) on top.
Install spring cup (3).

Secure mount (No. 11 0 853) to valve spring compressor (No. 11 0 851).

Adjust the compression fixture (No. 11 0 852) on spring cup (1) and secure it
on the valve spring compressor (No. 11 0 851).
Position the valve spring compressor (No. 11 0 851) on spring cup (1), press
down spring cup (1).

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them from sliding time
down.

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS

Lubricant
Molykote D paste

Use a suitable tool to install valve shims (1). Also ensure that they are
attached in the groove on the valve (arrow).
Turn back the special tool and remove it.

Repeat the procedure for all the valves.

Lubricate all components with engine oil.

(-) Installing cam followers

Position rocker arms (1) on the intake side.

Install rocker arm shafts (2).
Install needle rollers (3), making sure that needle rollers (3) engage in the
recesses (arrows) of rocker arm shafts (2).

Position rocker arms (1) on the exhaust side.

Install rocker arm shafts (2).
Install the needle rollers (3), ensuring that the needle rollers (3) engage in
the recesses (arrows) of the rocker arm shafts (2).

Install screws (1) with sealing washers (2).

Tightening torques
Screw plug (rocker arm shaft) to cylinder head
M10 x 1 Aluminium, 10 Nm
Steel, 15 Nm

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Follow-up work

052021 BMW Motorrad, UX-VA-4 4/5

BMW-Motorrad - F 850 GS
Installing camshaft sensor
Installing both air intake stubs
Installing bypass distributor
Installing thermostat housing
Installing valve shim

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052021 BMW Motorrad, UX-VA-4 5/5

BMW-Motorrad - F 850 GS

11 12 651 Check tilt clearance valve for valve guide (valves removed)

Core activity
(-) Checking tilt clearance valve to valve guide

Slide O-ring (1) 4x1.5 SNR: 07 11 9 906 969 onto valve stem (2).
Adjust gap for a valve lift of 10 mm +/-1 mm.
If necessary, secure O-ring with adhesive tape between O-ring and valve
head (arrow) to prevent shifting.
Insert valve with O-ring in cylinder head.

Use measuring shoe (No. 34 2 510) as gauge tip.

Align dial gauge (No. 00 2 510) with measuring axis at height of valve head
in measuring direction X (perpendicular to the direction of travel).
Make sure that if possible, dial gauge is working/preloaded in the upper
measuring range (5-9 mm).
Set dial gauge to 0. Valve is thereby in tilt limit position (due to dial gauge
preload).

Move valve against the dial gauge in X-direction to the other limit position.
CAUTION: pressing beyond point of resistance will lead to falsified
measuring results.

Technical data
Wear limit max 0.4 mm
New condition intake 0.05...0.15 mm
New condition 0.08...0.18 mm
exhaust

Perform measurement in the same way in measuring direction Y (in direction

of travel).

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052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

11 13 000 Removing/installing or sealing oil pan

+ 11 13 531

Core activity
(-) Removing oil pan

Remove screws (1).

Insert two of the removed screws (1) in the threaded holes (arrows) until the
oil sump (2) separates from the liquid seal. Do not insert screws (1)
completely!
Remove oil sump (2) from crankcase (3).
Remove screws (1) from oil sump (2).

(-) Seal oil sump

ATTENTION
Component damage, paint damage
Damage through contaminated, hard surfaces.
Lay component on clean, white surface.

Clean sealing surfaces of oil sump and crankcase.

Cleaner
Brake cleaner 83 19 2 154 780

Apply sealing compound evenly on the sealing surface (arrow) of the oil
sump (1).
Do not apply too much sealing compound, particularly around the bore hole
(2).

Sealant
Dow Corning 07 58 0 397 777

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052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
(-) Installing oil pan

Hold oil sump (2) in position at the crankcase (3).

Install screws (1) and tighten until hand-tight.
The oil sump (2) is not tensioned.

Tighten screws in the specified tightening sequence.

Tightening torques
Oil pan to crankcase
M6 x 30 Tightening
sequence:
Tightening
sequence: see
Repair Manual
10 Nm

Follow-up work
Pouring engine oil into engine
Installing bracket for front engine guard
Installing bracket for rear engine guard
Installing engine guard
Checking engine oil level
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 14 075 Replacing engine-block cover, left

+ 11 14 858

Core activity
(-) Removing left crankcase cover

NOTICE
If applicable, cover the underride guard to catch escaping residual oil.

Remove the cable straps (arrows).

Disconnect plug (1) for crankshaft sensor.

Remove all short screws(1).

Remove long screws(2).

Install suitable M 9 bolts (e.g. cylinder head, crankcase) (1) into

corresponding threads (arrows) in the engine housing cover (2).
Screws (1) serve as a removing aid.
By uniformly inserting the bolts(1), pry the engine housing cover (2) off the
crankcase (3).

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Release engine housing cover (1) and while doing so, pay attention to the
dowel pins (arrows).
052021 BMW Motorrad, UX-VA-4 1/5
BMW-Motorrad - F 850 GS
Hang the engine housing cover (1) aside; make sure the cable (2) is
draught-free, e.g. fasten with cable strap.

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Release rubber grommet (1).

Remove screw (2) and holder (3).
Remove screws (4).
Loosen alternator (5) from engine housing cover (6) and allow it to dangle to
one side.
Remove engine housing cover (6).

(-) Replacing left crankcase cover

Removing crankshaft sensor
Remove bolt (1).
Remove crankshaft sensor (2), paying attention to the O-ring (3) while doing
so.

Remove oil dipstick (1) and clean the dipstick.

Install oil dipstick (1) in the new part (2).

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Installing crankshaft sensor
Check O-ring (3) for damage; replace if necessary.
052021 BMW Motorrad, UX-VA-4 2/5
BMW-Motorrad - F 850 GS
Hold crankshaft sensor (2) in position, paying attention to the O-ring (3)
while doing so.
Install bolt (1).

Tightening torques
Crankshaft sensor to left engine lid
M6 x 16 10 Nm

(-) Installing left crankcase cover

Check mounting orientation of reduction gear for starter
Check installation position of the components, if necessary, this is to be
adjusted.

Check
Result:
Installation position of the components is not OK.
Measure:
Install shaft (1) correctly.
Check mounting orientation of gear (2). Gearings (arrow) must engage with
each other correctly.

ATTENTION
Component damage, paint damage
Damage through contaminated, hard surfaces.
Lay component on clean, white surface.

Clean sealing surface of engine housing cover and crankcase.

Cleaner
Brake cleaner 83 19 2 154 780

Position alternator (1) in engine housing cover (2).

Install screws (3).
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Tightening torques

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS
Stator to engine lid
M6 x 40 10 Nm
Thread-locking compound (micro-
encapsulated)

Install holder (4) and screw (5).

Tightening torques
Holder to engine housing cover
M5 x 16, Replace screw 6 Nm
Thread-locking compound (micro-
encapsulated)

Apply a thin coat of sealing compound evenly on the sealing surface (arrow).

Sealant
Dow Corning 07 58 0 397 777

Secure rubber grommet (6).

Apply sealing compound (arrow) evenly on the sealing surface of the engine
housing cover (1).

Sealant
Dow Corning 07 58 0 397 777

CAUTION
Crimping danger
Strong magnetic attraction force between magnet wheel and stator of the
alternator.
When assembling the components, do not reach at or in the sealing surface
edges.
Do not jam any lines or cables.

Position the engine housing cover (1) and while doing so, pay attention to
the dowel pins (arrows).

Install all short bolts (1) but do not tighten them.

Install all long bolts(2) but do not tighten them.

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052021 BMW Motorrad, UX-VA-4 4/5

BMW-Motorrad - F 850 GS
Tighten screws (1) to (12) in the sequence given.

Tightening torques
Engine housing cover, left, to crankcase
M7 x 30 - 10.9 20 Nm
M7 x 35 - 10.9 20 Nm

Connect plug (1) for crankshaft sensor.

Close the cable strap (arrows).

Follow-up work
Installing the cover for wiring harness
Pouring engine oil into engine
Checking engine oil level
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 5/5

BMW-Motorrad - F 850 GS

11 14 085 Replacing right engine-block cover

+ 11 14 859

Remove screws (1).

Remove gaskets (2).

Install suitable M 9 screws (e.g. cylinder head, crankcase) (1) into

corresponding threads (arrows) in the engine housing cover (2).
Screws (1) serve as a removing aid.
By uniformly inserting the screws (1), pry the engine housing cover (2) off
the crankcase (3) and remove.

(-) Seal right engine housing cover

ATTENTION
Component damage, paint damage
Damage through contaminated, hard surfaces.
Lay component on clean, white surface.

Clean sealing surface of engine housing cover and crankcase.

Cleaner
Brake cleaner 83 19 2 154 780

Apply sealing compound evenly on the sealing surface (arrow) of the engine
housing cover (1).

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Sealant
Dow Corning 07 58 0 397 777

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

(-) Installing right crankcase cover

Position engine housing cover (1).

Install new seals (2).
Install screws (3) and tighten until hand-tight.
Engine housing cover (1) is not tensioned.

Tighten screws in the specified tightening sequence.

Tightening torques
Engine housing cover, right, to crankcase
M7 x 35 - 10.9 20 Nm

Follow-up work
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 15 001 Replacing breather tube for crankcase

+ 11 15 552

Core activity
(-) Removing breather tube for crankcase

Press the locks (arrows) and pull off hose (1) for crankcase ventilation.

Remove bolt (1).

Remove line (2) with O-ring (3).

(-) Installing breather tube for crankcase

Lubricate the O-ring (3) with engine oil.

Position the line (2) with the O-ring (3).
Install bolt (1).

Tightening torques
Vent hose on crankcase
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8 Nm at any time

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Connect hose (1) for crankcase ventilation.

The locks (arrows) snap into position audibly.

Follow-up work
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 21 511 Renewing crankshaft (engine removed)

Preparatory work
Removing holder for front silencer
Removing the spacer bush
Securing engine to assembly stand
Removing engine guard
Removing bracket for front engine guard
Removing bracket for rear engine guard
Removing oil filter
Removing chain drop guard
Removing screw plug (crankshaft)
Removing right crankcase cover
Remove the pressure plate
Removing clutch pushrod
Removing lined plates
Removing clutch hub
Removing clutch basket
Removing left crankcase cover
Removing rotor
Removing freewheel for starter motor
Removing reduction gear for starter
Removing oil pan
Removing oil pump
Removing lower section of engine housing

Core activity
(-) Removing crankshaft

Remove screws (1).

Remove the connecting rod bearing cap with bearing shells (2), checking
the dowel pins (arrows).
Remove crankshaft (3).

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(-) Removing the crankshaft bearing shells

052021 BMW Motorrad, UX-VA-4 1/7
BMW-Motorrad - F 850 GS
Remove bearing shells (1) for the crankshaft out of the top half of the
crankshaft while noting the allocation of the components.

Remove bearing shells (1) for the crankshaft out of the bottom half of the
crankshaft while noting the allocation of the components.

(-) Installing crankshaft bearing shells

ATTENTION
Poor oil supply
Component damage
The bearing shells are different, ensure correct installation:
Install the bearing shells with groove in direction of piston.
Install the smooth bearing shells in direction of oil sump.

When installing the bearing shells (1), pay attention to the assignment and
correct fit of the lugs (arrow).

Select bearing shells with groove for crankshaft based on the marks on the
crankshaft/crankcase.
Bearing shell mark on crankcase: centre column in matrix.
L: Left C: Centre R: Right (in direction of travel, engine installed)
Bearing shell mark on crankshaft: laser mark on side on crank web -
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to be read from the left (in direction of travel, engine installed).

052021 BMW Motorrad, UX-VA-4 2/7

BMW-Motorrad - F 850 GS
Select the correct bearing shell colour based on the marks in the table.
Different bearing shell colours may be required at a single bearing position.

Technical data
Marks on crankcase Table on upper
Classification of crankshaft section of
bearing shells (main crankcase
bearing) (magnetic wheel
side)

Mark on the crankcase for centre Colour of crankshaft

the identification of the column bearing shells (main
bearing shells (arrow). L: bearing): 1
Left C: (yellow)/2 (green)
Centre R:
Right (in
direction of
travel,
engine
installed)

Assignment of the Left labelling Main bearing shell

crankshaft main bearing 1/2 on crank on the magnetic
shell web wheel side
Centre Main bearing shells
labelling 1/2 of centre mount
on crank
web
Right Main bearing shells
labelling 1/2 on the timing chain
on crank side (Arrow)
web
ID marks of crankshaft Colour Bearing shell, class
baring coding on 1
outer side
yellow
Colour mark Bearing shell, class
on outside 2
green

Mark for classification of Labelling on Crankshaft main

the crankshaft bearings crank web bearing
for identifying the bearing on magnetic
shells wheel side
1/2
Labelling on Connecting rod
crank web bearing
on magnetic
wheel side
A/B

Colour codes of crankshaft Crankcase 1 Bearing shells

bearing shells (yellow) / yellow
Crankshaft
1 (yellow)
Crankcase 1 Bearing shell at top
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(yellow) / anywhere, at any
yellow, bearing shell time
Crankshaft at bottom green
2 (green)

052021 BMW Motorrad, UX-VA-4 3/7

BMW-Motorrad - F 850 GS
Crankcase 2 Bearing shell at top
(green) / yellow, bearing shell
Crankshaft at bottom green
1 (yellow)
Crankcase 2 Bearing shells,
(green) / green
Crankshaft
2 (green)

Lubricate smooth bearing shells (1) for crankshaft with engine oil and install
in bottom crankcase half.
(in driving position, engine installed)

Lubricate bearing shells with oil groove (1) for crankshaft with engine oil
and install in top crankcase half.

(-) Removing conrod bearing shells

ATTENTION
Installation of parts that have not worn in together
Scoring of the bearing because running in is repeated
Do not mix up components.
Mark installed positions.

Remove connecting rod bearing shell (1) from connecting rod (2) and check
for damage, replace them if necessary.

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Delivering yourrod
connecting downloads
bearing shellanywhere, at any
(1) from connecting time cap
rod bearing
(2) and check for damage, replace them if necessary.

052021 BMW Motorrad, UX-VA-4 4/7

BMW-Motorrad - F 850 GS

(-) Install the conrod bearing shells

Lubricate connecting rod bearing shell (1) with engine oil and install in
connecting rod bearing cap (2), checking lug (arrow).

Technical data
Overview of conrod marks A Weight class
B Hole diameter

Conrod bearing, bore Identification A/red or B/blue

diameter on
connecting
rod bearing
cap

Mark for classification of Labelling on Crankshaft main

the crankshaft bearings crank web bearing
for identifying the bearing on magnetic
shells wheel side
1/2
Labelling on Connecting rod
crank web bearing
on magnetic
wheel side
A/B

Assignment of the Left labelling Main bearing shell

crankshaft main bearing 1/2 on crank on the magnetic
shell web wheel side
Centre Main bearing shells
labelling 1/2 of centre mount
on crank
web
Right Main bearing shells
labelling 1/2 on the timing chain
on crank side (Arrow)
web
Colour codes, conrod
Connecting Bearing shell red
bearings rod bore A
Assignment, (red) /
crankshaft A
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Delivering cap
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(red)
anywhere, at any time
Bearing shell violet

052021 BMW Motorrad, UX-VA-4 5/7

BMW-Motorrad - F 850 GS
Connecting
rod bore A
(red) /
crankshaft B
(blue)
Connecting Bearing shell blue
rod bore B
(blue) /
crankshaft B
(blue)
Connecting Bearing shell violet
rod bore B
(blue) /
crankshaft A
(red)

Lubricate connecting rod bearing shell (1) with engine oil and install in
connecting rod (2), checking lug (arrow).

(-) Installing crankshaft

Lubricate all bearing seats with engine oil.

Install crankshaft (3).
Install the connecting rod bearing cap with bearing shells (2), according to
the mark made during removal, checking the dowel pins (arrows).
Lubricate new bolts (1) with engine oil and install.

Tightening torques
Connecting rod bolt
M9 x 1 x 47, Renew screws 1st tightening torque,
Thread oiled 5 Nm
2nd tightening torque,
20 Nm
Additional angle of
rotation, 100+5°
Slacken bolts
1st tightening torque,
5 Nm
2nd tightening torque,
20 Nm
Additional angle of
rotation, 100+5°

Follow-up work
Installing the lower section of the engine housing
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oil pump
Installing oil pan

052021 BMW Motorrad, UX-VA-4 6/7

BMW-Motorrad - F 850 GS
Installing reduction gear for starter
Installing freewheel for starter motor
Installing rotor
Installing left crankcase cover
Adjusting tooth backlash of clutch basket
Installing clutch cage
Installing clutch hub
Installing lined plates
Installing clutch pushrod
Installing pressure plate
Installing right crankcase cover
Installing threaded plug (crankshaft)
Installing shaft sealing ring of output shaft
Installing chain drop guard
Installing oil filter
Installing bracket for rear engine guard
Installing bracket for front engine guard
Installing engine guard
Removing engine from assembly stand
Installing the spacer bush
Installing holder for front silencer

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052021 BMW Motorrad, UX-VA-4 7/7

BMW-Motorrad - F 850 GS

11 24 549 Replacing all conrod bearings (engine removed)

NOTICE
If connecting rods are renewed, check the weight class (Electronic Parts
Catalogue)
Install connecting rods only of the same weight class.

Core activity
(-) Removing conrod bearings

Remove screws (1).

Remove the connecting rod bearing cap with bearing shells (2) from
crankshaft (3), while checking the dowel pins (arrows).

Remove connecting rod bearing shell (1) from connecting rod bearing cap
(2) and check for damage, replace them if necessary.

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Twist the crankshaft slightly.

052021 BMW Motorrad, UX-VA-4 1/4
BMW-Motorrad - F 850 GS
Remove connecting rod bearing shell (1) from connecting rod (2).

(-) Installing conrod bearings

Select connecting rod bearing shells using the marks on crankshaft and
connecting rod.

Technical data
Conrod bearing, bore Identification A/red or B/blue
diameter on
connecting
rod bearing
cap

Mark for classification of Labelling on Crankshaft main

the crankshaft bearings crank web bearing
for identifying the bearing on magnetic
shells wheel side
1/2
Labelling on Connecting rod
crank web bearing
on magnetic
wheel side
A/B

Mark for classification of Left Bearing shell on the

the conrod bearings labelling A/B magnet wheel
on the crank side: Class A/B
web
Right Bearing shell on the
labelling A/B timing chain side:
on the crank Class A/B
web

Colour codes, conrod Connecting Bearing shell red

bearings rod bore A
Assignment, (red) /
conrod/conrod cap crankshaft A
(red)
Connecting Bearing shell violet
rod bore A
(red) /
crankshaft B
(blue)
Connecting Bearing shell blue
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rod bore Banywhere, at any time
(blue) /
crankshaft B
(blue)
052021 BMW Motorrad, UX-VA-4 2/4
BMW-Motorrad - F 850 GS
Connecting Bearing shell violet
rod bore B
(blue) /
crankshaft A
(red)

Lubricate connecting rod bearing shell (1) with engine oil and install in
connecting rod bearing cap (2), checking lug (arrow).

Lubricate connecting rod bearing shell (1) with engine oil and install in
connecting rod (2), checking lug (arrow).

Lubricate all bearing seats with engine oil.

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Installing engine housing lower section

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Installing oil pump
Installing oil pan
Installing left crankcase cover
Installing right crankcase cover
Installing threaded plug (crankshaft)
Installing shaft sealing ring of output shaft
Installing chain drop guard
Installing oil filter
Installing bracket for rear engine guard
Installing bracket for front engine guard
Installing engine guard
Removing engine from assembly stand
Installing the spacer bush
Installing holder for front silencer

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052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

11 25 510 Replacing all pistons (engine removed)

Preparatory work
Removing holder for front silencer
Removing the spacer bush
Securing engine to assembly stand
Removing engine guard
Removing bracket for front engine guard
Removing bracket for rear engine guard
Removing oil filter
Removing chain drop guard
Removing screw plug (crankshaft)
Removing right crankcase cover
Removing left crankcase cover
Remove the direct ignition coils
Removing spark plugs
Removing cylinder head cover
Rotating camshafts for valve clearance measurement
Checking valve clearance
Set engine to TDC and block it in position
Removing timing-chain tensioner
Removing camshaft bearing cap unit
Remove the camshafts
Removing cylinder head
Removing oil pan
Removing oil pump
Removing lower section of engine housing

Core activity
(-) Remove connecting rod with piston

Remove screws (1).

Remove the connecting rod bearing cap with bearing shells (2) from
crankshaft (3), while checking the dowel pins (arrows).

Note down piston-to-cylinder correlation for each connecting rod.

Remove the piston with connecting rod (1) upwards.
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052021 BMW Motorrad, UX-VA-4 1/5

BMW-Motorrad - F 850 GS

(-) Removing piston (conrod removed)

Clamp connecting rod (1) in a vice with vice jaw protectors.

Remove left or right circlip (2).
Remove gudgeon pin (3).
Remove piston (4).
Check
Check gudgeon pin (3) for wear (scoring, damage).

Result:
Piston pins show scoring or other signs of damage.
Measure:
Renew gudgeon pin (3).

(-) Installing piston (conrod removed)

Lubricate the piston pin with engine oil.

Insert connecting rod (1) and gudgeon pin (2) in piston (4), follow the
sequence.
ATTENTION
Loose circlips or gudgeon pin
Damage to cylinder barrel
Make sure that the circlips are correctly seated on the gudgeon pin.

Install new circlips (2).

Seat the tab of the circlip in the recess and work round the circumference,
pressing the circlip into the groove; the circlip must engage with an audible
click.

(-) Installing the connecting rod with the piston

Place lower section of engine housing (1) on upper section of engine

housing (2) and provisionally secure while taking care of dowel pins
(arrows).
Turn the engine to its normal position.
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052021 BMW Motorrad, UX-VA-4 2/5

BMW-Motorrad - F 850 GS

Lubricate surfaces with engine oil.

Offsetting piston-ring gaps

Make sure that the gaps of the piston rings are not in line with the piston's
axis of tilt.
Twist both gaps of oil scraper ring (3) approximately 30° in relation to each
other (magnified area).
Position the piston ring gap of other piston rings (2) and (1) offset 120° in
relation to the upper gap of the oil scraper ring.

Insert piston with connecting rod (1) in cylinder bore (2), making sure that
the mark (arrow) points to the exhaust.

Place the piston ring compressor (No. 11 5 731) around piston (1) such that
all the piston rings are enclosed evenly.
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compressor (No. atslide
11 5 731) and anypiston
time(1)
carefully in the cylinder, pressing it again with a hammer shaft if necessary
and making sure that the connecting rod does not make contact.

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS

Turn engine.
Remove lower section of engine housing.
Lubricate all bearing seats with engine oil.
P)lace connecting rod bearing cap with bearing shells (2) according to the
marks made while removing on crankshaft (3) while taking care of dowel
pins (arrows).
Lubricate new screws (1) with engine oil and install.

Follow-up work
Installing the lower section of the engine housing
Installing oil pump
Installing oil pan
Installing cylinder head
Installing camshafts
Installing camshaft bearing cap unit
Installing timing chain tensioner
Checking timing
Releasing TDC locator
Crank the engine over and check the timing
Recheck the valve clearance
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cylinder head cover
Installing spark plugs

052021 BMW Motorrad, UX-VA-4 4/5

BMW-Motorrad - F 850 GS
Installing direct ignition coils
Installing left crankcase cover
Installing shaft sealing ring of output shaft
Installing right crankcase cover
Installing threaded plug (crankshaft)
Installing chain drop guard
Installing oil filter
Installing bracket for rear engine guard
Installing bracket for front engine guard
Installing engine guard
Removing engine from assembly stand
Installing the spacer bush
Installing holder for front silencer

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052021 BMW Motorrad, UX-VA-4 5/5

BMW-Motorrad - F 850 GS

11 26 001 Replace reduction gear for starter motor

+ 11 26 608

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Drain engine oil from the oil sump
Removing screw plug (crankshaft)
Removing the cover for wiring harness
Releasing the left crankcase cover
Removing rotor
Removing freewheel for starter motor

Core activity
(-) Removing reduction gear for starter

Remove shaft (1).

Remove gear (2).

(-) Installing reduction gear for starter

Position gear (2).

Install shaft (1).

(-) Removing freewheel for starter motor

Remove bolt (1).

Remove sliding carriage (2) .
Remove Woodruff key (3) .
Remove gear (4).

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052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

(-) Installing freewheel for starter motor

Clean the threads.

Position gear (4).
Install Woodruff key (3).
Position sliding carriage (2).
Install bolt (1).

Tightening torques
Sliding carriage to crankcase
M6 x 20, Replace screw 10 Nm
Thread-locking compound (micro-
encapsulated)

Follow-up work
Installing freewheel for starter motor
Installing rotor
Securing left crankcase cover
Installing the cover for wiring harness
Installing threaded plug (crankshaft)
Pouring engine oil into engine
Checking engine oil level
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 26 002 Replacing freewheel for starter motor

+ 11 26 609

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Drain engine oil from the oil sump
Removing screw plug (crankshaft)
Removing the cover for wiring harness
Releasing the left crankcase cover
Removing rotor

Core activity
(-) Removing freewheel for starter motor

Remove bolt (1).

Remove sliding carriage (2) .
Remove Woodruff key (3) .
Remove gear (4).

(-) Removing freewheel (clamping element)

Remove screws (1).

Remove free-wheel housing (2) and freewheel (3).

(-) Installing freewheel (clamping element)

NOTICE
Always replace the freewheel together with the freewheel housing as a
complete unit.

Prior to assembly, lightly lubricate the freewheel with engine oil.

Threaded holes must be free of oil!
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Delivering your(1)
the freewheel downloads anywhere,
in the free-wheel housing (3).at any time
The collar (arrow) points to the magnet wheel (2).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Offset on freewheel housing (3) faces out.
Clean thread.
Install new screws (4).

Tightening torques
Freewheel to alternator
M8 x 16 - 12.9, Renew screw 35 Nm
Thread-locking compound (micro-
encapsulated)

Always install microencapsulated screws!

(-) Installing freewheel for starter motor

Clean the threads.

Position gear (4).
Install Woodruff key (3).
Position sliding carriage (2).
Install bolt (1).

Tightening torques
Sliding carriage to crankcase
M6 x 20, Replace screw 10 Nm
Thread-locking compound (micro-
encapsulated)

Follow-up work
Installing rotor
Securing left crankcase cover
Installing the cover for wiring harness
Installing threaded plug (crankshaft)
Pouring engine oil into engine
Checking engine oil level
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 31 051 Removing/installing or replacing timing chain

+ 11 31 777

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Remove the intake air silencer
Remove the direct ignition coils
Releasing the radiator with air duct and exhaust duct
Removing cylinder head cover
Removing screw plug (crankshaft)
Removing screw for dowel hole
Rotating camshafts for valve clearance measurement
Checking valve clearance
Set engine to TDC and block it in position
Removing timing-chain tensioner
Removing camshaft bearing cap unit
Remove the camshafts
Draining coolant
Releasing coolant hose from coolant pump
Removing coolant pump

Core activity
(-) Removing camshaft sprockets

Counter-hold camshaft (1) on the double flat (arrow).

Remove screws (2) and camshaft sprocket (3).
Remove camshaft sprocket (4) in the same way.

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052021 BMW Motorrad, UX-VA-4 1/6

11 31 080 Removing/installing or replacing timing-chain tensioner

+ 11 31 780

Remove screw plug (1) with O-ring (2).

Remove the timing-chain tensioner (3) with O-ring (4).

(-) Installing timing chain tensioner

Check O-rings (2) and (4) for damage; replace if necessary.

Install timing-chain tensioner (3) and O-ring (4).
Install screw plug (1) with O-ring (2).

Tightening torques
Timing-chain tensioner to cylinder head
M24 x 1.5 15 Nm

Follow-up work
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

11 31 101 Replacing timing chain tensioning rail

+ 11 31 783

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Remove the intake air silencer
Remove the direct ignition coils
Releasing the radiator with air duct and exhaust duct
Removing cylinder head cover
Removing screw plug (crankshaft)
Removing screw for dowel hole
Rotating camshafts for valve clearance measurement
Checking valve clearance
Set engine to TDC and block it in position
Removing timing-chain tensioner
Removing camshaft bearing cap unit
Remove the camshafts
Draining coolant
Releasing coolant hose from coolant pump
Removing coolant pump

Core activity
(-) Removing timing-chain tensioning rail

Remove axle (1).

Remove timing chain tensioning rail (2).

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052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
(-) Installing timing-chain tensioner rail

Position the timing chain tensioning rail (2).

Install axle (1).

Follow-up work
Installing coolant pump
Securing coolant hose to coolant pump
Installing camshafts
Installing camshaft bearing cap unit
Adjusting timing to camshaft sprockets
Installing timing chain tensioner
Crank the engine over and check the timing
Recheck the valve clearance
Installing screw in dowel hole
Installing threaded plug (crankshaft)
Installing cylinder head cover
Installing direct ignition coils
Securing the radiator with air duct and exhaust duct
Install the intake air silencer
Installing fuel tank
Filling cooling system
Checking coolant level
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 31 112 Replacing timing chain slide rails

+ 11 31 784

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Remove the intake air silencer
Remove the direct ignition coils
Releasing the radiator with air duct and exhaust duct
Removing cylinder head cover
Removing screw plug (crankshaft)
Removing screw for dowel hole
Rotating camshafts for valve clearance measurement
Checking valve clearance
Set engine to TDC and block it in position
Removing timing-chain tensioner
Removing camshaft bearing cap unit
Remove the camshafts
Draining coolant
Releasing coolant hose from coolant pump
Removing coolant pump

Core activity
(-) Removing timing chain slide rail

Remove axle (1).

Remove timing chain guide rail (2).

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052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
(-) Installing timing-chain slide rail

Position timing chain guide rail (2).

Install axles (1).

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 31 539 Replacing all camshafts (cylinder-head cover removed)

Preparatory work
Removing screw plug (crankshaft)
Set engine to TDC and block it in position
Removing timing-chain tensioner

Core activity
(-) Removing camshaft bearing cap unit

Remove the bearing bracket only in the indicated camshaft position (arrows)
to prevent distortion of the camshafts.

Remove screws (1) and remove slide rail (2).

Release screws (3) taking care to proceed uniformly crosswise.
Remove screws (3) and sealing washers (4).
Remove bearing bracket (5).

Remove sealing rings (1).

(-) Remove the camshafts

Feed out exhaust camshaft (1) from timing chain (2) and remove.
Remove inlet camshaft (3) in the same way.

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052021 BMW Motorrad, UX-VA-4 1/6

BMW-Motorrad - F 850 GS

(-) Removing camshaft sprockets

Counter-hold camshaft (1) on the double flat (arrow).

Remove screws (2) and camshaft sprocket (3).
Remove camshaft sprocket (4) in the same way.

(-) Installing camshaft sprockets

Position camshaft sprocket (1) on camshaft (2) (the bore holes are offset,
the camshaft sprocket only fits in one position).
Install screws (3) until hand-tight, do not tighten them.
Install second camshaft sprocket (4) in the same way, do not tighten it.

(-) Installing camshafts

Requirement
Engine is secured in TDC setting with alignment pin

Lubricate the bearing seats with engine oil.

Tighten the timing chain (1) on the inlet side and insert inlet camshaft (2) in
timing chain (1), while noting the marks (arrows).
The marks are parallel to the sealing surface.
Tighten the timing chain (1) on the inlet side and install and align the
exhaust camshaft (3) in the same way.
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marks are in line with each other and parallel to the sealing surface.

052021 BMW Motorrad, UX-VA-4 2/6

BMW-Motorrad - F 850 GS

Make sure that the cam positions/sensor gear position (arrows) are correct.
Cam positions are set according to the image, left cylinder on the overlap.

(-) Installing camshaft bearing cap unit

Check sealing rings (1), change if necessary.

Lubricate sealing rings (1) with engine oil and install.
If necessary, install fitting sleeves (2) and needle rollers (3)

ATTENTION
Incorrectly positioned camshaft axial guide
Component damage
Before tightening down the fasteners of the bearing cap, make sure that the
camshaft axial guide is correctly positioned.

Lubricate bearing bracket (1) on sliding surfaces with engine oil and install,
checking the axial guidance.
Install bolts (2) and new sealing washers (3), following the tightening
sequence.

Tightening sequence for camshaft bearing cap unit

Tightening sequence for fasteners of camshaft bearing cap unit, see (1) to
www.software-motor.com | (12).
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052021 BMW Motorrad, UX-VA-4 3/6

BMW-Motorrad - F 850 GS

Tightening torques
Camshaft bearing cap to cylinder head
M7 x 38 Tightening
sequence: See
repair manual
1st tightening torque,
5 Nm
2nd tightening torque,
15 Nm

Install slide rail (2) and bolts (1).

Tightening torques
Slide rail to bearing bracket
M6 x 12 10 Nm

(-) Adjusting timing to camshaft sprockets

Requirement
The crankshaft is retained in the top dead centre, the camshaft sprockets
are loosened slightly.

NOTICE
Use of the holding fixture
Side A (0°) for checking the timing
Side B (1.6° and 1.7°) for screw connection of the chain sprockets (e.g. when
installing new parts)

Turn back adjusting screw (1).

Install timing-chain tensioner (No. 11 0 773) and tighten until hand-tight.
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sure thatyour downloads
adjusting anywhere,
screw (1) does at any
not press against time
timing chain rail
(2).
Tighten adjusting screw (1).
052021 BMW Motorrad, UX-VA-4 4/6
BMW-Motorrad - F 850 GS

Tightening torques
Adjusting screw in timing chain tensioner
Special tool for adjusting timing 1.2 Nm

Check
Insert socket wrench (No. 11 0 774) with the mark (arrow) up.
Twist intake camshaft (1) and exhaust camshaft (2) using the socket wrench
(No. 11 0 774) and, at the same time, try to push the holding fixture (No. 11
0 772) with side B (1.6 ° and 1.7 °).
NOTICE
If the camshafts can only be turned with difficulty, loosen the chain sprocket
screws on the camshaft, if required.

Result:

Locking device can be pushed on for adjustment.

Measure:
Remove socket wrench (No. 11 0 774).

Tighten screws of camshaft sprockets (1) until hand-tight.

Tighten accessible screws (1) with the tightening torque.

Tightening torques
Sprocket to camshaft
M7 x 12 - 10.9 19 Nm

Remove the holding fixture (No. 11 0 772).

Releasing TDC locator
Remove locating pin (No. 11 3 510).

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052021 BMW Motorrad, UX-VA-4 5/6

BMW-Motorrad - F 850 GS

Turn the crankshaft.

Tighten the screws of camshaft sprockets (1) that have not been tightened
yet, counter-hold the double flat if necessary.

Tightening torques
Sprocket to camshaft
M7 x 12 - 10.9 19 Nm

Turn back adjusting screw (1).

Remove timing-chain tensioner (No. 11 0 773).

Follow-up work
Installing timing chain tensioner
Crank the engine over and check the timing
Checking valve clearance
Installing threaded plug (crankshaft)

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052021 BMW Motorrad, UX-VA-4 6/6

BMW-Motorrad - F 850 GS

11 33 295 Removing/installing or replacing all cam followers

+ 11 33 694

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Remove the intake air silencer
Releasing the radiator with air duct and exhaust duct
Remove the direct ignition coils
Removing cylinder head cover
Rotating camshafts for valve clearance measurement
Checking valve clearance
Removing screw plug (crankshaft)
Removing screw for dowel hole
Set engine to TDC and block it in position
Removing timing-chain tensioner
Removing camshaft bearing cap unit
Remove the camshafts

Core activity
(-) Removing all cam followers

Remove screws (1) with sealing washers (2).

Removing rocker arms on exhaust side

Remove needle rollers (1).

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052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Move rocker arm shaft (1) to the left.

Remove rocker arms (2).
Move rocker arm shaft (3) to the left.
Remove rocker arms (4) and (5).

Move rocker arm shaft (1) to the right.

Move rocker arm shaft (2) to the right.
Remove rocker arms (3).

Removing rocker arms on the inlet side

Remove needle rollers (1).
Remove rocker arm shafts (2) to the left.
Remove rocker arms (3).

(-) Installing all cam followers

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Installing rocker arms on the inlet side

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Position rocker arms (1).
Position rocker arm shafts (2).
Install needle rollers (3), making sure that needle rollers (3) engage in the
recesses (arrows) of rocker arm shafts (2).

Installing rocker arms on exhaust side

Position rocker arms (1).
Move rocker arm shaft (2) to the left.
Move rocker arm shaft (3) to the left.

Position rocker arms (1) and (2).

Move rocker arm shaft (3) to the left.
Position rocker arms (4).
Move rocker arm shaft (5) to the left.

Install needle rollers (1), making sure that needle rollers (1) engage in the
recesses (arrows) of rocker arm shafts (2).

Install screws (1) with sealing washers (2).

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Tightening torques

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Screw plug (rocker arm shaft) to cylinder head
M10 x 1 Aluminium, 10 Nm
Steel, 15 Nm

Follow-up work
Installing camshafts
Installing camshaft bearing cap unit
Installing timing chain tensioner
Checking timing
Releasing TDC locator
Crank the engine over and check the timing
Installing screw in dowel hole
Installing threaded plug (crankshaft)
Recheck the valve clearance
Installing cylinder head cover
Installing direct ignition coils
Securing the radiator with air duct and exhaust duct
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

11 34 001 Checking valve clearance

+ 11 34 501

Core activity
(-) Removing cylinder head cover

Disconnect connector (1) for fuel injectors.

Remove screws (2).
Remove cylinder head cover (3) with seal (4).

Remove seals (1) and replace them.

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(-) Rotating camshafts for valve clearance measurement

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS
Turn the engine on the crankshaft so that the camshafts (1) are on the base
circle with the rocker arms (2).
Between camshafts (1) and rocker arms (2), a play (arrows) must be
noticeable.
Rocker arms are not actuated.

(-) Checking valve clearance

At each valve, measure valve clearance with feeler gauge (1) between
camshaft (2) and rocker arm (3).
Note down the measured results on a record sheet.
Check
Continue turning the engine until the right cylinder is at firing TDC; measure
vale clearance in the same way and note down the values.

Noting measured results

Note down the measured results on a record sheet.

Technical data
Inlet valve clearance Engine 0.11...0.20 mm
cold max 35 °
C
Exhaust valve Engine 0.30...0.35 mm
clearance cold max 35 °
C

Result:
Valve clearance is out of tolerance.
Measure:

www.software-motor.com |=>Delivering
11 34 504, Adjusting valve clearanceanywhere,
your downloads (cylinder-headat
cover
anyremoved)
time (Billed
as a separate item)

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
(-) Installing cylinder head cover

Install new seals (1).

Seal new seal (1) in the areas shown (arrows).

Sealant
3 - Bond 1209 07 58 9 062 376

Install new seal (4).

Position cylinder head cover (3), checking that the seal (4) is seated
correctly.
Install screws (2).

Tightening torques
Cylinder head cover to cylinder head
M6 x 20 10 Nm

Connect connector (1) for fuel injectors.

Follow-up work
Installing threaded plug (crankshaft)
Installing direct ignition coils
Securing the radiator with air duct and exhaust duct
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
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Installing front spray guard
Installing seat
052021 BMW Motorrad, UX-VA-4 3/4
BMW-Motorrad - F 850 GS
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

11 34 502 Checking valve clearance (for maintenance)

Preparatory work
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Remove the intake air silencer
Remove the direct ignition coils
Releasing the radiator with air duct and exhaust duct
Removing screw plug (crankshaft)

Core activity
(-) Removing cylinder head cover

Disconnect connector (1) for fuel injectors.

Remove screws (2).
Remove cylinder head cover (3) with seal (4).

Remove seals (1) and replace them.

(-) Rotating camshafts for valve clearance measurement

Turn the engine on the crankshaft so that the camshafts (1) are on the base
circle with the rocker arms (2).
Between camshafts (1) and rocker arms (2), a play (arrows) must be
noticeable.
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arms are not actuated.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

(-) Checking valve clearance

Noting measured results

Note down the measured results on a record sheet.

Technical data
Inlet valve clearance Engine 0.11...0.20 mm
cold max 35 °
C
Exhaust valve Engine 0.30...0.35 mm
clearance cold max 35 °
C

Result:
Valve clearance is out of tolerance.
Measure:

www.software-motor.com |=>Delivering
11 34 504, Adjusting valve clearanceanywhere,
your downloads (cylinder-headat
cover
anyremoved)
time (Billed
as a separate item)

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
(-) Installing cylinder head cover

Install new seals (1).

Seal new seal (1) in the areas shown (arrows).

Sealant
3 - Bond 1209 07 58 9 062 376

Install new seal (4).

Position cylinder head cover (3), checking that the seal (4) is seated
correctly.
Install screws (2).

Tightening torques
Cylinder head cover to cylinder head
M6 x 20 10 Nm

Connect connector (1) for fuel injectors.

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

11 34 504 Adjusting valve clearance (cylinder-head cover removed)

Preparatory work
Set engine to TDC and block it in position
Removing timing-chain tensioner
Removing camshaft bearing cap unit

Core activity
(-) Remove the camshafts

Feed out exhaust camshaft (1) from timing chain (2) and remove.
Remove inlet camshaft (3) in the same way.

(-) Adjusting valve clearance (change adjustment plate)

Swing rocker arm (1) up.

Remove adjustment plate (2) from the valve and place it in the correct
position in rack (No. 11 1 844).

Check the thickness of the adjustment plates with a caliper gauge.

Determine the thickness of the new adjustment plate in accordance with the
valve clearance measurement.
Place lightly oiled adjustment plate (2) on the valve.
Swing rocker arm (1) down.

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(-) Installing camshafts

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Requirement
Engine is secured in TDC setting with alignment pin

Lubricate the bearing seats with engine oil.

Tighten the timing chain (1) on the inlet side and insert inlet camshaft (2) in
timing chain (1), while noting the marks (arrows).
The marks are parallel to the sealing surface.
Tighten the timing chain (1) on the inlet side and install and align the
exhaust camshaft (3) in the same way.
The marks are in line with each other and parallel to the sealing surface.

Make sure that the cam positions/sensor gear position (arrows) are correct.
Cam positions are set according to the image, left cylinder on the overlap.

Follow-up work
Installing camshaft bearing cap unit
Installing timing chain tensioner
Checking timing
Releasing TDC locator
Crank the engine over and check the timing
Recheck the valve clearance

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 34 740 Replacing one valve (cylinder head removed)

Core activity
(-) Removing valve shims

Swing rocker arm (1) up.

Remove adjustment plate (2) from the valve and place it in the correct
position in rack (No. 11 1 844).

(-) Removing valve

Secure mount (No. 11 0 853) to valve spring compressor (No. 11 0 851).

Use a suitable tool to remove valve shims (1).

Turn back the special tool and remove it.

Remove spring cup (1).
Remove valve spring (2).
Remove exhaust valve (3).

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052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

(-) Remove the valve stem seal and spring retainer

Remove valve stem seal (1) with the puller (No. 11 1 756).
Remove spring cup (2).

(-) Installing valve stem seal and spring retainer

Install spring cup (1) with the smooth side facing down.
Install new valve stem seal (2) with the drift (No. 11 5 602) carefully up to the
limit position.

(-) Installing valve

Lubricate the valve stem with engine oil.

Install valve (1).
Install valve spring (2) with the smaller diameter (arrow) on top.
Install spring cup (3).

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Secure mount (No. 11 0 853) to valve spring compressor (No. 11 0 851).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Adjust the compression fixture (No. 11 0 852) on spring cup (1) and secure it
on the valve spring compressor (No. 11 0 851).
Position the valve spring compressor (No. 11 0 851) on spring cup (1), press
down spring cup (1).

Lubricate valve shims (1) lightly to keep them from sliding down.

Lubricant
Molykote D paste

Use a suitable tool to install valve shims (1). Also ensure that they are
attached in the groove on the valve (arrow).
Turn back the special tool and remove it.

Lubricate all components with engine oil.

(-) Installing valve shim

Place lightly oiled adjustment plate (2) on the valve.

Swing rocker arm (1) down.

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052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

11 41 002 Removing/installing or replacing oil suction pump

+ 11 41 814

Core activity
(-) Removing oil pump

Remove screws (1).

Remove intake snorkel (2) .
Remove O-ring (3) and change.

Remove screws (1) and (2).

Loosen and remove oil pump pinion (3) cover using light impact blows.

Remove the nut (1).

ATTENTION
Damage of oil pumps
Component damage
Do not lever off the oil pump sprocket from the shaft with a tool.
If applicable, crank the engine to slacken the chain.

Loosen oil pump pinion (2) with chain (3) from shaft (4) .
Loosen and remove oil pump pinion (2) from chain (3) .
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Remove screws (1) and (2).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS
Loosen oil pump (3) and dry sump pan (4) with light impact blows using a
rubber mallet.
Remove oil pump (3) with dry sump pan (4) .
Remove fitting sleeves (5) if necessary.
Remove O-ring (6) and change.

Disconnect oil pump (1) from intake pipe (2) .

Remove O-ring (3) and change.
Remove bolt (4) and oil separator hose (5) .

(-) Installing oil pump

Install screw plug (1).

Tightening torques
Screw plug in dry sump
M10 x 1 8 Nm

Lubricate new O-ring (2) with engine oil and install on intake pipe (3).
Connect oil pump (4) on intake pipe (3).
Install oil separator hose (6) and bolt (5).

Tightening torques
Oil separator hose to oil pump
M6 x 16 10 Nm

Clean sealing surfaces of dry sump pan and engine housing.

Apply sealing compound evenly on sealing surfaces for dry sump pan and
oil pump housing (arrows) to engine housing (1).

Sealant
Dow Corning 07 58 0 397 777

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Lubricate new O-ring (6) with engine oil and install.

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Pay attention to fitting sleeves (5).
Install oil pump (3) with dry sump pan (4).
Install bolts (2) and (1), do not tighten.
Tighten the screws (2).

Tightening torques
Dry sump oil pan to crankcase
M6 x 16 Tightening
sequence: tighten in
diagonally opposite
sequence
10 Nm

Tighten screws (1).

Tightening torques
Oil pump to engine housing
M6 x 60 10 Nm

Insert oil pump piston (1) in chain (2).

Push oil pump piston (1) with chain (2) on to shaft (3) and let it engage in
two-flats (arrows).
Install the nut (4).

Tightening torques
Oil-pump pinion to oil-pump shaft
M6 10 Nm

Clean sealing surfaces of cover for oil pump sprocket(1).

Apply sealing compound evenly on sealing surface (arrow) of cover for oil
pump piston (1).

Sealant
Dow Corning 07 58 0 397 777

Install cover for oil pump sprocket(3).

Install short screws (2) and long screws (1), but do not tighten.
Tighten the screws (2).

Tightening torques
Oil pump pinion cover to engine housing
M6 x 20 10 Nm
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Delivering
screwsyour
(1). downloads anywhere, at any time

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Tightening torques
Oil pump pinion cover to oil pump
M6 x 25 10 Nm

Lubricate new O-ring (3) with engine oil and install on intake snorkel (2).
Install intake snorkel (2).
Install screws (1).

Tightening torques
Intake snorkel to oil pump
M6 x 16 10 Nm

Follow-up work
Seal oil sump
Installing oil pan
Pouring engine oil into engine
Installing bracket for front engine guard
Installing bracket for rear engine guard
Installing engine guard
Checking engine oil level
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

11 41 004 Measuring engine oil pressure

+ 11 41 817

CAUTION
Working with hot components
Risk of burn injury
Wear protective gloves.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing threaded plug for oil system

Remove oil filler plug (1) with sealing ring (2), collect any leaking engine oil if
necessary.

(-) Measuring engine-oil pressure

Requirement
Make sure that engine and engine oil are at operating temperature.

Install the adapter (No. 11 4 607) with O-ring (1) and the adapter (No. 11 4
608) with sealing ring (2) in the engine housing.
Secure pressure gauge (No. 11 4 601) with hose (No. 11 4 602).
Check

Start the engine.

Check oil pressure across the entire engine rpm range.

Technical data
Oil pressure at idle speed min approx. 1.2 bar
Engine oil is at - at engine 4.0 bar
normal operating speed 4000 min
temperature (fan has -1
started)

Result:

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Delivering
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lower than specified. anywhere, at any time
Measure:

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Identify and rectify the cause of the fault.

Remove the tools.

(-) Installing threaded plug for oil system

Install screw plug (1) with new sealing ring (2).

Tightening torques
Screw plug in engine housing
M14 x 1.5 25 Nm

Wipe away any engine oil that has leaked.

Follow-up work
Checking engine oil level
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 51 002 Removing/installing coolant pump (without draining/refilling coolant system)

+ 11 51 563

Preparatory work
=> Draining coolant, refilling/bleeding system (Description in
item: 17 00 504, Billed as a separate item)
Releasing coolant hose from coolant pump

Core activity
(-) Removing coolant pump

ATTENTION
Timing chain disengages from immediate shaft, timing changes
Component damage
Push the intermediate shaft back to remove the water pump.
Screw bolt M6 x 100 into pump impeller and tap carefully toward engine.

Remove bolt (1) with sealing washer (2).

Remove screws (3).

Remove lid (1) and seal (2) .

Remove bolt (1) with sealing washer (2).

Install suitable M8 bolts (3) in the appropriate thread (arrows) in the coolant
pump (4) .
Screws (3) serve as a removing aid.
Push off coolant pump (4) by screwing in the bolts (3) evenly and remove
with the seal.
At the same time, push intermediate shaft back with bolt M6 x 100 (light
hammer taps).
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052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Remove sealing ring (1).

(-) Installing coolant pump

Lubricate new sealing ring (1) with engine oil.

Install the sealing ring (1).
Check if sealing ring (1) is installed correctly in groove (arrow) over the
entire radius, correct if necessary.

Install new seal (1) on new coolant pump (2).

Hold coolant pump (1) in position.

Insert two bolts (2) of the coolant pump in bore holes with fitting sleeves
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Bolts (2) serve as a removing aid.

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Install coolant pump (1) by screwing in bolts (2) evenly up to the limit
position.
Remove screws (2).
Fit bolt (3) with new sealing washer (4).

Tightening torques
Coolant pump wheel to reduction gear double wheel
M6 x 65 - 10.9, Renew sealing 15 Nm
washer

Install only bolt M6 x 65.

Hold seal (2) and lid (1) in position.

Insert screws (3) and screw (1) with new sealing washer (2).
Tighten bolts (3) and (1).

Tightening torques
Coolant pump to crankcase
M6 x 35 Tightening
sequence: tighten in
diagonally opposite
sequence
10 Nm
M6 x 35, Bolt of the dowel hole (with 10 Nm
sealing washer, next to drain plug)
Thread-locking compound (Loctite
243, Medium strength)

Follow-up work
Securing coolant hose to coolant pump
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

11 61 178 Removing/installing/sealing or replacing left and right intake stubs

+ 11 61 580

Core activity
(-) Removing both air intake stubs

Remove screw (1) and sleeve (2).

Remove clip (3).

Remove screws (1).

ATTENTION
Unnoticed cases of small part in the engine
Engine damage
Cover or close openings with suitable auxiliary materials. Remove again the
auxiliary materials with assembly.

Remove air intake stub (2).

Remove the air intake stub on the left in the same way.

(-) Installing both air intake stubs

Clean the threads.

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Delivering your
the sealing facedownloads
(arrow). anywhere, at any time
Check air intake stubs (1) for damage; replace if necessary.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Position air intake stubs (1).
Install screws (2).

Tightening torques
Air intake to cylinder head
M6 x 16, Replace screw 8 Nm
Thread-locking compound (micro-
encapsulated)

Install the air intake stub on the left in the same way.

Position clamp (3).

Install sleeve (2) and screw (1), but do not tighten the screw (1) while doing
so.

Follow-up work
Installing throttle-valve assembly
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 78 000 Replacing oxygen sensor

+ 11 78 500

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

Remove plug connection (1) for the oxygen sensor and disconnect.
Remove cable strap (arrow).
Remove oxygen sensor (2).

(-) Installing oxygen sensor(s)

Install oxygen sensor (3).

Tightening torques
Lambda probe to manifold
M12 x 1.25 25 Nm
Lubricate thread, Lubricant (Optimoly
TA)

Route cable (2) for oxygen sensor.

Connect plug connection (1) for the oxygen sensor and install.
Secure the cable strap (arrow).

Follow-up work
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
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Delivering yourperformed
downloads anywhere, at any time

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

11 78 007 Replace front oxygen sensor

+ 11 78 507
Construction status:

August 2020

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

Core activity
(-) Disconnecting plug connection for front oxygen sensor

Remove the cable strap (arrows).

Disconnect plug connection (1) for front oxygen sensor and release.

(-) Removing front oxygen sensor

Release cable (1).

Remove oxygen sensor (2).

(-) Installing front oxygen sensor

Lubricate thread on oxygen sensor (2) lightly.

Lubricant
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Optimoly TA 18 21 9 062 599

Install oxygen sensor (2).

052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS

Tightening torques
Front oxygen sensor to exhaust manifold
M14 x 1.25 45 Nm
Thinly lubricate thread, Lubricant
(Optimoly TA)

Route cable (1).

(-) Fastening plug connection for front oxygen sensor

Fasten and connect plug connection (1) for front oxygen sensor.
Close the cable strap (arrows).

Follow-up work
Installing heat protection cover for catalytic converter
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 78 008 Replace monitoring oxygen sensor

+ 11 78 508
Construction status:

August 2020

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

Core activity
(-) Disconnecting plug connection for monitoring oxygen sensor

Remove the cable strap (arrows).

Disconnect plug connection (1) for monitoring oxygen sensor and release.

(-) Remove monitoring oxygen sensor

Release cable (1) from holder (2).

Remove oxygen sensor (3).

(-) Install monitoring oxygen sensor

Insert cable (1) in holder (2).

Lubricate thread on oxygen sensor (3) lightly.

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Lubricant
Optimoly TA 18 21 9 062 599

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Install oxygen sensor (3).

Tightening torques
Monitoring oxygen sensor to exhaust manifold
M12 x 1.25 25 Nm
Thinly lubricate thread, Lubricant
(Optimoly TA)

(-) Fastening plug connection for monitoring oxygen sensor

Secure plug connection (1) for monitoring oxygen sensor and connect.
Close the cable strap (arrows).

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

11 84 005 Replacing crash bars

+ 11 84 505

Remove screws (1).

Remove engine guard (2).

(-) Installing engine guard

Position engine guard (2).

Install screws (1).

Tightening torques
Engine guard to bracket
M6 x 25 8 Nm

Follow-up work
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

12 00 014 Performing vehicle test with BMW Motorrad diagnostic system

+ 12 00 516

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat

Core activity
(-) Connect the BMW Motorrad diagnostic system to the vehicle

Connect the BMW Motorrad battery charger.

NOTICE
When carrying out diagnosis and programming, use a battery charger with 30
A approved by BMW Motorrad that ensures an on-board system voltage of
13 V.

Loosen diagnostic connector (1) from holder (2).

Connect diagnostic connector (1) with connecting cable (3) for diagnosis
system.
NOTICE
See the information about the BMW Motorrad diagnostic system for all further
instructions.

(-) Performing vehicle test with BMW Motorrad diagnostic system

Perform the vehicle test with the BMW Motorrad diagnostic system and
read out the fault memory.

NOTICE
When working with the BMW Motorrad diagnostic system, always follow the
instructions it issues.

Perform all requisite repair work or diagnostic routines, as applicable.

(-) Disconnecting BMW Motorrad diagnostic system from vehicle

Close all diagnostic programs and switch off the ignition.

Disconnect connecting cable (3) for BMW Motorrad diagnosis system from
diagnostic connector (1) on the vehicle and insert diagnostic connector (1)
into holder (2).
Disconnect the BMW Motorrad battery charger from the vehicle.

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052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Follow-up work
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

12 12 011 Renewing all spark plugs

+ 12 12 513

Core activity
(-) Removing spark plugs

Clean the spark plug shafts with compressed air.

Remove spark plugs (1) with spark plug wrench (No. 12 1 220).

(-) Replacing spark plugs

Use only spark plugs recommended by BMW Motorrad.

Technical data
Spark plugs, NGK LMAR9J-9E
manufacturer and
designation

(-) Installing spark plugs

Install spark plugs (1) with spark-plug wrench (No. 12 1 220).

Tightening torques
Spark plug to cylinder head
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M10 x 1 12 Nm

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Follow-up work
Installing direct ignition coils
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

12 12 509 Replace all spark plugs (for maintenance)

Core activity
(-) Removing spark plugs

Clean the spark plug shafts with compressed air.

Remove spark plugs (1) with spark plug wrench (No. 12 1 220).

(-) Replacing spark plugs

Use only spark plugs recommended by BMW Motorrad.

Technical data
Spark plugs, NGK LMAR9J-9E
manufacturer and
designation

(-) Installing spark plugs

Install spark plugs (1) with spark-plug wrench (No. 12 1 220).

Tightening torques
Spark plug to cylinder head
M10 x 1 12 Nm

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052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

12 13 155 Replacing direct ignition coil

+ 12 13 655

Core activity
(-) Remove the direct ignition coils
Information on disconnecting vibration-resistant plug

ATTENTION
Disconnection of the connector not in compliance with correct
procedure
Damage to locking tab
Push the connector away from the locking tab, do not lift or bend the locking
tab.

Unlock locking tab (1) in direction of arrow (arrow 1).

Press down locking tab (1) in direction of arrow (arrow 2) and disconnect
connector (2).

Clean the cylinder-head cover with compressed air prior to removal.

Unlock and disconnect connector (1) for the direct ignition coil.
Remove direct ignition coils (2) using puller (No. 12 3 621).

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052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

(-) Installing direct ignition coils

Insert direct ignition coils (1) in the spark plug shaft, connect to the spark
plug and engage.
Connect and lock connector (2) for the direct ignition coils.

Information for connecting vibration-resistant connectors

Check if the contact carrier (1) protrudes significantly from the connector
housing (2).
If necessary, hold down the connector housing (2) and slide contact carrier
from the rear at the cable inlet (3) toward the front until the contact carrier (1)
is visible

Ensure that the release tab (1) is unlocked.

Slide connector (2) in direction of arrow (arrow 1).
The connector (2) engages audibly.
Slide connector (2) in direction of arrow (arrow 2) further.
The connector (2) engages audibly.
Slide locking tab (1) in direction of arrow (arrow 3).
The locking tab (1) engages audibly.

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Installing top front-wheel cover

Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

12 31 022 Replace generator

+ 12 31 673

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Draining engine oil
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Removing battery
Release support for seat bench
Removing bracket for fuel tank
Removing cover for voltage regulator with spray guard
Removing the cover for wiring harness

Core activity
(-) Removing alternator

Disconnect connector (1) for alternator and work it up out of the rear-wheel
cover (2).

Remove the cable straps (arrows).

Release cable (1) for alternator.

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Remove the cable straps (arrows).

052021 BMW Motorrad, UX-VA-4 1/9
BMW-Motorrad - F 850 GS
Release cable (1) for alternator from cable clip (2).

Remove the cable straps (arrows).

Disconnect plug (1) for crankshaft sensor.
Feed out cable (2) for alternator.

Remove short screws (1) and long screws (2).

Install suitable M 9 screws (e.g. cylinder head, crankcase) (1) into

corresponding threads (arrows) in the engine housing cover (2).
Screws (1) serve as a removing aid.
By uniformly inserting the screws (1), pry the engine housing cover (2) off
the crankcase (3).

Release engine housing cover (1)and while doing so, pay attention to the
dowel pins (arrows).
Remove engine housing cover (1).

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052021 BMW Motorrad, UX-VA-4 2/9

BMW-Motorrad - F 850 GS

Release rubber grommet (1).

Remove screw (2) and holder (3).
Remove screws (4).
Remove alternator (5) from engine housing cover (6).

(-) Removing screw plug (crankshaft)

Remove screw plug (1) with sealing ring (2).

(-) Removing rotor

ATTENTION
Overloading of the alignment pin
Component damage, tool damage
Use alignment pin only to install the crankshaft and check the timings.
Do not use alignment pin as a locking tool.

Remove bolt (1) with washer (2), counter-holding to crankshaft (3).

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press-off bolt (No. 12 5 523) . at any time

052021 BMW Motorrad, UX-VA-4 3/9

BMW-Motorrad - F 850 GS

(-) Removing freewheel (clamping element)

Remove screws (1).

Remove free-wheel housing (2) and freewheel (3).

(-) Installing freewheel (clamping element)

NOTICE
Always replace the freewheel together with the freewheel housing as a
complete unit.

Prior to assembly, lightly lubricate the freewheel with engine oil.

Threaded holes must be free of oil!
Insert the freewheel (1) in the free-wheel housing (3).
The collar (arrow) points to the magnet wheel (2).
Offset on freewheel housing (3) faces out.
Clean thread.
Install new screws (4).

Tightening torques
Freewheel to alternator
M8 x 16 - 12.9, Renew screw 35 Nm
Thread-locking compound (micro-
encapsulated)

Always install microencapsulated screws!

(-) Installing rotor

ATTENTION
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Delivering your
loosens due downloads
to insufficient anywhere,
taper at any time
press connection
Component damage

052021 BMW Motorrad, UX-VA-4 4/9

BMW-Motorrad - F 850 GS
Clean and degrease both taper surfaces carefully.

Position rotor (1), checking the correct positioning (arrows).

Twist rotor counter-clockwise.

ATTENTION
Overloading of the alignment pin
Component damage, tool damage
Use alignment pin only to install the crankshaft and check the timings.
Do not use alignment pin as a locking tool.

Install bolt (1) with washer (2), counter-holding to crankshaft (3).

Tightening torques
Rotor to crankshaft
M14 x 1.5 x 40 - 10.9 150 Nm

(-) Installing threaded plug (crankshaft)

Install screw plug (1) with new sealing ring (2).

Tightening torques
Screw plug (crankshaft) in crankcase
M24 x 1.5 10 Nm

(-) Installing alternator

Check mounting orientation of reduction gear for starter
Check installation position of the components, if necessary, this is to be
adjusted.

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052021 BMW Motorrad, UX-VA-4 5/9

BMW-Motorrad - F 850 GS
Check
Result:
Installation position of the components is not OK.
Measure:
Install shaft (1) correctly.
Check mounting orientation of gear (2). Gearings (arrow) must engage with
each other correctly.

ATTENTION
Component damage, paint damage
Damage through contaminated, hard surfaces.
Lay component on clean, white surface.

Clean sealing surface of engine housing cover and crankcase.

Cleaner
Brake cleaner 83 19 2 154 780

Clean the threads.

Position alternator (1) in engine housing cover (2).
Install screws (3).

Tightening torques
Stator to engine lid
M6 x 40 10 Nm
Thread-locking compound (micro-
encapsulated)

Install holder (4) and screw (5).

Tightening torques
Holder to engine housing cover
M5 x 16, Replace screw 6 Nm
Thread-locking compound (micro-
encapsulated)

Apply sealing compound (arrow) evenly on the sealing surface of the engine
housing cover (2).

Sealant
Dow Corning 07 58 0 397 777

Secure rubber grommet (6).

Apply sealing compound (arrow) evenly on the sealing surface of the engine
housing cover (1).

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Dow Corning 07 58 0 397 777

052021 BMW Motorrad, UX-VA-4 6/9

BMW-Motorrad - F 850 GS

Position the engine housing cover (1) and while doing so, pay attention to
the dowel pins (arrows).

Install short screws (1) and long screws (2) but do not tighten.

Tighten screws (1) to (12) in the sequence given.

Tightening torques
Engine housing cover, left, to crankcase
M7 x 30 - 10.9 20 Nm
M7 x 35 - 10.9 20 Nm

Route cable (2) for alternator.

Connect plug (1) for crankshaft sensor.
Close the cable strap (arrows).

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052021 BMW Motorrad, UX-VA-4 7/9

BMW-Motorrad - F 850 GS

Secure cable (1) for alternator in cable holder (2).

Close the cable strap (arrows).

Route cable (1) for alternator.

Close the cable strap (arrows).

Feed connector (1) for alternator down through the rear-wheel cover (2) and
connect.

Follow-up work
Installing the cover for wiring harness
Installing cover for voltage regulator with spray guard
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for fuel tank anywhere, at any time
Secure support for seat bench

052021 BMW Motorrad, UX-VA-4 8/9

BMW-Motorrad - F 850 GS
Installing battery
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Pouring engine oil into engine
Checking engine oil level
Checking, if necessary correcting date
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 9/9

BMW-Motorrad - F 850 GS

12 32 000 Removing/installing voltage regulator

+ 12 32 500

Core activity
(-) Removing voltage regulator

Disconnect connector (1) and connector (2) from voltage regulator (3).
Remove nuts (4) and remove voltage regulator (2).

(-) Installing voltage regulator

Hold voltage regulator (2) in position and install nuts (1).

Tightening torques
Voltage regulator to bracket
M6, Replace nut 8 Nm
Thread-locking compound
(mechanical)

Connect connector (1) and connector (2) with voltage regulator (3).

Follow-up work
Installing cover for voltage regulator with spray guard
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

12 41 025 Replacing starter

+ 12 41 528

Core activity
(-) Removing starter

Disconnect plug (1) for the horn.

Remove the protective cap (2).
Remove nut (3) and disconnect positive wire (4) for starter.

Remove screws (1).

Remove starter (2) with O-ring (3).

(-) Installing starter

Check O-ring (3) for damage; replace if necessary.

Lubricate O-ring (3).

Lubricant
Molykote D paste

Hold starter (2) with O-ring (3) in position.

Install screws (1).

Tightening torques

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M6 x 75 10 Nm

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Connect positive wire (4) for starter and install nut (3).

Tightening torques
Positive wire to starter motor
M6, Replace nut 5 Nm
Thread-locking compound
(mechanical)

Install protective cap (2).

Connect plug (1) for the horn.

Follow-up work
Connect battery with vehicle
Checking, if necessary correcting date
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

12 62 010 Replacing coolant-temperature sensor

+ 12 62 510

CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.

Disconnect connector (1) for coolant temperature sensor.

Remove coolant temperature sensor (2) .
Use long socket.
Catch escaping coolant in a suitable container.

(-) Installing coolant-temperature sensor

Install coolant temperature sensor (2).

Tightening torques
Temperature sensor to thermostat housing
M12 x 1.5 15 Nm

Connect connector (1) for coolant temperature sensor.

If necessary, wipe coolant from components.

Follow-up work
Removing right radiator cowl
Checking coolant level
Installing right radiator cowl
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

12 72 001 Replacing crankshaft sensor

+ 12 72 501

Core activity
(-) Removing crankshaft sensor

Disconnect connector (1) from crankshaft sensor (2).

Remove bolt (3).
Remove crankshaft sensor (2), paying attention to the O-ring (4) while doing
so.

(-) Installing crankshaft sensor

Hold crankshaft sensor (2) in position, paying attention to the O-ring (4)
while doing so.
Install bolt (3).

Tightening torques
Crankshaft sensor to left engine lid
M6 x 16 10 Nm

Connect connector (1) with crankshaft sensor (2).

Follow-up work
Installing the cover for wiring harness
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

12 72 020 Replacing camshaft sensor

+ 12 72 520

Core activity
(-) Removing camshaft sensor

Disconnect connector (1) for camshaft sensor.

Remove bolt (2).
Remove camshaft sensor (3) with O-ring (4).

(-) Installing camshaft sensor

Lightly lubricate O-ring (4) with engine oil and install on camshaft sensor (3).
Hold camshaft sensor (3) in position, paying attention to the O-ring (4) while
doing so.
Install bolt (2).

Tightening torques
Camshaft sensor to cylinder head
M6 x 16 10 Nm

Connect connector (1) for camshaft sensor.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

12 72 030 Replace knock sensor

+ 12 72 530
Construction status:

August 2020

Disconnect the connector (1) for knock sensor .

Remove bolt (2).
Remove knock sensor (3).

(-) Installing knock sensor

Position knock sensor (3).

Install bolt (2).

Tightening torques
Knock sensor to crankcase
M8 x 30 20 Nm

Connect connector (1) for knock sensor .

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052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

13 51 001 Replacing fuel pressure sensor

+ 13 51 501

Core activity
(-) Remove the fuel-pressure sensor

Release hoses (1) from the holder (arrow) and press them down.
Disconnect connector (2) for fuel pressure sensor.
ATTENTION
Escape of fuel when pressurised fuel lines are opened
Damage to surfaces
Employ suitable means to catch escaping fuel.

Place a cloth under fuel pressure sensor (3) to catch any escaping fuel.
Remove fuel pressure sensor (3), checking O-ring (4).

(-) Installing fuel-pressure sensor

Install new O-ring (4) on fuel pressure sensor (3).

Install fuel pressure sensor (3).

Tightening torques
Fuel pressure sensor on fuel injection line
M10 x 1 11 Nm

Connect connector (2) for fuel pressure sensor.

Secure hoses (1) in the holder (arrow).
Remove the cloth.

Follow-up work
Installing fuel tank
Installing right fairing side panel with badge carrier
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Installing right radiator cowl
Installing left fairing side panel with badge carrier
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Performing vehicle test with BMW Motorrad diagnostic system and
resetting the adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

www.software-motor.com | Delivering your downloads anywhere, at any time

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

13 51 002 Measuring fuel pressure

+ 13 51 502

Core activity
(-) Measuring fuel pressure

WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.

ATTENTION
Escape of fuel when pressurised fuel lines are opened
Damage to surfaces
Employ suitable means to catch escaping fuel.

Cut suitable fuel hose (1) to length (A) and connect to tester for fuel
pressure (No. 16 1 500).

Technical data
Dimension (A) Length approx. 15 cm
of fuel hose for tester

Connect screw clamps (2) to hoses (1) and (3).

Install the coupling receptacle (part number 7 659 120) (4) and quick-
release coupling (part number 8 8558 301) (5).
Tighten screw clamps (2).

Lift the fuel tank (1) and secure.

ATTENTION
Application of force to close locked quick-action couplings
Leak due to damaged O-rings
Close the quick-action coupling of the fuel line only with the latch
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052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Connect tester (No. 16 1 500) by pressing the lock (arrow) to fuel hose (2)
and female coupling (3) of the fuel tank.
Lock the locks by hand.
Connect plug connection (4) for electric fuel pump and plug connection (5)
for fuel-level sensor.
Cover the tester on the coupling receptacle (3) with paper towels and push
into each other, wear protective gloves.
Start the engine and read the pressure from test instrument (No. 16 1 500).

Technical data
Fuel pressure of the 4.5...6.0 bar
injection system

Stop the engine and switch off the ignition.

Disconnect plug connection (3) for electric fuel pump and plug connection
(4) for the fuel-level sensor and remove tester (No. 16 1 500).
Mount the fuel tank.

Follow-up work
Securing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

13 53 000 Renewing injector pipe

+ 13 53 500

WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.

Core activity
(-) Removing injection line

Disconnect connector (1) for fuel pressure sensor.

Disconnect connectors (2) and (3) for fuel injectors.

Remove clamps (1).

Remove screws (2).
Remove injection line(3).
Check O-rings (4) and renew, if required.

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(-) Installing injection line

052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Lubricate O-rings (3) lightly.

Care products
Rubber care product 83 12 0 397 018

Connect fuel injection line (3) and install screws (2).

Install clamps (1).

Connect connectors (2) and (3) for fuel injectors.

Connect connector (1) for fuel low pressure sensor.

Follow-up work
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Performing vehicle test with BMW Motorrad diagnostic system and
resetting the adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

13 54 016 Removing/installing power reduction

+ 13 54 528

NOTICE
A change in power output consists of a change of the software version.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat

Core activity
(-) Checking possibilities for conversion/retrofit,
converting/retrofitting as applicable

Requirement
Engine is off.
Battery is fully charged and battery charger is connected.

Connect the BMW Motorrad diagnostic system to the vehicle

Connect the BMW Motorrad battery charger.

NOTICE
When carrying out diagnosis and programming, use a battery charger with 30
A approved by BMW Motorrad that ensures an on-board system voltage of
13 V.

Loosen diagnostic connector (1) from holder (2).

Connect diagnostic connector (1) with connecting cable (3) for diagnosis
system.
NOTICE
See the information about the BMW Motorrad diagnostic system for all further
instructions.

Switch off all electrical consumers.

NOTICE
Do not attempt to perform work of any other kind on the motorcycle while
programming/coding is in progress.

Perform diagnosis. Rectify faults, if found, before starting

conversion/retrofitting.
Start conversion/retrofitting

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Delivering your downloads anywhere, at any time
Check for option of conversion/retrofitting.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Result:
A conversion/retrofit is possible.
Measure:
Perform conversion with the BMW Motorrad diagnostic system.
Result:
A conversion/retrofit is not possible.
Measure:
Terminate the session.
Disconnecting BMW Motorrad diagnostic system from vehicle
Close all diagnostic programs and switch off the ignition.
Disconnect connecting cable (3) for BMW Motorrad diagnosis system from
diagnostic connector (1) on the vehicle and insert diagnostic connector (1)
into holder (2).
Disconnect the BMW Motorrad battery charger from the vehicle.

Follow-up work
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

13 54 017 Replacing complete throttle-valve assembly

+ 13 54 521

Core activity
(-) Removing throttle-valve assembly

Pull off bypass hoses (1) and (2).

Disconnect connector (3) for the throttle-valve assembly.
Disconnect connector (4) for fuel pressure sensor.
Disconnect connectors (5) and (6) for fuel injectors.

Loosen bolt (1).

Release throttle-valve assembly(2).
Disconnect hose (3) for the tank vent valve.
Remove throttle-valve assembly (2).

(-) Installing throttle-valve assembly

Hold throttle-valve assembly (2) in position.

Insert hose (3) for the tank vent valve.
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throttle-valve assembly (2). anywhere, at any time
Tighten the screw (1).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Tightening torques
Throttle-valve assembly to intake manifold
5 Nm

Connect connectors (5) and (6) for fuel injectors.

Connect connector (4) for fuel low pressure sensor.
Connect connector (3) for the throttle-valve assembly.
Push bypass hoses (1) and (2) on.

Follow-up work
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

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052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

13 61 030 Clean the contacts

+ 13 61 530

Core activity
(-) Clean contacts on removed control unit

Requirement
Control unit is removed.

Coat cleaning surface inside on cleaning contact (1) with brake cleaner.

Cleaner
Brake cleaner 83 19 2 154 780

Position cleaning contact on pin contacts vertically.

Do not bend or spread pin contacts apart.
Make sure that the opening of the cleaning contact can slide onto the pin
contact and is not open on the side.
Damage to pin contacts is prevented.

Slide cleaning contact (1) onto pin contacts to stop and pull off again.
Repeat process two more times.
Clean all pin contacts.
NOTICE
In case of visible contamination of the cleaning contact, change cleaning
contact.

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052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

13 61 510 Replacing engine management control unit (not including checking/programming

software)

NOTICE
Before removal, test the control unit with the BMW Motorrad diagnostic
system and make a backup copy of the data.

Preparatory work
Removing luggage carrier
Removing rear carrier
Removing battery
Loosening holder for control units

Core activity
(-) Removing control unit for engine management system

Disconnect connector (1) for main wiring harness and (2) for engine wiring
harness.
Remove engine control unit (3).

(-) Installing control unit for electronic engine management

system

NOTICE
Do not, under any circumstances temporarily install control units from other
vehicles by way of testing.
The possible consequences include:
Coding data could be overwritten.
The control units could malfunction.

Hold engine control unit (3) in position.

Connect connector (2) for engine wiring harness and (1) for main wiring
harness.

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work
Securing holders for control units

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Installing battery
Installing rear carrier
Installing luggage carrier
Checking, if necessary correcting date

=> Testing software (Description in item: 61 00 502, Billed as

a separate item)

=> Programming control units of vehicle (along with testing

software) (Description in item: 61 00 510, Billed as a
separate item)

www.software-motor.com | Delivering your downloads anywhere, at any time

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

13 62 010 Replacing intake-air temperature sensor

+ 13 62 501

Core activity
(-) Removing intake-air temperature sensor

Disconnect connector (1) for the intake-air temperature sensor.

Turn the intake air temperature sensor (2) downwards until the lugs (arrows)
are free and remove from intake silencer (3).

(-) Installing intake-air temperature sensor

Install the intake air temperature sensor (1) in the intake silencer (2) while
minding the lugs (arrows).
Turn the intake air temperature sensor (1) upwards until the lugs (arrows)
lock in the intake silencer (2).
Connect connector (3).

Follow-up work
Installing fuel tank
Installing right fairing side panel with badge carrier
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Installing right radiator cowl
Installing left fairing side panel with badge carrier
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

13 64 165 Renewing one injector

+ 13 64 501

WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.

Core activity
(-) Disconnecting injection line

Disconnect connector (1) for fuel pressure sensor.

Disconnect connectors (2) and (3) for fuel injectors.

Remove screws (1).

Disconnect injection line (2).

(-) Replacing injection valve

052021 BMW Motorrad, UX-VA-4 1/3
BMW-Motorrad - F 850 GS
Remove clamp (1) and injection valve (2).
Lubricate O-rings (3).

Care products
Rubber care product 83 12 0 397 018

Position injection valve (2) and install clamp (1).

(-) Securing injection line

Position injection line (2).

Install screws (1).

Connect connectors (2) and (3) for fuel injectors.

Connect connector (1) for fuel low pressure sensor.

Follow-up work
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

13 71 010 Replace intake-air silencer

+ 13 71 510

WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.

Core activity
(-) Remove the intake air silencer
Removing left intake air pipe

Remove intake snorkel (1) and while doing so, press the lock (Arrow) and
release it from holder (2).

Removing right intake air pipe

Remove intake snorkel (1) and while doing so, press the lock (Arrow) and
release it from holder (2).

052021 BMW Motorrad, UX-VA-4 1/5

BMW-Motorrad - F 850 GS

Release hose (1) and hose (2) from locators (arrows).

Remove bolt (3).

Press the locks (arrows) and pull off hose (1) for crankcase ventilation.

Open clamping collars (1) using pliers (No. 13 1 512) .

Release intake silencer (1).

Disconnect the connector (2) for the air temperature sensor.
Remove intake silencer (1).

052021 2/5
BMW-Motorrad - F 850 GS

(-) Replacing intake air silencer

Remove the air filter frame (1) and air filter (2).
Remove the intake air temperature sensor (3).
Convert the removed and reusable parts to the new part.

(-) Install the intake air silencer

Position intake silencer (1), pushing pipe (2) for bypass on to throttle-valve
assembly (3).
Connect the connector (4) for the air temperature sensor.

Close clamping collars (1) using pliers (No. 13 1 512).

Connect hose (1) for crankcase ventilation.

The locks (arrows) snap into position audibly.

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS

Install bolt (3).

Tightening torques
Intake air silencer to frame
M6 x 25 8 Nm

Secure hose (1) and hose (2) in locators (arrows).

Installing right intake air pipe

Install intake snorkel (1) and while doing so, secure in holder (2).
Make sure that the lock (arrow) engages.

Installing left intake air pipe

Install intake snorkel (1) and while doing so, secure in holder (2).
Make sure that the lock (arrow) engages.

Follow-up work
Installing fuel tank
052021 BMW Motorrad, UX-VA-4 4/5
BMW-Motorrad - F 850 GS
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Performing vehicle test with BMW Motorrad diagnostic system and
resetting the adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 5/5

BMW-Motorrad - F 850 GS

13 72 001 Renewing air cleaner insert

+ 13 72 532

Core activity
(-) Removing air filter element

Disengage the hose (1) from locators (arrows).

Clean the working area with compressed air.

Press push-button (1) and remove filter frame (2) with air filter insert (3).
Remove air filter insert (3) from filter frame (2).

(-) Installing air filter element

ATTENTION
Poor filter function, drawing in of dirt particles. Air filter insert slips
during insertion.
Component damage
Correctly insert the air filter insert in the filter frame and hook into the pins.

Insert the air filter insert (1) in the filter frame(2), while sliding the pins into
the bore holes (arrows).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Install filter frame (2) with air filter insert (3).

Make sure the air filter insert does not slip during the insertion.
Push-button (1) engages.

Secure the hose (1) in locators (arrows).

Follow-up work
Installing the fuel tank cover
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

13 72 505 Replace air filter cartridge (for maintenance)

Core activity
(-) Removing air filter element

Disengage the hose (1) from locators (arrows).

Clean the working area with compressed air.

Press push-button (1) and remove filter frame (2) with air filter insert (3).
Remove air filter insert (3) from filter frame (2).

(-) Installing air filter element

Insert the air filter insert (1) in the filter frame(2), while sliding the pins into
the bore holes (arrows).

Install filter frame (2) with air filter insert (3).

Make sure the air filter insert does not slip during the insertion.
Push-button (1) engages.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Secure the hose (1) in locators (arrows).

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

13 72 508 Checking or replacing air filter element (for maintenance)

Preparatory work
Removing the fuel tank cover

Core activity
(-) Removing air filter element

Disengage the hose (1) from locators (arrows).

Clean the working area with compressed air.

Press push-button (1) and remove filter frame (2) with air filter insert (3).
Remove air filter insert (3) from filter frame (2).

(-) Checking air filter

Check

Check the air filter for clogging and cracking.

Result:
Air filter is dirty:
Measure:
Clean the air filter element.
Result:
Cracks are visible:
Measure:
Replace the air filter element.

(-) Installing air filter element

ATTENTION
Poor filter function, drawing in of dirt particles. Air filter insert slips
during insertion.
Component damage

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Correctly insert the air filter insert in the filter frame and hook into the pins.

Insert the air filter insert (1) in the filter frame(2), while sliding the pins into
the bore holes (arrows).

Install filter frame (2) with air filter insert (3).

Make sure the air filter insert does not slip during the insertion.
Push-button (1) engages.

Secure the hose (1) in locators (arrows).

Follow-up work
Installing the fuel tank cover

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

16 11 030 Removing/installing fuel tank

+ 16 11 533

WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.

Core activity
(-) Removing fuel tank

Pull off hoses (1) and (2).

Remove screws (1).

Raise fuel tank (1) and lay it on a suitable wood block (2).
Disconnect connectors (3) and (4) for electric fuel pump (4).
ATTENTION

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Wetting of plastic surfaces by fuel
Damage to the surfaces (surfaces become unsightly or dull)
Clean plastic surfaces immediately after contact with fuel.

Open the lock (arrow) and disconnect fuel line (5).

Remove fuel tank (1), pulling it off rubber damper (2).

(-) Installing fuel tank

Check O-ring (1) for fuel line for damage, replace if necessary.

Position fuel tank (1) to rubber damper (2).

Raise fuel tank (1) and lay it on a suitable wood block (2).
Connect connectors (3) and (4) for electric fuel pump (4).
ATTENTION
Application of force to close locked quick-action couplings

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Leak due to damaged O-rings
Close the quick-action coupling of the fuel line only with the latch
open/pressed.

Open the latch (arrow) (5) and, applying light pressure, press the fuel line
into the bush. Release lock and check for tight fit.

Install screws (1).

Tightening torques
Fuel tank to holder for fuel tank
M8 x 45 19 Nm

Push hoses (1) and (2).

Follow-up work
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

16 11 213 Renewing fuel tank cover flap

+ 16 11 543

WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.

Core activity
(-) Removing lock barrel for fuel filler cap

Open fuel filler cap (1).

Cover the fuel filler neck.
ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Push the latching tab (arrow) down using a suitable tool until holes (2) are
aligned.
Secure the latching tab (arrow) using drill (3) into fuel filler cap (1).

Technical data
Drill-bit diameter 2 mm

Turn key (4) to the "Open" position and remove lock barrel (5).

(-) Removing fuel-tank cap

Pull off hoses (1) and (2).

Remove screws (3).
Remove screws (4).
Detach fairing side panel (5) and fairing side panel (6) on retaining tabs
(arrows) .

Remove fuel filler cap (1) with holder (2) and seal (3) .

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

(-) Replacing fuel filler cap

Turn extension of fuel filler neck (1) in the counterclockwise direction,

unlocking retaining lugs (arrows).
Remove extension of fuel filler neck (1) from fuel filler cap (2).

Position extension of fuel filler neck (1) on fuel filler cap (2).
Turn extension of fuel filler neck (1) in the clockwise direction, locking
retaining lugs (arrows).

(-) Installing fuel-tank cap

Check seal (1) for damage, change if necessary.

Install seal (1) with lug (arrow) upwards in fuel filler cap (2).
Position fuel filler cap (2) with seal (1) and holder (3).

Attach fairing side panel (5) and fairing side panel (6) to retaining tabs
(arrows).
Install screws (4).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Tightening torques
Fuel filler cap to fuel tank
M5 x 28 3 Nm

Install screws (3).

Push hoses (1) and (2).

(-) Installing lock barrel for fuel filler cap

Open fuel filler cap (1).

Cover the fuel filler neck.
ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Push the latching tab (arrow) down using a suitable tool until holes (2) are
aligned.
Secure the latching tab (arrow) using drill (3) into fuel filler cap (1).

Technical data
Drill-bit diameter 2 mm

Lubricate the lock barrel (5).

Lubricant
MI-Setral-43 N 83 23 2 152 082

Install lock barrel (5) in the "Open" position in fuel filler cap (1) until it cannot
be turned.
Lock barrel (5) sits flush in fuel filler cap (1).
Turn key (4) to the "Closed" position and remove drill (3) from fuel filler cap
(1).
Remove the cover from fuel filler neck and close fuel filler cap (1).

Follow-up work
Installing the fuel tank cover
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

16 11 531 Replacing fuel tank (fuel tank removed)

Preparatory work
Draining fuel tank

Core activity
(-) Removing fuel-tank cap

Remove screws (1).

Remove fuel filler cap (1) with holder (2) and seal (3) .

(-) Removing fuel-pump unit

Remove screws (1) and remove pressure plate (2).

Loosen fuel-pump unit (1) to removing aid (arrow) and pull out carefully with
seal (2) from fuel tank (3) .
Check fuel strainer (4) and lever sensor (5) in particular.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

(-) Replacing fuel tank

Remount small parts on new fuel tank (1), if necessary replace with new
parts.
2 x flat nut, M5
2 x bushing
2 x rubber mount
2 x spacer buffer
8 x seal
Clean the surfaces for adhesion.
NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.

Fix new thermal protection (2) on the inside of new fuel tank (1).

(-) Installing fuel-pump unit

Check seal (1), change if necessary.

Lightly lubricate seal (1) and position it on fuel-pump unit (2).

Installation tool
Silicone spray 83 19 2 208 609

Feed in fuel-pump unit (2) with seal (1) carefully in fuel tank (3), checking
lever sensor (4) and fuel strainer (5) in particular.
NOTICE
Bridge on fuel-pump unit must be in the opposite direction of travel.

Position fuel-pump unit (2) with bridge (arrow) as shown.

Hold pressure plate (1) in position and align with recess (arrow) to bridge of
fuel-pump unit (arrow).
Turn pressure plate (1) and fuel-pump unit (2) slightly, together if necessary,
so that the bore holes for bolts (3) are aligned.
Install bolts (3) and tighten gradually.

Tightening torques
Electric fuel pump to fuel tank
M5 x 20 5 Nm

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

(-) Installing fuel-tank cap

Check seal (1) for damage, change if necessary.

Install seal (1) with lug (arrow) upwards in fuel filler cap (2).
Position fuel filler cap (2) with seal (1) and holder (3).

Install screws (1).

Tightening torques
Fuel filler cap to fuel tank
M5 x 28 3 Nm

Follow-up work
Filling fuel tank

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

16 13 001 Replacing carbon canister

+ 16 13 500

Core activity
(-) Removing carbon canister

Pull hoses (1), (2) and (3) off the carbon canister (4).

Remove carbon canister (1) from bracket (2), slightly pushing retaining tab
(arrow) backwards and while doing so unlock carbon canister (1).

(-) Installing carbon canister

Install carbon canister (1) in holder (2), making sure that the carbon canister
(1) is locked.

Push hoses (1), (2) and (3) on carbon canister (4).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Follow-up work
Securing bracket for activated charcoal filter
Installing left side cap
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

16 13 002 Replacing fuel-evaporation control valve, activated charcoal filter

+ 16 13 510

Core activity
(-) Removing tank vent valve

Disconnect connector (1) for the tank vent valve.

Pull off hose (to throttle-valve assembly) (2).
Pull off hose (to the carbon canister) (3).
Pull off tank vent valve (4) from bracket (5).

(-) Installing tank vent valve

Push the tank venting valve (1) onto the holder (2), noting the marks (arrow)
for flow direction.
Push on hose (to the carbon canister) (3).
Push on hose (to throttle-valve assembly) (4).
Connect connector (1) for the tank vent valve.

Follow-up work
Securing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

16 14 003 Replacing fuel-level sensor

+ 16 14 554

WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.

Core activity
(-) Removing fuel-level sensor

Remove cable strap (arrow).

Disconnect connector (1) and release cable from holder (2).
Raise the lug (3), pulling off the fuel-level sensor (4) and removing it while
doing so.

(-) Installing fuel-level sensor

Hold fuel-level sensor (1) in position and press until it engages with an
audible click.
Secure cable (2) in holder and connect connector (3).
Secure the cable strap (arrow).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Follow-up work
Installing fuel-pump unit
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Filling fuel tank
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

16 14 009 Removing/installing fuel-pump unit

+ 16 14 502

WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.

Core activity
(-) Removing fuel-pump unit

Remove screws (1) and remove pressure plate (2).

Loosen fuel-pump unit (1) to removing aid (arrow) and pull out carefully with
seal (2) from fuel tank (3) .
Check fuel strainer (4) and lever sensor (5) in particular.

(-) Installing fuel-pump unit

052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Check seal (1), change if necessary.
Lightly lubricate seal (1) and position it on fuel-pump unit (2).

Installation tool
Silicone spray 83 19 2 208 609

Position fuel-pump unit (2) with bridge (arrow) as shown.

Tightening torques
Electric fuel pump to fuel tank
M5 x 20 5 Nm

Follow-up work
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Filling fuel tank
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

16 14 060 Replacing fuel hose, flow hose

+ 16 14 555

Core activity
(-) Removing fuel hose

Release clamps (1).

Remove quick-release coupling (2).
Remove hose (3).

(-) Installing fuel hose

Connect new clamps (1) to new hose (2).

Connect hose (2) to fuel injection pipe (3).
Install quick-release coupling (4) on hose (2) and align it.
Secure clamps (1) with pliers (No. 13 1 500).

Follow-up work
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Performing vehicle test with BMW Motorrad diagnostic system and
resetting the adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

17 00 010 Checking cooling system for leaks (with cooling system tester)
+ 17 00 502

CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.

Core activity
(-) Checking cooling system for leaks

Requirement
Engine is cold.

Removing radiator cap

Remove radiator cap (1).

Secure radiator connection (No. 17 5 554) on coolant filler neck (1), connect
pump (No. 17 0 511).
Check
Pressure-test the cooling system; the pressure must remain unchanged for
at least 5 minutes.

Technical data
Cooling system test Test pressure 1.2 bar
pressure must remain
unchanged: 5 min

Result:
Pressure loss
Measure:
Check for leaks and rectify.
Install the radiator cap

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Install the radiator cap (1).

Follow-up work
Installing right radiator cowl
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

17 00 020 Checking coolant composition

+ 17 00 503

Core activity
(-) Check the coolant composition

Check
Open lid (2).
Check the ability of the coolant to resist freezing temperatures by checking
the antifreeze concentration in expansion tank(1).

Technical data
Coolant, frost Silicate min −25 °C
protection radiator
protective
agent

Result:
Ability to resist freezing temperatures is not ensured.
Measure:
Increase the proportion of frost protection until ability to resist freezing
temperatures is ensured, renew coolant if applicable.

Close lid (1).

Follow-up work
Installing right radiator cowl
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

17 00 035 Draining coolant, refilling/bleeding system

+ 17 00 504

CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.

Core activity
(-) Draining coolant

CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.

Remove coolant drain plug (1) with sealing ring (2).

Drain the coolant into a suitable container.
Slowly open the radiator cap (3) and catch coolant in a suitable container.
Install coolant drain plug (1) with new sealing ring (2).

Tightening torques
Coolant drain plug to water pump
M5 x 12 6 Nm

(-) Draining coolant expansion tank

Remove screws (1).

Release coolant expansion tank(2).
Open lid (3) and drain coolant from coolant expansion tank (2) into the
container.

052021 BMW Motorrad, UX-VA-4 1/5

BMW-Motorrad - F 850 GS

(-) Filling cooling system

Preparing and priming radiator filler for cooling system

Fill canister (No. 17 5 553) with an adequate quantity of coolant.

Technical data
Coolant capacity total in the 1.9 l
coolant circuit
Coolant top- 0.2 l
up quantity
(difference
between the
minimum and
maximum
mark on the
expansion
tank
General consumable (Antifreeze and corrosion
inhibitor)

Connect canister (No. 17 5 553), venturi nozzle (No. 17 5 552) and

distributor unit (No. 17 5 551).
Put the end of the drain hose of venturi nozzle (No. 17 5 552) into a suitable
container.
ATTENTION
Connecting compressor to distributor unit of filler adapter with
compressed-air valve open
Damage to pressure meter due to pressure peaks
Make sure the valves are closed when you connect the compressor to the
distributor unit.

Connect the compressor to the venturi nozzle (No. 17 5 552).

Technical data
Minimum Print min 8 bar
requirement,
compressor Delivery rate min 125 l/min

Begin by fully opening coolant cock (1) and then fully opening negative-
pressure cock (2) of distributor unit (No. 17 5 551).
Coolant is drawn in by vacuum from the tank.
Draw in coolant until the hose to distributor unit (No. 17 5 551) is full of
bubble-free coolant.
Close coolant cock (1) and negative-pressure cock (2).

052021 BMW Motorrad, UX-VA-4 2/5

BMW-Motorrad - F 850 GS
Disconnect the compressor from venturi nozzle (No. 17 5 552).

Connecting radiator filler to cooling system

Requirement
The coolant canister must be higher than the motorcycle's radiator.

Position coolant canister (No. 17 5 553) on a higher level.

Secure the preassembled radiator filler in position at the motorcycle.
Connect radiator port (No. 17 5 554) to distributor unit (No. 17 5 551) and
radiator filler neck.
Put the end of the drain hose of venturi nozzle (No. 17 5 552) into a suitable
container.
Prepare the compressor.

Technical data
Minimum Print min 8 bar
requirement,
compressor Delivery rate min 125 l/min

Evacuating cooling system

ATTENTION
Connecting compressor to distributor unit of filler adapter with
compressed-air valve open
Damage to pressure meter due to pressure peaks
Make sure the valves are closed when you connect the compressor to the
distributor unit.

Connect the compressor to the venturi nozzle (No. 17 5 552).

Open negative-pressure cock (2) of distributor unit (No. 17 5 551).
A vacuum builds up in the system.
Evacuate the cooling system until the requisite negative pressure is
established and the needle of the pressure gauge is steady.

Technical data
Requisite vacuum for min −0.8 bar
filling the cooling
system

Close negative-pressure cock (2).

Disconnect the compressor from venturi nozzle (No. 17 5 552).

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS
Observe the needle of the pressure gauge of distributor unit (No. 17 5 551)
for a time and check that the partial vacuum in the cooling system does not
rise to ambient pressure.

Technical data
Requisite vacuum for min −0.8 bar
filling the cooling
system

Slowly open coolant cock (1) until it is fully open.

Coolant flows into the cooling system.
When the level of fluid in the canister (No. 17 5 553) ceases to drop and
the vacuum corresponds to ambient pressure, disconnect the radiator filler
from the radiator.

Disconnecting radiator filler from radiator

Disconnect the radiator filler from the radiator and remove it from the
vehicle.

Check the coolant level; top up if necessary. (The level of coolant in the
cooling system must be at the bottom edge (arrow) of the coolant filler neck
(1).)

General consumable
Antifreeze and corrosion inhibitor 83 51 2 445 463

Install the radiator cap

Install the radiator cap (1).

052021 BMW Motorrad, UX-VA-4 4/5

BMW-Motorrad - F 850 GS
(-) Securing coolant expansion tank

Position coolant expansion tank (1).

Install screws (2).

Tightening torques
Expansion tank to radiator
M6 x 17.5 8 Nm

(-) Fill up the coolant expansion tank

Fill coolant expansion tank (1) with coolant and close lid (2).

Technical data
Coolant, specified level Engine cold Between MIN and
MAX mark on the
expansion tank

(-) Checking coolant level

Allow the engine to warm up until the fan cuts in.

Allow the engine to cool down.

Check the coolant level; top up if necessary.

Technical data
Coolant, specified level Engine cold Between MIN and
MAX mark on the
expansion tank

052021 BMW Motorrad, UX-VA-4 5/5

BMW-Motorrad - F 850 GS

17 11 008 Removing/installing radiator (without draining/refilling coolant system)

+ 17 11 508
Construction status:

August 2020

Core activity
(-) Removing radiator
Disconnecting plug connection(s) for oxygen sensor
Remove the cable strap (arrows).
Disconnect plug connection (1) for front oxygen sensor.
Disconnect plug connection (2) for monitoring oxygen sensor.

Disconnect plug connection for fan

Disconnect plug connection (1) for fan.

Release clamp (1) with pliers (No. 17 5 571).

Release coolant hose (2).
Catch coolant in a suitable container.

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Release clamp (1) with pliers (No. 17 5 571).

Release coolant hose (2).
Catch coolant in a suitable container.

Release clamp (1) with pliers (No. 17 5 571).

Release breather hose (2).

Remove screws (1).

Remove air guide (2) with radiator (3), releasing radiator (3) from strut (4)
while doing so.

(-) Installing radiator

Position air guide (2) with radiator (3), securing radiator (3) in strut (4).
Install screws (1).

Tightening torques

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Radiator to bracket
M6 x 25 8 Nm

Position breather hose (1).

Lug (2) engages in recess of coolant hose (1).
Align clamp (3) using pliers (No. 17 5 571) to mark (arrow).

Position coolant hose (1).

Lug (2) engages in recess of coolant hose (1).
Align clamp (3) using pliers (No. 17 5 571) to mark (arrow).

Position coolant hose (1).

Lug (2) engages in recess of coolant hose (1).
Align clamp (3) using pliers (No. 17 5 571) to mark (arrow).

Connect plug connection for fan

Connect plug connection (1) for fan.

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Connecting plug connection(s) for oxygen sensor

Install plug connection (1) for front oxygen sensor.
Install plug connection (2) for monitoring oxygen sensor.
Close the cable strap (arrows).

Follow-up work
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

17 11 008 Removing/installing radiator (without draining/refilling coolant system)

+ 17 11 508

Core activity
(-) Removing radiator
Disconnecting plug connection(s) for oxygen sensor
Release plug connection (1) for oxygen sensor and release cable (2) from
holder (arrow).

Disconnect plug connection for fan

Disconnect plug connection (1) for fan.

Release clamp (1) with pliers (No. 17 5 571).

Release coolant hose (2).
Catch coolant in a suitable container.

Release clamp (1) with pliers (No. 17 5 571).

052021 BMW Motorrad, UX-VA-4 1/4
BMW-Motorrad - F 850 GS
Release coolant hose (2).
Catch coolant in a suitable container.

Release clamp (1) with pliers (No. 17 5 571).

Release breather hose (2).

Remove screws (1).

Remove air guide (2) with radiator (3), releasing radiator (3) from strut (4)
while doing so.

(-) Installing radiator

Position air guide (2) with radiator (3), securing radiator (3) in strut (4).
Install screws (1).

Tightening torques
Radiator to bracket
M6 x 25 8 Nm

Position breather hose (1).

Lug (2) engages in recess of coolant hose (1).
Align clamp (3) using pliers (No. 17 5 571) to mark (arrow).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

Position coolant hose (1).

Lug (2) engages in recess of coolant hose (1).
Align clamp (3) using pliers (No. 17 5 571) to mark (arrow).

Position coolant hose (1).

Lug (2) engages in recess of coolant hose (1).
Align clamp (3) using pliers (No. 17 5 571) to mark (arrow).

Connect plug connection for fan

Connect plug connection (1) for fan.

Connecting plug connection(s) for oxygen sensor

Install plug connection (1) for oxygen sensor and secure cable (2) in holder
(arrow).

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Follow-up work
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

17 11 510 Replacing radiator (radiator removed)

Core activity
(-) Replace the radiator
Removing air guide
Release air guide (1) with bushes (2) from radiator (3) on top.
Remove air guide (1), detaching it from the retaining tab (arrow) while doing
so.

Removing fan
Remove expanding rivet (1).
Remove fan (2), detaching it from the retaining tab (arrows) while doing so.

Removing expansion tank

Remove clip (1).
Release overflow hose (2).
Remove expansion tank (3).

Convert rubber grommets (1) and flat nuts (2) to new part, replace if
necessary.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Installing expansion tank

Hold expansion tank (1) in position.
Position overflow hose (2).
Secure clamp (3) with pliers (No. 13 1 500).

Installing fan
Position fan (2), attaching it in retaining catches (arrows) while doing so.
Install expanding rivet (1).

Installing air guide

Position air guide (1), attaching it in retaining catches (arrow) while doing so.
Secure air guide (1) with bushes (2) in radiator (3) on top.

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

17 12 100 Replacing coolant hose from radiator (without draining/ refilling coolant system)
+ 17 12 600

CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.

Preparatory work
=> Draining coolant, refilling/bleeding system (Description in
item: 17 00 504, Billed as a separate item)

Core activity
(-) Remove the coolant hose from radiator

Release clamp (1) with pliers (No. 17 5 571).

Release coolant hose (2).
Catch coolant in a suitable container.

Release clamp (1) with pliers (No. 17 5 571).

Remove coolant hose (2).
Catch coolant in a suitable container.

(-) Replace the coolant hose from radiator

Transfer clamps (1) using pliers (No. 17 5 571) to the new coolant hose (2).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
(-) Installing coolant hose from radiator

Position coolant hose (1).

Align clamp (2) using pliers (No. 17 5 571) to mark (arrow).

Position coolant hose (1).

Lug (2) engages in recess of coolant hose (1).
Align clamp (3) using pliers (No. 17 5 571) to mark (arrow).
If necessary, wipe coolant from components.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

17 12 105 Replacing coolant hose to radiator (without draining/ refilling coolant system)
+ 17 12 605

CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.

Core activity
(-) Removing coolant hose to radiator

Release clamp (1) with pliers (No. 17 5 571).

Release coolant hose (2).
Catch coolant in a suitable container.

Release clamp (1) with pliers (No. 17 5 571).

Remove coolant hose (2).
Catch coolant in a suitable container.

(-) Replace the coolant hose to radiator

Transfer clamps (1) using pliers (No. 17 5 571) to the new coolant hose (2).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

(-) Installing coolant hose to radiator

Position coolant hose (1).

Lug (2) engages in recess of coolant hose (1).
Align clamp (3) using pliers (No. 17 5 571) to mark (arrow).

Position coolant hose (1).

Align clamp (2) using pliers (No. 17 5 571) to mark (arrow).
If necessary, wipe coolant from components.

Follow-up work
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

17 13 001 Replace expansion tank

+ 17 13 501

CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.

Core activity
(-) Draining coolant expansion tank

Remove screws (1).

Release coolant expansion tank(2).
Open lid (3) and drain coolant from coolant expansion tank (2) into the
container.

(-) Replacing expansion tank

Open clamp (1) and pull off overflow hose (2) from expansion tank (3).
Replace expansion tank (3).
Connect overflow hose (2) with clamp (1) to the new part.
Secure clamp (1) with pliers (No. 13 1 500).

(-) Securing coolant expansion tank

Position coolant expansion tank (1).

Install screws (2).

052021 BMW Motorrad, UX-VA-4 1/2

Follow-up work
Installing thermostat cover
Securing coolant hose to radiator
Installing throttle-valve assembly
Install the intake air silencer
Installing fuel tank
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

17 40 000 Removing/installing or replacing fan

+ 17 40 500

CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.

Core activity
(-) Disconnect plug connection for fan

Disconnect plug connection (1) for fan.

(-) Removing fan

Remove expanding rivet (1).

Remove fan (2), detaching it from the retaining tab (arrows) while doing so.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
(-) Installing fan

Position fan (2), attaching it in retaining catches (arrows) while doing so.
Install expanding rivet (1).

(-) Connect plug connection for fan

Connect plug connection (1) for fan.

Follow-up work
Securing radiator with air guide
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing the fuel tank cover
Installing left radiator cowl
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

17 65 000 Replacing thermostat for coolant (without draining/ refilling coolant system)
+ 17 65 500

Core activity
(-) Removing coolant thermostat

Remove cable strap (arrow).

Remove screws (1).
Release thermostat cover (2) and hang it aside.
If necessary, collect escaping coolant.

Remove thermostat (1).

(-) Installing coolant thermostat

Install thermostat (1).

Guide the cable strap (arrow) into the holder.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Clean the sealing faces.
Position thermostat cover(2).
Install screws (1).

Tightening torques
Thermostat cover to thermostat
M6 x 18 10 Nm

Secure the cable strap (arrow).

Follow-up work
Installing fuel tank
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

17 65 001 Removing/installing / sealing or replacing thermostat housing (without draining coolant

and refilling system)
+ 17 65 501

Preparatory work
=> Draining coolant, refilling/bleeding system (Description in
item: 17 00 504, Billed as a separate item)
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing fuel tank
Remove the intake air silencer
Removing throttle-valve assembly
Removing coolant thermostat
Remove the heat exchanger

Core activity
(-) Removing thermostat housing

Disconnect connector (1) for coolant temperature sensor.

Release clamp (2) with pliers (No. 17 5 571).
Release breather hose (3).
If necessary, collect escaping coolant.

Remove screws (1).

Remove thermostat housing (2) to the side.

(-) Replacing thermostat housing

Remove coolant temperature sensor (1) with sealing ring (2) and remount it
with new sealing ring (2) on new thermostat housing (3).
Install new seal (4).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

(-) Installing thermostat housing

Install thermostat housing (2) from the side.

Install screws (1).

Tightening torques
Thermostat housing to cylinder head
M6 x 18 10 Nm

Connect vent hose (3).

Install new clamp (2) with pliers (No. 17 5 571).
Connect connector (1) for coolant temperature sensor.

Follow-up work
Installing heat exchanger
Installing coolant thermostat
Installing throttle-valve assembly
Install the intake air silencer
Installing fuel tank
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

18 51 000 Replacing silencer

+ 18 51 500

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

Slacken nut (1) on the clamp (2).

Remove bolt (3) with shaped washer (4) and washer (5).
Remove silencer (6).

(-) Replace the silencer

Lubricate clamp (1) on inner surface (arrow) thinly.

Lubricant
Optimoly TA 18 21 9 062 599

Slide clamp (1) onto new silencer (2) and align recess (3) with the lug (4).
Remove shouldered bushing (5) from old part and insert in rubber decoupler
(6) of new silencer (2).

(-) Installing silencer

NOTICE
To ensure the leaktightness of the exhaust system, the exhaust clamps have
to be lubricated for installation.
It is particularly important to apply lubricant to the vicinity of the joint.

Lubricate connecting area lightly.

Lubricant

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Optimoly TA 18 21 9 062 599

Hold silencer (6) in position and align.

Install screw (3) with shaped washer (4) and washer (5).

Tightening torques
Silencer to bracket
M8 x 40 19 Nm

Tighten nut (1) on the clamp (2).

Tightening torques
Silencer to front silencer
M8 14 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

18 51 001 Replacing exhaust manifold

+ 18 51 502
Construction status:

August 2020

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

Preparatory work
Removing oxygen sensor(s)

Core activity
(-) Removing exhaust manifold

Remove nuts (1).

Slacken nut (1) on the clamp (2).

Remove exhaust manifold (1) and exhaust manifold seals (2) .

(-) Replacing exhaust manifold

052021 BMW Motorrad, UX-VA-4 1/3
BMW-Motorrad - F 850 GS
Removing heat protection cover
Remove screws (1).
Remove heat protection cover (2) .
Remove flat nuts (3) .

Installing heat protection cover

Install flat nuts (3).
Position heat protection cover (2).
Install screws (1).

Tightening torques
Heat protection cover to exhaust manifold
M5 x 10 5 Nm

(-) Installing exhaust manifold

NOTICE
To ensure the leaktightness of the exhaust system, the exhaust clamps have
to be lubricated for installation.
It is particularly important to apply lubricant to the vicinity of the joint.

If necessary, lightly lubricate clamp (1) on inner surface (arrow).

Lubricant
Optimoly TA 18 21 9 062 599

Push clamp (1) on to front silencer (2) and adjust recess (3) to lug (4).

Lightly lubricate new seals (1) and position in cylinder head, checking the
mounting orientation (arrows).
Position exhaust manifold (2).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Install nuts (1).

Tightening torques
Exhaust header to cylinder head
M7 14 Nm
Thread-locking compound
(mechanical)

Tighten nut (1) on the clamp (2).

Tightening torques
Front silencer to exhaust manifold
M8 14 Nm

Follow-up work
Installing oxygen sensor(s)
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

18 51 001 Replacing exhaust manifold

+ 18 51 502

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

Preparatory work
Removing oxygen sensor(s)

Core activity
(-) Removing exhaust manifold

Remove nuts (1).

Slacken nut (1) on the clamp (2).

Remove exhaust manifold (1) and exhaust manifold seals (2) .

(-) Replacing exhaust manifold

Removing heat protection cover

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Remove screws (1).
Remove heat protection cover (2) .
Remove flat nuts (3) .

Installing heat protection cover

Install flat nuts (3).
Position heat protection cover (2).
Install screws (1).

Tightening torques
Heat protection cover to exhaust manifold
M5 x 10 5 Nm

(-) Installing exhaust manifold

NOTICE
To ensure the leaktightness of the exhaust system, the exhaust clamps have
to be lubricated for installation.
It is particularly important to apply lubricant to the vicinity of the joint.

If necessary, lightly lubricate clamp (1) on inner surface (arrow).

Lubricant
Optimoly TA 18 21 9 062 599

Push clamp (1) on to front silencer (2) and adjust recess (3) to lug (4).

Lightly lubricate new seals (1) and position in cylinder head, checking the
mounting orientation (arrows).
Position exhaust manifold (2).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Install nuts (1).

Tightening torques
Exhaust header to cylinder head
M7 14 Nm
Thread-locking compound
(mechanical)

Tighten nut (1) on the clamp (2).

Tightening torques
Front silencer to exhaust manifold
M8 14 Nm

Follow-up work
Installing oxygen sensor(s)
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

18 51 003 Replacing front silencer

+ 18 51 504

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing silencer

Core activity
(-) Removing front silencer

Slacken nut (1) on the clamp (2).

Pull front silencer (3) off the bracket (4) and exhaust manifold (5) and
remove.

(-) Replacing front silencer

Lubricate clamp (1) on inner surface (arrow) thinly.

Lubricant
Optimoly TA 18 21 9 062 599

Slide clamp (1) onto new front silencer (2) and align recess (3) with the lug
(4).
Remount screws (5) and trim (6) on new front silencer (2) .

Tightening torques
Trim to front silencer
M5 x 10 5 Nm

(-) Installing front silencer

NOTICE
To ensure the leaktightness of the exhaust system, the exhaust clamps have
to be lubricated for installation.
It is particularly important to apply lubricant to the vicinity of the joint.

Push front silencer (3) on holder (4) and exhaust manifold (5).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Tighten nut (1) on the clamp (2).

Tightening torques
Front silencer to exhaust manifold
M8 14 Nm

Follow-up work
Installing silencer
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

18 51 015 Replacing heat shield for silencer

+ 18 51 518

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

Core activity
(-) Removing the heat protection cover for the front silencer

Remove screws (1).

Remove heat protection cover (2) .

(-) Installing the heat protection cover for the front silencer

Position heat protection cover (2).

Install screws (1).

Tightening torques
Trim to front silencer
M5 x 10 5 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

18 51 018 Replace trim for exhaust manifold

+ 18 51 618

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

Core activity
(-) Removing heat protection cover

Remove screws (1).

Remove heat protection cover (2) .

(-) Installing heat protection cover

Position heat protection cover (2).

Install screws (1).

Tightening torques
Heat protection cover to exhaust manifold
M5 x 10 5 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

Clutch and Gearbox

Repair Guide

BMW Motorrad
BMW-Motorrad - F 850 GS

21 00 004 Adjusting clutch operating clearance

+ 21 00 500

Requirement
Engine is cold.

NOTICE
Before the adjustment of the clutch cable, it must be ensured that a correct
adjustment range is available on the coupling hand armature.

Adjusting the adjustment range (clutch cable) on clutch handlebar

fitting
Loosen lock nut (1)and adjust distance (A) using adjusting screw (2).

Technical data
Distance between 8.0+1.5 mm
adjusting screw and −1.5
locknut

If necessary, re-adjust clutch cable on engine.

If necessary, loosen nuts (1) and adjust clutch play until the adjustment
range on the clutch handlebar fitting is correct.
Tighten nuts (1) until hand-tight.

Operate clutch lever (1) several times till the limit position at the handle.
Operate clutch lever (1) lightly until resistance can be felt, while observing
the clutch play (B).
Check
Measure the free travel/clutch play (B) between handlebar weight (2) and
clutch lever (1).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Technical data
Clutch cable play at the outer 3...5 mm
end of the
handlebar
lever,
handlebars in
straight-
ahead
position,
engine cold

Result:
Clearance is out of tolerance.
Measure:
Removing the cover for wiring harness
Release the cable (1) from the holder (arrow).
Remove screw (2), release cover (3) of detent pins (4) and remove.

Adjusting clutch cable at engine housing

Loosen nuts (1) and adjust clutch play.

Technical data
Clutch cable play at the outer 3...5 mm
end of the
handlebar
lever,
handlebars in
straight-
ahead
position,
engine cold

Tighten nuts (1).

Measure the free travel/clutch play (B) between handlebar weight (2) and
clutch lever (1) again and if necessary, adjust on engine housing.

Technical data
Clutch cable play at the outer 3...5 mm
end of the
handlebar
lever,
handlebars in
straight-
ahead

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
position,
engine cold

Installing the cover for wiring harness

Lightly lubricate detent pins (1).

Installation tool
Silicone spray 83 19 2 208 609

Hold cover (2) in such a way that cable (3) for side-stand switch runs above
the spacer (4).
Cable (3) is not trapped.
Clip cover (2) into detent pin (1) and install screw (5).
Secure the cable (6) in the holder (arrow).

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

21 21 000 Removing and installing or replacing clutch

+ 21 21 606

Core activity
(-) Remove the pressure plate

Loosen bolts (1) alternately and remove.

Remove retaining panel (2).

Remove pressure plate (1) with spring retainer (2) and compression springs
(3) .

(-) Removing clutch pushrod

Remove clutch pushrod (1) with O-ring (2).

052021 BMW Motorrad, UX-VA-4 1/7

BMW-Motorrad - F 850 GS

(-) Removing lined plates

• Remove friction plates (1)with a red mark and steel disc (2)with a larger
inner diameter.

• Remove steel discs (1)and friction plates (2)with a green mark.

• Remove friction plate (1)with a red mark .

• Remove clutch release spring (2).
• Remove mounting (3)for clutch release spring.

(-) Removing clutch hub

• Insert driver stop (No. 21 4 606)between clutch hub (1)and clutch basket
(2).

052021 BMW Motorrad, UX-VA-4 2/7

BMW-Motorrad - F 850 GS

• Remove caulkings (arrows).

_.. ATTENTION
Overloading of the alignment pin
Component damage, tool damage
• Use alignment pin only to install the crankshaft and check the timings.
• Do not use alignment pin as a locking tool.

• Remove nut (1), counter-holding to crankshaft (2) .

• Remove clutch hub (3) with driver stop (No. 21 4 606) .
• Remove thrust washer (4) .

(-) Removing clutch basket

• Remove clutch basket (1) .

• Remove needle bearing (2), bush (3), thrust washer (4) and shim (5) .

K81_R21013b

(-) Installing clutch cage

• Lubricate the components with engine oil.

• Install shim (1), thrust washer (2), bush (3) and needle bearing (4).

052021 BMW Motorrad, UX-VA-4 3/7

BMW-Motorrad - F 850 GS
• Install clutch basket (5), ensuring that gears (arrow) engage.

=> Adjusting tooth backlash of primary drive (clutch removed)

(Description in item: 21 21 505, Billed as a separate item)
(-) Installing clutch hub

• Clean and degrease the threads.

• Install thrust washer (4).
• Position clutch basket (3) with driver stop (No. 21 4 606).
• ATTENTION
Overloading of the alignment pin
Component damage, tool damage
• Use alignment pin only to install the crankshaft and check the timings.
• Do not use alignment pin as a locking tool.

• Install nut (1), counter-holding to crankshaft (2).

,.IQ,

"',Tightening torques
Clutch hub to drive shaft
M20 x 1.5, Replace nut Tightening
Thread-locking compound (micro- sequence: 1st
encapsulated) tightening torque
190 Nm
Disengage fastener
Tightening
sequence:2nd
tightening torque
190 Nm
Caulk nut to
transmission shaft

• Caulk (arrows) with a drift.

052021 BMW Motorrad, UX-VA-4 4/7
BMW-Motorrad - F 850 GS

!] Technical data
Diameter of drift
I 14 mm
I

• Remove driver lock (No. 21 4 606).

(-) Lubricating new plate cluster

.- ATTENTION
Installation of the clutch plates dry
Burning of the clutch plates
• Immerse new clutch disc package in clean engine oil.

• Immerse new lined plates in engine oil.

» The friction faces of the lined plates are wetted by oil.

(-) Installing lined plates

• During installation, ensure friction plates (1) and (2) and steel discs (3) and
(4) are arranged correctly.
- different colour coding at the edge of friction plates
- different diameter of steel discs
- offset installation of last friction plate

• Install mounting (1) for clutch release spring.

• Install clutch release spring (2) with curvature (arrow) inwards.
• Install friction plate (3) with a red mark.

I
:!] Technical data
I
052021 BMW Motorrad, UX-VA-4 5/7
BMW-Motorrad - F 850 GS
Number of friction Outer friction 3 pieces, marked red
plates and steel discs plates
Inner friction 6 pieces, marked
plates green
Steel discs 1 of
(larger inner
diameter)
Steel discs 7 of

• Install steel discs (1) and friction plates (2) with a green mark alternately.

• Install friction plate (1) with a red mark and steel disc (2) with a larger inner
diameter.
• Install friction plate (3) with an offset red mark.

(-) Installing clutch pushrod

• Check 0-ring (2) for damage; replace if necessary.

• Lubricate the clutch pushrod (1) with 0-ring (2) using engine oil.
• Install clutch pushrod (1) with 0-ring (2).

• Check for correct mounting orientation of clutch pushrod (1):

• The clutch pushrod (1) is in the (arrow) the release shaft (2) with recess
(test lever function).
• Distance (A) is correct.

052021 BMW Motorrad, UX-VA-4 6/7

BMW-Motorrad - F 850 GS

!] Technical data
Distance of approx. 5.2 mm
transmission input
shaft to collar (outer
side) on pushrod

(-) Installing pressure plate

• Install pressure plate (1) with spring retainer (2) and compression springs
(3).
>> Marks (arrows) on pressure plate (1) and spring retainer (2) face each other.

• Lubricate bolts (1) with engine oil.

• Position retaining panel (2) with bolts (1) with the labelling (arrow) facing
outwards.
• Tighten bolts (2) alternately and evenly.

•�Tightening torques
Retaining panel to clutch hub
M6 x 30 10 Nm
lubricate with engine oil

Follow-up work
Installing threaded plug (crankshaft)
Seal right engine housing cover
Installing right crankcase cover
Checking/adjusting clutch play
Checking engine oil level
Final check of work performed

052021 BMW Motorrad, UX-VA-4 7/7

BMW-Motorrad - F 850 GS

21 21 122 Replacing clutch hub

+ 21 21 608

Core activity
(-) Removing clutch hub

Insert driver stop (No. 21 4 606) between clutch hub (1) and clutch basket
(2) .

Remove caulkings (arrows).

ATTENTION
Overloading of the alignment pin
Component damage, tool damage
Use alignment pin only to install the crankshaft and check the timings.
Do not use alignment pin as a locking tool.

Remove nut (1), counter-holding to crankshaft (2) .

Remove clutch hub (3) with driver stop (No. 21 4 606) .
Remove thrust washer (4) .

(-) Installing clutch hub

052021 BMW Motorrad, UX-VA-4 1/3
BMW-Motorrad - F 850 GS
Clean and degrease the threads.
Install thrust washer (4).
Position clutch basket (3) with driver stop (No. 21 4 606).
ATTENTION
Overloading of the alignment pin
Component damage, tool damage
Use alignment pin only to install the crankshaft and check the timings.
Do not use alignment pin as a locking tool.

Install nut (1), counter-holding to crankshaft (2).

Tightening torques
Clutch hub to drive shaft
M20 x 1.5, Replace nut Tightening
Thread-locking compound (micro- sequence: 1st
encapsulated) tightening torque
190 Nm
Disengage fastener
Tightening
sequence: 2nd
tightening torque
190 Nm
Caulk nut to
transmission shaft

Completely remove screw locking agent (arrow) that has been expelled.

Caulk (arrows) with a drift.

Technical data
Diameter of drift 4 mm

Remove driver lock (No. 21 4 606).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Follow-up work
Lubricating new plate cluster
Installing lined plates
Installing clutch pushrod
Installing pressure plate
Installing threaded plug (crankshaft)
Seal right engine housing cover
Installing right crankcase cover
Checking/adjusting clutch play
Checking engine oil level
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

21 21 140 Removing and installing or replacing lined plates

+ 21 21 609

Core activity
(-) Remove the pressure plate

Loosen bolts (1) alternately and remove.

Remove retaining panel (2).

Remove pressure plate (1) with spring retainer (2) and compression springs
(3) .

(-) Removing lined plates

Remove friction plates (1) with a red mark and steel disc (2) with a larger
inner diameter .

Remove steel discs (1) and friction plates (2) with a green mark .

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Remove friction plate (1) with a red mark .

Remove clutch release spring (2) .
Remove mounting (3) for clutch release spring.

(-) Lubricating new plate cluster

ATTENTION
Installation of the clutch plates dry
Burning of the clutch plates
Immerse new clutch disc package in clean engine oil.

Immerse new lined plates in engine oil.

The friction faces of the lined plates are wetted by oil.

(-) Installing lined plates

During installation, ensure friction plates (1) and (2) and steel discs (3) and
(4) are arranged correctly.
different colour coding at the edge of friction plates
different diameter of steel discs
offset installation of last friction plate

Install mounting (1) for clutch release spring.

Install clutch release spring (2) with curvature (arrow) inwards.
Install friction plate (3) with a red mark.

Technical data

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Number of friction Outer friction 3 pieces, marked red
plates and steel discs plates
Inner friction 6 pieces, marked
plates green
Steel discs 1 of
(larger inner
diameter)
Steel discs 7 of

Install steel discs (1) and friction plates (2) with a green mark alternately.

Install friction plate (1) with a red mark and steel disc (2) with a larger inner
diameter.
Install friction plate (3) with an offset red mark.

(-) Installing pressure plate

Install pressure plate (1) with spring retainer (2) and compression springs
(3).
Marks (arrows) on pressure plate (1) and spring retainer (2) face each other.

Lubricate bolts (1) with engine oil.

Position retaining panel (2) with bolts (1) with the labelling (arrow) facing
outwards.
Tighten bolts (2) alternately and evenly.

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Tightening torques
Retaining panel to clutch hub
M6 x 30 10 Nm
lubricate with engine oil

Follow-up work
Seal right engine housing cover
Installing right crankcase cover
Checking/adjusting clutch play
Checking engine oil level
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

21 21 161 Checking tooth backlash of primary drive, adjusting if necessary

+ 21 21 616

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing right crankcase cover
Removing screw plug (crankshaft)
Remove the pressure plate
Removing clutch pushrod
Removing lined plates
Removing clutch hub
Removing clutch basket

Core activity
(-) Adjusting tooth backlash of clutch basket

Loosen screws (1).

Remove screw (2) from eccentric plate (3).

Installing clutch cage

Lubricate the components with engine oil.
Install shim (1), thrust washer (2), bush (3) and needle bearing (4).
Install clutch basket (5), ensuring that gears (arrow) engage.

Determining the bore hole for the setting of the tooth backlash and
inserting the alignment pin

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS
Example of the procedure, the actual procedure may require other
holding points.
Insert a 1/4" square extension in the elongated hole on the eccentric plate.
Preload eccentric plate with torque wrench (No. 00 2 703) clockwise .

Tightening torques
Torque for pre-tensioning the eccentric plate
Insert square in elongated hole 0.7 Nm

If the eccentric plate is preloaded, the exposed/detachable bore hole

represents the 1st holding option
If there is no open bore hole, swivel clockwise to the next bore hole.
The counting method of the holding options is alternately top/bottom,
following the contour.

Swivel the eccentric plate in the counterclockwise direction to the 3rd

Swivel the holding option counterclockwise.
Example of the procedure, the actual procedure may require other
holding points.

Alignment pin (1) in 3. Insert the holding option.

Install bolt (1).

Tightening torques
Eccentric plate (tooth backlash) to engine housing
M8 x 16 10 Nm

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

Removing clutch basket

Remove clutch basket (1) .
Remove needle bearing (2), bush (3), thrust washer (4) and shim (5) .

Tighten screws (1).

Tightening torques
Transmission to engine housing
M7 x 26 - 10.9 18 Nm

Remove alignment pin (1).

Follow-up work
Installing clutch cage
Installing clutch hub

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Lubricating new plate cluster
Installing lined plates
Installing clutch pushrod
Installing pressure plate
Installing threaded plug (crankshaft)
Seal right engine housing cover
Installing right crankcase cover
Checking/adjusting clutch play
Checking engine oil level
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

21 21 505 Adjusting tooth backlash of primary drive (clutch removed)

Core activity
(-) Adjusting tooth backlash of clutch basket

Loosen screws (1).

Remove screw (2) from eccentric plate (3).

Installing clutch cage

Lubricate the components with engine oil.
Install shim (1), thrust washer (2), bush (3) and needle bearing (4).
Install clutch basket (5), ensuring that gears (arrow) engage.

Determining the bore hole for the setting of the tooth backlash and
inserting the alignment pin
Example of the procedure, the actual procedure may require other
holding points.
Insert a 1/4" square extension in the elongated hole on the eccentric plate.
Preload eccentric plate with torque wrench (No. 00 2 703) clockwise .

Tightening torques

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Torque for pre-tensioning the eccentric plate
Insert square in elongated hole I 0.7 Nm I

• If the eccentric plate is preloaded, the exposed/detachable bore hole

represents the 1st holding option
• If there is no open bore hole, swivel clockwise to the next bore hole.
• The counting method of the holding options is alternately top/bottom,
following the contour.

• Swivel the eccentric plate in the counterclockwise direction to the 3rd

Swivel the holding option counterclockwise.
• Example of the procedure, the actual procedure may require other
holding points.

• Alignment pin(1) in 3. Insert the holding option.

◄
• Install bolt(1).

""Tightening torques
Eccentric plate (tooth backlash) to engine housing
M8 x 16 110 Nm I
052021 BMW Motorrad, UX-VA-4 2/3
BMW-Motorrad - F 850 GS

► Removing clutch basket

• Remove clutch basket (1) .
• Remove needle bearing (2), bush (3), thrust washer (4) and shim (5) .

K81_R21028b

◄
• Tighten screws (1).

�Tightening torques
Transmission to engine housing
M7x26-10.9 I 1a Nm I

• Remove alignment pin (1).

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

21 51 000 Replacing release bearing

+ 21 51 727

NOTICE
The release bearing is only available in combination with the pressure plate.

Core activity
(-) Remove the pressure plate

Loosen bolts (1) alternately and remove.

Remove retaining panel (2).

Remove pressure plate (1) with spring retainer (2) and compression springs
(3) .

(-) Installing pressure plate

Install pressure plate (1) with spring retainer (2) and compression springs
(3).
Marks (arrows) on pressure plate (1) and spring retainer (2) face each other.

Lubricate bolts (1) with engine oil.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Position retaining panel (2) with bolts (1) with the labelling (arrow) facing
outwards.
Tighten bolts (2) alternately and evenly.

Tightening torques
Retaining panel to clutch hub
M6 x 30 10 Nm
lubricate with engine oil

Follow-up work
Seal right engine housing cover
Installing right crankcase cover
Checking/adjusting clutch play
Checking engine oil level
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

21 51 151 Replacing shaft sealing ring for cutch actuation

+ 21 51 651

Core activity
(-) Removing clutch pushrod

Remove clutch pushrod (1) with O-ring (2).

(-) Disengaging clutch cable

Detach clutch cable (1) from lever (2).

(-) Removing release lever

Remove release lever (1) with bush (2), while paying attention to spring (3).
Remove contact disc (4).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
(-) Removing shaft sealing ring of the release lever

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Lever out shaft sealing ring (1) with a suitable tool.

(-) Installing shaft sealing ring of release lever

Clean the seat for the shaft sealing ring (1).

Install the shaft seal (1) with e.g. the fitting socket flush , the open side
faces the crankcase.

Technical data
Outer diameter of 18 mm
shaft seal

(-) Installing release lever

Install washer (1).

Install release lever (2) with bush (3) and spring (4).
The recess (arrow) points in the direction of the engine.
Check function (spring resets release lever).

(-) Installing clutch pushrod

Check O-ring (2) for damage; replace if necessary.

Lubricate the clutch pushrod (1) with O-ring (2) using engine oil.
Install clutch pushrod (1) with O-ring (2).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Check for correct mounting orientation of clutch pushrod (1):
The clutch pushrod (1) is in the (arrow) the release shaft (2) with recess
(test lever function).
Distance (A) is correct.

Technical data
Distance of approx. 5.2 mm
transmission input
shaft to collar (outer
side) on pushrod

(-) Securing the clutch cable

Attach clutch cable (1) in lever (2).

Follow-up work
Installing pressure plate
Seal right engine housing cover
Installing right crankcase cover
Checking/adjusting clutch play
Installing the cover for wiring harness
Checking engine oil level
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

23 12 078 Replace shaft sealing ring of output shaft

+ 23 12 620

Preparatory work
Placing motorcycle on rear-wheel stand
Relieving chain tension
Installing engine lifter
Disengaging gearshift rod
Removing front left footrest plate
Remove pinion with drive chain

Core activity
(-) Removing shaft sealing ring of output shaft

ATTENTION
Drilling of pilot hole in radial shaft seal not in compliance with correct
procedure
Housing damage
Do not use too large a twist drill.
Centre the hole.

Carefully drill the centre of the shaft sealing ring (1) using drill stop (No. 00 8
586).

Technical data
Hole diameter max 3 mm

Screw pull rod (No. 00 8 581) with adapter for cone-head self-tapping screw
(No. 00 8 587) and impact weight (No. 00 8 582) into the drilled shaft sealing
ring.
Remove radial shaft seal (1).

(-) Installing shaft sealing ring of output shaft

Position sliding sleeve (No. 23 1 671) on transmission output shaft (1).

Top up shaft sealing ring (2) between the inner sealing lips with lubricant.

Lubricant
Acid-free friction-bearing grease 81 22 9 407 174

Remove sufficient lubricant to leave a fillet (arrow).

Clean the housing.
Install shaft sealing ring (2) until flush.
Remove sliding sleeve (No. 23 1 671).

Follow-up work
Installing pinion with drive chain
Installing front left footrest plate
Securing selector rod
Removing engine lifter

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Removing motorcycle from rear-wheel stand
Adjust chain sag
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

23 12 090 Replace shaft sealing ring of selector drum

+ 23 12 590

Core activity
(-) Removing shaft sealing ring of selector drum

Turn back press-off bolt (A) in puller (No. 24 5 410) .

Position puller (No. 24 5 410) and screw into shaft sealing ring (1) until
hand-tight .
Screw in press-off bolt (A) and remove shaft sealing ring (1) .

(-) Installing shaft sealing ring of selector drum

Clean the seat for the shaft sealing ring (1).

Install shaft sealing ring (1) with drift (No. 21 4 630) up to the limit position
with the open side (arrow) facing the crankcase.

Follow-up work
Install the potentiometer for gear indicator
Securing gearshift lever
Installing the cover for wiring harness
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

23 12 111 Replacing shaft sealing ring of selector shaft

+ 23 12 621

Core activity
(-) Removing shaft sealing ring of selector shaft

Turn back press-off bolt (A) in puller (No. 24 5 410) .

Position puller (No. 24 5 410) and screw into shaft sealing ring (1) until
hand-tight .
Screw in press-off bolt (A) and remove shaft sealing ring (1) .

(-) Installing shaft sealing ring of selector shaft

Clean the seat for the shaft sealing ring (1).

Cover the gearing of gearshift shaft (2) using suitable auxiliary materials
(e.g. foil).
Install shaft sealing ring (1) with drift (No. 36 3 700) up to the limit position
with the open side (arrow) facing the crankcase.
Remove auxiliary materials (e.g. foil).

Follow-up work
Securing gearshift lever
Installing the cover for wiring harness
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

23 14 006 Removing/installing shift assistant

+ 23 14 509
Equipment trim-level variant:

0222 - Shift assistant ProOE

NOTICE
If the Gear Shift Assistant is not taught in, the gear indicator will flash (for
example, after initial operation).
After successful learning in, the fault display goes out.

Remove retaining clip (1).

Release gearshift rod (2) from ball head (3), checking sealing washer (4).

Unlock plug connection (1) for shift assistant and disconnect.

Remove retaining clip (2).
Release gearshift rod (3) from ball head (4) and remove.

(-) Installing shift assistant

Insert gearshift rod (3) and press on ball head (4).

Install retaining clip (2).
Connect and lock plug connection (1) for shift assistant.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Secure gearshift rod (2) to gearshift lever (3), checking sealing washer (4).
Install retaining clip (1).

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

23 14 051 Replacing potentiometer for gear indicator

+ 23 14 507

Core activity
(-) Removing potentiometer for gear indicator

Disconnect plug (1) for the potentiometer for the gear indicator.
Remove screws (2), push gearshift lever (3) up if necessary.
Remove potentiometer (4) for the gear indicator, paying attention to the O-
ring (5) .

(-) Install the potentiometer for gear indicator

Check O-ring (5) for damage; replace if necessary.

Lubricate O-ring (5) and install on potentiometer (4) for gear indicator.

Installation tool
Silicone spray 83 19 2 208 609

Position potentiometer (4) for the gear indicator, paying attention to the O-
ring (5) .
Install screws (2), push gearshift lever (3) up if necessary.

Tightening torques
Potentiometer for gear indicator to crankcase
M5 x 14 5 Nm

Connect plug (1) for the potentiometer for the gear indicator.

Follow-up work
Installing the cover for wiring harness
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

23 21 503 Removing/installing transmission shafts (engine removed)

Preparatory work
Removing holder for front silencer
Removing the spacer bush
Securing engine to assembly stand
Removing engine guard
Removing bracket for front engine guard
Removing bracket for rear engine guard
Removing pivot mount with side stand
Removing chain drop guard
Removing gear selector lever
Removing potentiometer for gear indicator
Removing screw plug (crankshaft)
Removing right crankcase cover
Remove the pressure plate
Removing clutch pushrod
Removing lined plates
Removing clutch hub
Removing clutch basket
Removing left crankcase cover
Removing oil pan
Removing oil pump
Removing lower section of engine housing
Removing locking lever
Remove the selector shaft
Removing eccentric to adjust tooth backlash

Core activity
(-) Removing gearbox

Remove screws (1).

Slightly raise bearing (1) and remove shaft sealing ring (2).

052021 BMW Motorrad, UX-VA-4 1/5

BMW-Motorrad - F 850 GS

• Slightly raise bearing (1).

• Pull transmission (2) completely to the side and loosen from engine housing
(3).

• When gear (1) and housing protrusion (arrow) are flush, remove
transmission (2) to the top.

(-) Removing gearbox shafts

• Remove axle (1).

• Remove gearshift forks (2) and (3).
• Release gearshift fork (4).

V--lkt �l='l��I,..........,..._

K81_R23036b

• Pull transmission shafts (1) and (2) evenly out of differential cover (3) and
remove along with gearshift fork (4) and while doing so, selector drum (5)
remains in differential cover (3).
• Remove gearshift fork (4).

052021 BMW Motorrad, UX-VA-4 2/5

BMW-Motorrad - F 850 GS

(-) Installing gearbox shafts

• Insert gearshift fork (4) into transmission input shaft (2).

• Install transmission input shaft (2) and transmission output shaft (1) evenly
together in differential cover (3) while guiding gearshift fork (4) bypassing
the selector drum (5).

• Install gearshift forks (2) and (3) as shown.

• Align gearshift forks (2), (3) and (4).
• Install axle (1).

G)
I�

KB1 _R23036b

(-) Installing gearbox

• Position transmission (1) such that the housing protrusion (Arrow) and gear
(2) align and then insert in engine housing (3).

• Push transmission (1) evenly into engine housing (2) and while doing so, lift
bearing (3) slightly in order to avoid tilting.
>> Lid (4) is positioned up to the limit position (arrow) in engine housing (2).

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS

• Install bolts (1), but do not tighten.

+ 23 31 620

NOTICE
It may be necessary to space the gearshift shaft and locking lever. The
gearshift set includes shims in three thicknesses.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing right crankcase cover
Removing screw plug (crankshaft)
Remove the pressure plate
Removing clutch pushrod
Removing lined plates
Removing clutch hub
Removing clutch basket

Core activity
(-) Removing locking lever

Detach helical coiled spring (1) on locking lever (2).

Remove cylindrical pin (1).

Remove spring sleeve (2), helical coiled spring (3), locking lever (4) and
shim (5).

(-) Installing locking lever

Lubricate the components with engine oil.

Install shim (1), locking lever (2), helical coiled spring (3) and spring sleeve
(4), making sure that they are in the correct position.
Install cylindrical pin (5).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Check
Check locking lever for side clearance (A).
Side clearance between spring sleeve and engine housing

Technical data
Side clearance of 0.1 mm
locking lever

Result:
Minimum side clearance must be maintained, locking lever must not be
jammed
Measure:
Adjust side clearance with a shim (1).
3 thicknesses available.

Attach helical coiled spring (1) to locking lever (2).

Follow-up work
Installing clutch cage
Installing clutch hub
Installing lined plates
Installing clutch pushrod
Installing pressure plate
Installing threaded plug (crankshaft)
Seal right engine housing cover
Installing right crankcase cover
Checking engine oil level
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

23 31 130 Replacing selector shaft

+ 23 31 904

NOTICE
It may be necessary to space the gearshift shaft and locking lever. The
gearshift set includes shims in three thicknesses.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing the cover for wiring harness
Releasing gearshift lever
Removing right crankcase cover
Removing screw plug (crankshaft)
Remove the pressure plate
Removing clutch pushrod
Removing lined plates
Removing clutch hub
Removing clutch basket
Removing locking lever

Core activity
(-) Remove the selector shaft

Release latch (1) from shift star (2).

Remove gearshift shaft (3) with thrust washer (4).

(-) Installing selector shaft

Install gearshift shaft (3) with shim (4).

Position latch (1) on shift star (2).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Check the mounting orientation of spring (1) and latch (2) and adjust it if
necessary.

Check
Result:
Installation position of the components is not OK.
Measure:
Position latch (2) correctly on shift star (3).
Check the mounting orientation of spring (1). The spring engages in the
recess (arrow) of latch (2).

Check

Check latch for ease of movement:

Turn gearshift shaft in shift direction by hand and pretension lightly.

Lift latch off shift star. Latch must snap back by spring force.
Twist gearshift shaft in opposite direction, pretension and repeat check.
Result:
Latch does not snap back by spring force.
Measure:
Remove gearshift shaft and install thinner shim.
3 thicknesses available, do not skip increments.

Follow-up work
Installing locking lever
Installing clutch cage
Installing clutch hub
Installing lined plates
Installing clutch pushrod
Installing pressure plate
Installing threaded plug (crankshaft)
Seal right engine housing cover
Installing right crankcase cover
Securing gearshift lever
Installing the cover for wiring harness
Checking engine oil level
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

23 31 502 Replacing shift forks (engine removed)

Preparatory work
Removing holder for front silencer
Removing the spacer bush
Securing engine to assembly stand
Removing engine guard
Removing bracket for front engine guard
Removing bracket for rear engine guard
Removing pivot mount with side stand
Removing chain drop guard
Removing gear selector lever
Removing potentiometer for gear indicator
Removing screw plug (crankshaft)
Removing right crankcase cover
Remove the pressure plate
Removing clutch pushrod
Removing lined plates
Removing clutch hub
Removing clutch basket
Set engine to TDC and install alignment pin
Removing left crankcase cover
Removing oil pan
Removing oil pump
Removing lower section of engine housing
Removing locking lever
Remove the selector shaft
Removing eccentric to adjust tooth backlash
Removing gearbox

Core activity
(-) Remove the shift forks

Remove axle (1).

Remove gearshift forks (2) and (3).
Release gearshift fork (4).

Pull transmission shafts (1) and (2) evenly out of differential cover (3) and
remove along with gearshift fork (4) and while doing so, selector drum (5)
remains in differential cover (3).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Remove gearshift fork (4).

(-) Installing shift forks

Insert gearshift fork (4) in transmission input shaft (2).

Install transmission input shaft (2) and transmission output shaft (1) together
evenly in differential cover (3) and while doing so, bypass gearshift fork (4)
on selector drum (5).

Install gearshift forks (2) and (3) as shown.

Align gearshift forks (2), (3) and (4).
Install axle (1).

Follow-up work
Installing gearbox
Installing selector shaft
Installing locking lever
Installing the lower section of the engine housing
Removing locating pin
Installing oil pump
Installing oil pan
Installing left crankcase cover
Adjusting tooth backlash of clutch basket
Installing clutch cage
Installing clutch hub
Installing lined plates

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Installing clutch pushrod
Installing pressure plate
Installing right crankcase cover
Installing threaded plug (crankshaft)
Installing shaft sealing ring of output shaft
Install the potentiometer for gear indicator
Installing gear selector lever
Installing chain drop guard
Installing pivot mount with side stand
Installing bracket for rear engine guard
Installing bracket for front engine guard
Installing engine guard
Removing engine from assembly stand
Installing the spacer bush
Installing holder for front silencer

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

23 31 626 Replacing shift drum (engine removed)

Preparatory work
Removing holder for front silencer
Removing the spacer bush
Securing engine to assembly stand
Removing engine guard
Removing bracket for front engine guard
Removing bracket for rear engine guard
Removing pivot mount with side stand
Removing chain drop guard
Removing gear selector lever
Removing potentiometer for gear indicator
Removing screw plug (crankshaft)
Removing right crankcase cover
Remove the pressure plate
Removing clutch pushrod
Removing lined plates
Removing clutch hub
Removing clutch basket
Set engine to TDC and install alignment pin
Removing left crankcase cover
Removing oil pan
Removing oil pump
Removing lower section of engine housing
Removing locking lever
Remove the selector shaft
Removing eccentric to adjust tooth backlash
Removing gearbox

Core activity
(-) Removing the selector drum with the differential cover

Remove axle (1).

Remove gearshift forks (2) and (3).
Release gearshift fork (4).

Pull transmission shafts (1) and (2) evenly out of differential cover (3) and
remove along with gearshift fork (4) and while doing so, selector drum (5)
remains in differential cover (3).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Remove gearshift fork (4).

(-) Installing the selector drum with the differential cover

Insert gearshift fork (4) in transmission input shaft (2).

Install transmission input shaft (2) and transmission output shaft (1) together
evenly in differential cover (3) and while doing so, bypass gearshift fork (4)
on selector drum (5).

Install gearshift forks (2) and (3) as shown.

Align gearshift forks (2), (3) and (4).
Install axle (1).

052021 BMW Motorrad, UX-VA-4 2/3

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

23 41 300 Removing/installing or replacing gearshift lever

+ 23 41 551

Preparatory work
Releasing lower gearshift rod

Core activity
(-) Removing gearshift lever

Remove shouldered bushing (1), counter-holding screw (2).

Remove gearshift lever (3) and washer (4).

(-) Replacing gearshift lever

Install new bearing bush (1) in gearshift lever (2).

Remount sealing washer (3) from the old to the new gearshift lever (1) and
renew it if necessary.

(-) Installing gearshift lever

ATTENTION
Damage of the bearing due to lubricants.
Component damage, stiff movement
Lubricants can damage the coating chemically.
Lubricant bind dirt particles and increase the wear by this.
A PTFE-bearing is maintenance free; do not lubricate the bearing.

Cleaning components.
Position shouldered bushing (1) , gearshift lever (3) and washer (4), counter-
holding screw (2).
Tighten shouldered bushing (1), counter-holding screw (2).

Tightening torques
Gearshift lever to footrest plate
M8 x 25 19 Nm
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS

Follow-up work
Securing lower gearshift rod
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

23 41 325 Replacing selector rod on pedals

+ 23 41 555

Remove retaining clip (1).

Release gearshift rod (2) from ball head (3), checking sealing washer (4).

Remove retaining clip (1).

Release gearshift rod (2) from ball head (3) and remove.

(-) Replacing selector rod

Adjust gearshift rod according to used part.

Tightening torques
Ball joint to shift rod
Locknut, M6 8 Nm

(-) Installing shift rod

Insert gearshift rod (2) and press on ball head (3).

Install retaining clip (1).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Secure gearshift rod (2) to gearshift lever (3), checking sealing washer (4).
Install retaining clip (1).

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

23 41 329 Replacing shift lever on selector shaft

+ 23 41 556

Core activity
(-) Removing gear selector lever

Remove bolt (1).

Release gearshift lever (2) from gearshift shaft (3) and remove.

(-) Installing gear selector lever

Push gearshift lever (1) on gearshift shaft (2).

Mark (arrow) on gearshift shaft (2) is aligned with the gap of gearshift lever
(1).
Install bolt (3).

Tightening torques
Selector lever to selector shaft
M6 x 25 8 Nm

Follow-up work
Securing selector rod
Installing the cover for wiring harness
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

Wheels - Suspensions - Brakes

Repair Guide

BMW Motorrad
BMW-Motorrad - F 850 GS

31 42 005 Oil change in telescopic front forks

+ 31 42 899

Preparatory work
Placing motorcycle on rear-wheel stand
Installing engine lifter
Removing left brake caliper
Remove the right brake caliper
Removing front wheel
Removing bottom front-wheel cover
Disengaging front wheel-speed sensor
Releasing brake hose to front suspension
Removing the fork partition
Removing steering damper
Slackening left and right fork lid
Removing left and right fork legs

Core activity
(-) Draining oil from left fork leg

Firmly and repeatedly compress the fork leg to free any dirt that may be
inside.
Install fixture (No. 31 3 715) into pre-tensioning tool (No. 31 3 712).
Insert fork leg (1) in pre-tensioning tool (No. 31 3 712).
Secure fork leg (1) with rubber retainer (A).

Unscrew lid (1) fully with special wrench SW32 (No. 31 1 528) and special
wrench mounting (No. 31 1 529) from fixed fork tube (2) and carefully lower
fixed fork tube (2).
Loosen lock nut (3), counter-holding it to lid (1).
Remove the lid (1).

Lower fixed fork tube completely.

Position piece of wood (1) between piston rod (2) and press-down tool (A).
Turn down spindle (B) with press-down tool (A) until the snap ring (3) is
tension-free.
Remove snap ring (3) with a suitable tool.
Remove piece of wood (1) between piston rod (2) and press-down tool (A).

052021 BMW Motorrad, UX-VA-4 1/10

BMW-Motorrad - F 850 GS

• Loosen rubber retainer (A).

• Remove fork leg (1) from pre-tensioning tool (No. 31 3 712), noting
mounting (No. 31 3 715).

-- · --.....,
• Remove support disc (1), piston rod (2), spring (3), support disc (4) and
spacer pipe (5).
/
/
/

--- K81_R31017b

.- ATTENTION
Sharp-edged vent hole in the slider tube
Damage to the radial shaft seal in the fixed fork tube
• Do not pull the slider tube out of the fixed fork tube past the as-installed
position.

• Carefully turn around the fork leg and empty the oil into a suitable collection
container without exposing bore holes (arrows) of slider tube (1).

KB1_R31018b

(-) Pouring oil into left fork leg

• Carefully lower fixed fork tube (1).

• Fill oil slowly in slider tube (2).

I
ID Technical data

052021 BMW Motorrad, UX-VA-4 2/10

1
BMW-Motorrad - F 850 GS
Fork oil, capacity of
left fork leg
I approx. 660 ml I
Telescopic fork oil (Telescopic fork oil, type 4)

• Allow the oil to settle for a few minutes.

K81_R31019b

• Place the fork leg vertical.

• Adjust the correct oil level on filler dipstick (No. 31 6 551), inserting filler
dipstick in telescopic forks (1) and draw off the excess fork oil.

!] Technical data
Level of fork oil in left Fork fully 140 mm
fork leg (air chamber) compressed,
compression
spring and
spacer
removed
R13_R31241c Telescopic fork oil (Telescopic fork oil, type 4)

• Position support disc (1) on spacer pipe (2) and install in fork leg (3).
o---G) >> Shoulder (arrow) of support disc (1) shows the direction of fork leg (3).
,,,,

K81_R31021b

• Install spring (1), piston rod (2) and support disc (3) in fork leg (4).
» Shoulder (arrow) of support disc (3) faces up.

K81_R31022b

• Insert fork leg (1) in pre-tensioning tool (No. 31 3 712), positioning it on

mounting (No. 31 3 715).
• Secure fork leg (1) with rubber retainer (A).

052021 BMW Motorrad, UX-VA-4 3/10

BMW-Motorrad - F 850 GS

• Position piece of wood (1) between piston rod (2) and press-down tool (A).
• Turn down spindle (B) with press-down tool (A) until snap ring (3) can be
inserted.
• Install snap ring (3) with a suitable tool.
• Remove piece of wood (1) between piston rod (2) and press-down tool (A).

• Screw lock nut (1) up to the limit position on the piston rod (2).
• Check the O-ring (arrow) for damage; replace if necessary.
• Lubricate O-ring (arrow) with oil.
• Install lid (3) and lock with lock nut (1).

"'",Tightening torques
Locknut to cover
120 Nm
I
• Lift fixed fork tube (4) and tighten lid (3) with special wrench SW32 (No. 31 1
528) and special wrench mounting (No. 31 1 529) in fixed fork tube (4) until
hand-tight.
• Loosen rubber retainer (A).
• Remove fork leg (1) from pre-tensioning tool (No. 31 3 712), noting
mounting (No. 31 3 715).

(-) Drain the oil from right fork leg

• Firmly and repeatedly compress the fork leg to free any dirt that may be
inside.
• Screw out lid (1) fully with special wrench (No. 31 1 528) SW32 and special
wrench mounting (No. 31 1 529) and carefully lower fixed fork tube (2).

052021 BMW Motorrad, UX-VA-4 4/10

BMW-Motorrad - F 850 GS
• Empty the oil from the fork leg in a suitable collection container.

• Install fixture (No. 31 3 715) into pre-tensioning tool (No. 31 3 712).

• Insert fork leg (1) in pre-tensioning tool (No. 31 3 712).
• Secure fork leg (1) with rubber retainer (A).

• Rotate hold-down tool (A) out of pre-tensioning tool (No. 31 3 712)and

position it.
• Position short mountings (B) in bore holes (arrows) of bush (1) with knurled
screws (C).

• Press bush (1) down with press-down tool (A) and spindle (B) out of pre
tensioning tool (No. 31 3 712).
• Push lid (2) up and remove support disc (3).

• Counter-hold lid (1) with special wrench (No. 31 1 528) SW32 and special
wrench mounting (No. 31 1 529) and loosen lock nut (2).
• Remove the lid (1).

052021 BMW Motorrad, UX-VA-4 5/10

BMW-Motorrad - F 850 GS

• Rotate hold-down tool (A) with spindle (B) out of pre-tensioning tool (No. 31
3 712) in the reverse direction.
• Remove spindle (B) from pre-tensioning tool (No. 31 3 712) .
• Remove press-down tool (A) with mountings (C) and bush (1) from pre
tensioning tool (No. 31 3 712).

• Disengage pre-tensioning tool (No. 31 3 712) and relieve tension.

• Loosen rubber retainer (A) and remove fork leg (1) from mounting (No. 31 3
715).

• Remove spring (1).

KB1_R31030b

_. ATTENTION
Sharp-edged vent hole in the slider tube
Damage to the radial shaft seal in the fixed fork tube
• Do not pull the slider tube out of the fixed fork tube past the as-installed
position.

052021 BMW Motorrad, UX-VA-4 6/10

BMW-Motorrad - F 850 GS
• Carefully turn around the fork leg and empty the oil into a suitable collection
container without exposing bore holes (arrows) of slider tube (1).

K81_R31032b

• Clamp fork leg (1) to brake caliper mounting (2) in a vice with vice jaw
protectors.

CD / • Remove bolt (3) with sealing ring (4), pressing damper unit (5) to prevent it
from rotating.

. ·· ® • Remove damper unit (5) with centering plate (6) and drain damper unit (5)
by pumping.

·'°l.v/ ®

(-) Pouring oil into right fork leg

• Clean thread in bottom damper unit (5).

• Position damper unit (5) with centering plate (6) in fork leg (1).
• Install bolt (3) with a new sealing ring (4).

'""'!Tightening torques
Damper unit to forkleg
M8 x 22 20 Nm
Thread-locking compound (Loctite
243, Medium strength)

• Take out brake caliper mounting (2) of the fork leg (1) from vice.
• Carefully lower fixed fork tube (1).
• Fill oil slowly in slider tube (2).

!] Technical data
Fork oil, capacity of
right fork leg
I approx. 557 ml I
Telescopic fork oil (Telescopic fork oil, type 4)

• Move the piston rod (3) of the damper unit up and down several times.
>> The damper unit is filled with oil and is bled.
• Allow the oil to settle for a few minutes.
• Repeat the procedure until the oil is free of bubbles and the oil level no
longer changes.
• Lower piston rod (1).
• Place the fork leg vertical.

052021 BMW Motorrad, UX-VA-4 7/10

BMW-Motorrad - F 850 GS
Adjust the correct oil level on filler dipstick (No. 31 6 551), inserting filler
dipstick in the telescopic forks and draw off the excess fork oil.

!] Technical data
Level of fork oil in Forks fully 132 mm
right fork leg (air compressed
chamber) and damper
unit bled,
316551 compression
spring
removed
Telescopic fork oil (Telescopic fork oil, type 4)
K16_R31014b

• Install spring (1).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS
(-) Replacing top fork bridge

• Punch-mark shear screws (1) in the centre (arrows).

• First pre-drill shear screws (1) with a small drill and then drill them out with
a larger drill.

!] Technical data
Ignition (Pilot) hole min 10 mm
switch/steering lock - diameter 2 mm
drilling depth for
drilling out tamper- Hole 10 mm
proof shear screws diameter 5 mm

• Heat the area around the thread of shear screws (1) without overheating the
ignition steering lock.

!}
I I
Technical data
Release/mating 80 °C
1
tern perature

• Remove shear screws (1) with a suitable screw extractor.

• Remove ignition steering lock (2).

• Position ignition steering lock (1) on new fork bridge (2).

• Install shear screws (3) and tighten until the tool engagement (arrow) tears
off head (4).

•�Tightening torques
Ignition/steering lock to fork bridge
M8 x 18, Replace screw Tighten bolt until tool
Thread-locking compound (micro- handle shears off.
encapsulated)

(-) Installing top fork bridge

• ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
• Take care not to scratch components; cover or mask as necessary.

• Clean the threads.

• Apply screw locking agent on steering-head screw (1) all around in the area
shown.

!] Technical data
Screw lock on A: Width on approx. 10 mm
steering-head screw thread
B: Distance approx. 3 mm
from end of
thread
052021 BMW Motorrad, UX-VA-4 2/4
BMW-Motorrad - F 850 GS

Thread-locking compound
Loctite 243, Medium strength 183 19 2 210 339

• Lubricate steering-head screw (1) at the bottom of the head (arrow)

lightly.

Lubricant
Kluberplex Fluoropan T PTFE 183 23 0 154 884

• Position fork bridge (2).

• Lay the handlebars towards the rear on the fuel tank.
• Connect plug (3) for the ignition steering lock.
• Secure cable clip (1) on fork bridge (2).
• Secure the cable strap (arrow).

• Position holder (2) and install bolt (1).

• Lay the handlebars towards the front and fit fork bridge (3).
.- ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
• Take care not to scratch components; cover or mask as necessary.

• Cover steering-head screw (2) to prevent scratches and install with

hexagon socket nut without collar.

�Tightening torques
Fork bridge, top, to steering tube
M28 x 1.5 130 Nm
Secure thread in the lower area,
Thread-locking compound (Loctite
243, Medium strength)
Lubricate at the bottom of the head
lightly , Lubricant (Kluberplex
Fluoropan T PTFE)

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
• Install clamping bolts (1 ).

�Tightening torques
Fork bridge, top, to fork fixed tube
M8 x35 119 Nm I
Follow-up work
Securing handlebars
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

31 42 029 Replace lower fork bridge

+ 31 42 527

Preparatory work
Placing motorcycle on rear-wheel stand
Disengaging top fork bridge
Installing engine lifter
Removing left brake caliper
Remove the right brake caliper
Removing front wheel
Removing bottom front-wheel cover
Disengaging front wheel-speed sensor
Releasing brake hose to front suspension
Removing the fork partition
Removing steering damper
Removing left and right fork legs
Remove the bottom fork bridge
Removing top steering-head bearing
Removing outer races for top and bottom steering-head bearings

Core activity
(-) Replace the bottom fork bridge

Install new dust cap (1).

Heat inner ring (2).

Technical data
Release/mating 80 °C
temperature

ATTENTION
Installation of the inner ring of the steering-head bearing not in
compliance with correct procedure
Damage to the inner ring
Use a suitable tool, do not subject the tyre tread of the inner ring to load.

Install inner ring (2) with suitable pipe to the limit position.
Remount screws (1) from the old to the new fork bridge (2), but do not
tighten them.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Follow-up work
Installing outer races for top and bottom steering-head bearings
Installing top steering-head bearing
Installing bottom fork bridge
Installing left and right fork legs
Securing top fork bridge
Adjust the fork-tube projection
Tightening steering-head screw and clamping bolts
Installing steering damper
Installing the fork partition
Securing brake hose to front suspension
Securing front wheel-speed sensor
Installing bottom front-wheel cover
Install the front wheel
Removing engine lifter
Removing motorcycle from rear-wheel stand
Securing right brake caliper
Securing left brake caliper
Bedding in brake pads
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

31 42 321 Replacing both steering-head bearings

+ 31 42 879

NOTICE
When the steering-head bearing has been replaced, the new bearing has to
be checked for play after approx. 1000 km and, if necessary, adjusted.

Core activity
(-) Removing top steering-head bearing

Remove cover plate (1).

Remove inner ring (2) and ball cage (3).

(-) Removing outer races for top and bottom steering-head

bearings

Remove top outer ring (1) and bottom outer ring (2) by tapping with a
suitable tool at the recesses (arrows) and taking care to proceed
uniformly.

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

(-) Removing inner race for bottom steering-head bearing

• Clamp the handlebar tube (1) in a vice, while doing so, place a block of
wood (2) as protection between the handlebar tube and face.
• ATTENTION
Driving out steering-head bearing with a punch that is too small
Damage to fork bridge
• Use a punch that is a snug fit the hole.

• Use a punch to remove dust cap (3) and inner ring (4) taking care to prevent
the inner ring from tilting by alternating from one bore hole to the other.

!] Technical data
Diameter (A) of
punch
I 1
4mm
I
(-) Installing inner race for bottom steering-head bearing

• Install new dust cap (1).

• Heat inner ring (2).

!] Technical data
Release/mating
tern perature

.- ATTENTION
I 180 °C
I
Installation of the inner ring of the steering-head bearing not in
compliance with correct procedure
K80_R31021b
Damage to the inner ring
• Use a suitable tool, do not subject the tyre tread of the inner ring to load.

• Install inner ring (2) with suitable pipe to the limit position.

(-) Installing outer races for top and bottom steering-head

bearings

• Clean the bearing seats.

• From below, position long spindle (No. 36 5 551), pressure disc with thread
55 mm and 45 mm (No. 36 5 553) and outer ring (1).
• From above, position pressure disc without thread 55 mm (No. 36 5 554)
and pull-in nut (2) and install steering-head bearing outer ring (1) until
seated.

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
• Remove the tools and turn them round the other way.
• Install upper outer ring (3) in the same way, use 60 mm shim at bottom.

(-) Installing top steering-head bearing

• Lubricate sealing lip (1) of cover plate (2).

Lubricant
Acid-free friction-bearing grease I a1 22 9 407 17 4

K53_R31023b

• Clean the frame at the steering head, top.

• Lubricate and install ball cage (3).

CD Lubricant
Acid-free friction-bearing grease 1 a1 22 9 407 174
• Install inner ring (2).
• Lay cover plate (1) in position.

K80_R31018b

Follow-up work
Installing bottom fork bridge
Installing left and right fork legs
Securing top fork bridge
Adjust the fork-tube projection
Tightening steering-head screw and clamping bolts
Installing steering damper
Installing the fork partition
Securing brake hose to front suspension
Securing front wheel-speed sensor
Installing bottom front-wheel cover
Install the front wheel
Removing engine lifter

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Removing motorcycle from rear-wheel stand
Securing right brake caliper
Securing left brake caliper
Bedding in brake pads
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

31 42 341 Removing/installing left fork leg

+ 31 42 841

NOTICE
During the replacement, any installed reflectors must be re-installed in the
same position.

Core activity
(-) Loosening the left fork lid

NOTICE
If the fork legs are going to be disassembled for further work, the fork caps
have to be slackened beforehand prior to removal of the assembly.

Loosen bolt (1).

Loosen screws (2).
Pull fork leg (3) down slightly.
Tighten the screws (2).

Loosen lid (1) with special wrench SW32 (No. 31 1 528) and special wrench
fixture (No. 31 1 529).

(-) Removing left fork leg

Loosen screws (1).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Remove fork leg (2) downwards.
NOTICE
Do not lay down or turn over removed fork legs in order to prevent air from
entering the damping system. Store upright.

(-) Secure the left fork cap

Insert the fork leg (2), the fork cap must be accessible.
Tighten screws (1).

Tighten lid (1) with special wrench SW32 (No. 31 1 528) and special wrench
fixture (No. 31 1 529).

Tightening torques
Cover to fixed fork tube
35 Nm

(-) Installing left fork leg

NOTICE
Align the fork legs so that the reflectors are facing out.

Secure fork leg (2) and loosen screws (1).

Slide in fork leg (2) and adjust fork-tube projection.

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Information for setting fork-tube projection
Fork-tube projection is correct when the groove (arrow) of the fork leg (1)
and upper edge (arrow) of top fork bridge (2) are flush with each other.

Install fork leg (1) from the bottom and adjust fork-tube projection (arrow).

Technical data
Projection of fork tube Groove flush with top
in fork bridge, top edge of fork bridge

Tighten the screws (2).

Tightening torques
Fork bridge, bottom, to fork fixed tube
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence

19 Nm

Tighten the screw (3).

Tightening torques
Fork bridge, top, to fork fixed tube
M8 x 35 19 Nm

Follow-up work
Securing fork partition
Installing bottom front-wheel cover
Install the front wheel
Securing right brake caliper
Securing left brake caliper
Bedding in brake pads
Securing front wheel-speed sensor
Removing engine lifter
Removing motorcycle from rear-wheel stand
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

31 42 342 Removing/installing right fork leg

+ 31 42 842

NOTICE
During the replacement, any installed reflectors must be re-installed in the
same position.

Preparatory work
Placing motorcycle on rear-wheel stand
Installing engine lifter
Removing left brake caliper
Remove the right brake caliper
Removing front wheel
Removing bottom front-wheel cover
Releasing brake-hose distributor
Releasing fork partition
Removing steering damper

Core activity
(-) Loosening the right fork lid

NOTICE
If the fork legs are going to be disassembled for further work, the fork caps
have to be slackened beforehand prior to removal of the assembly.

Loosen bolt (1).

Loosen screws (2).
Pull fork leg (3) down slightly.
Tighten the screws (2).

Loosen lid (1) with special wrench SW32 (No. 31 1 528) and special wrench
fixture (No. 31 1 529).

(-) Removing right fork leg

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Loosen screws (1).
Remove fork leg (2) downwards.
NOTICE
Do not lay down or turn over removed fork legs in order to prevent air from
entering the damping system. Store upright.

(-) Secure right fork cap

Insert the fork leg (2), the fork cap must be accessible.
Tighten screws (1).

Tighten lid (1) with special wrench SW32 (No. 31 1 528) and special wrench
fixture (No. 31 1 529).

Tightening torques
Cover to fixed fork tube
35 Nm

(-) Install the right fork leg

NOTICE
Align the fork legs so that the reflectors are facing out.

Secure fork leg (2) and loosen screws (1).

Slide in fork leg (2) and adjust fork-tube projection.

052021 BMW Motorrad, UX-VA-4 2/3

Install fork leg (1) from the bottom and adjust fork-tube projection (arrow).

Technical data
Projection of fork tube Groove flush with top
in fork bridge, top edge of fork bridge

Tighten the screws (2).

Tightening torques
Fork bridge, bottom, to fork fixed tube
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence

19 Nm

Tighten the screw (3).

Tightening torques
Fork bridge, top, to fork fixed tube
M8 x 35 19 Nm

Follow-up work
Securing steering damper
Securing fork partition
Securing brake-hose distributor
Installing bottom front-wheel cover
Install the front wheel
Securing right brake caliper
Securing left brake caliper
Bedding in brake pads
Removing engine lifter
Removing motorcycle from rear-wheel stand
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

31 42 514 Adjusting steering-head bearing (with checking steering-head bearing)

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Disengaging top fork bridge

Core activity
(-) Adjusting steering-head bearing

Requirement
Motorcycle's front wheel is on a firm, level surface.

NOTICE
The steering head screw must be installed with the screw lock, follow the
repair manual.

Remove lock plate (1).

Remove slotted nut (2) with pin wrench (No. 31 3 721) and adapter (No. 31
3 723) and rubber washer (3).
Adjust the steering-head bearing at slotted nut (4) with pin wrench (No. 31 3
721) and adapter (No. 31 3 723) and install rubber washer (3) and slotted
nut (2) with pin wrench (No. 31 3 721) and adapter (No. 31 3 723).

Tightening torques
Adjusting steering-head bearing (for maintenance)
Bottom slotted nut, M35 x 1 (forks turned fully to
right), 15 Nm
Rubber washer
Top slotted nut, M35 x 1 Tightening torque,
Secure with circlip 1 Nm
turn further until
circlip can be installed

Ensure that the grooves (arrows) of the slotted nuts (2) and (4) align.
Install lock plate (1).

Follow-up work
Securing top fork bridge

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

31 42 516 Disassembling and assembling left fork fork leg (fork leg removed)

Core activity
(-) Draining oil from left fork leg

Position piece of wood (1) between piston rod (2) and press-down tool (A).
Turn down spindle (B) with press-down tool (A) until the snap ring (3) is
tension-free.
Remove snap ring (3) with a suitable tool.
Turn press down tool (A) to the top.
Remove piece of wood (1) between piston rod (2) and press-down tool (A).

Loosen rubber retainer (A).

Remove fork leg (1) from pre-tensioning tool (No. 31 3 712), noting
mounting (No. 31 3 715).

052021 BMW Motorrad, UX-VA-4 1/6

BMW-Motorrad - F 850 GS
Remove support disc (1), piston rod (2), spring (3), support disc (4) and
spacer pipe (5).
Turn the fork leg over carefully and empty oil in a suitable collection
container.

(-) Removing fixed fork tube

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Loosen dust boot (1) with a suitable tool.

Loosen circlip (2).
Remove slider tube (3) from fixed fork tube (4) with a firm tug.

(-) Removing seal of fork leg

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Spread upper sliding bush (1) and lower sliding bush (2) slightly using a
suitable tool and remove them.
Remove support disc (3), fork sealing ring (4), circlip (5) and dust boot (6).

(-) Installing seal of fork leg

Oil the inner sealing lips of sealing ring (1) lightly.

Note the mounting orientation and while doing so, ensure that the protruding
sealing lip (Arrow) points in the direction of the dust boot.

052021 BMW Motorrad, UX-VA-4 2/6

BMW-Motorrad - F 850 GS

Clean the slider tube.

Slip bag (1) over the slider tube so that the new sealing ring is not damaged
by sharp edges.
Slide dust boot (2) and circlip (3).
Slide sealing ring (4).
Remove bag (1).

Lubricate components with fork oil.

Push the support disc (1) and the top sliding bush (2) onto slider tube (3).
Slightly spread the bottom sliding bush (4) and install in bead (Arrow) of
slider tube (3).

(-) Install the fixed tube

Carefully slide the fixed fork tube (1) onto the slider tube (2).
Install sliding bush (3), contact disc (4) and sealing ring (5) with impact bush
(No. 31 3 691).

Check circlip (1) for damage and corrosion, replace if required.

Lubricate circlip (1) and install and while doing so, ensure the correct
seating in the groove (Arrow) of fixed fork tube (2).

052021 BMW Motorrad, UX-VA-4 3/6

BMW-Motorrad - F 850 GS

Lubricant
Acid-free friction-bearing grease 81 22 9 407 174

Turn impact bush (No. 31 3 691) over and install a new dust boot (3) into
the fixed fork tube (2).

(-) Pouring oil into left fork leg

Carefully lower fixed fork tube (1).

Fill oil slowly in slider tube (2).

Technical data
Fork oil, capacity of approx. 660 ml
left fork leg Telescopic fork oil (Telescopic fork oil, type 4)

Allow the oil to settle for a few minutes.

Place the fork leg vertical.

Adjust the correct oil level on filler dipstick (No. 31 6 551), inserting filler
dipstick in telescopic forks (1) and draw off the excess fork oil.

Technical data
Level of fork oil in left Fork fully 140 mm
fork leg (air chamber) compressed,
compression
spring and
spacer
removed
Telescopic fork oil (Telescopic fork oil, type 4)

Position support disc (1) on spacer pipe (2) and install in fork leg (3).
Shoulder (arrow) of support disc (1) shows the direction of fork leg (3).

Install spring (1), piston rod (2) and support disc (3) in fork leg (4).
Shoulder (arrow) of support disc (3) faces up.

052021 BMW Motorrad, UX-VA-4 4/6

BMW-Motorrad - F 850 GS

Insert fork leg (1) in pre-tensioning tool (No. 31 3 712), positioning it on

mounting (No. 31 3 715).
Secure fork leg (1) with rubber retainer (A).

Position piece of wood (1) between piston rod (2) and press-down tool (A).
Turn down spindle (B) with press-down tool (A) until snap ring (3) can be
inserted.
Install snap ring (3) with a suitable tool.
Turn press down tool (A) to the top.
Remove piece of wood (1) between piston rod (2) and press-down tool (A).

Install stop pad (1).

Screw lock nut (2) up to the limit position on the piston rod (3).
Check the O-ring (arrow) for damage; replace if necessary.
Lubricate O-ring (arrow) with oil.
Install lid (4) and lock with lock nut (2).

Tightening torques
Locknut to cover
20 Nm

Lift fixed fork tube (5) and tighten lid (3) with special wrench SW32 (No. 31 1
528) and special wrench mounting (No. 31 1 529) in fixed fork tube (5) until
hand-tight.
Loosen rubber retainer (A).
Remove fork leg (1) from pre-tensioning tool (No. 31 3 712), noting
mounting (No. 31 3 715).

052021 BMW Motorrad, UX-VA-4 5/6

BMW-Motorrad - F 850 GS

052021 BMW Motorrad, UX-VA-4 6/6

BMW-Motorrad - F 850 GS

31 42 517 Disassembling and assembling right fork fork leg (fork leg removed)

Core activity
(-) Drain the oil from right fork leg

Rotate hold-down tool (A) out of pre-tensioning tool (No. 31 3 712)and

position it.
Position short mountings (B) in bore holes (arrows) of bush (1) with knurled
screws (C).

Press bush (1) down with press-down tool (A) and spindle (B) out of pre-
tensioning tool (No. 31 3 712).
Push lid (2) up and remove support disc (3).

Counter-hold lid (1) with special wrench (No. 31 1 528) SW32 and special
wrench mounting (No. 31 1 529) and loosen lock nut (2).
Remove the lid (1).

052021 BMW Motorrad, UX-VA-4 1/7

BMW-Motorrad - F 850 GS
Rotate hold-down tool (A) with spindle (B) out of pre-tensioning tool (No. 31
3 712) in the reverse direction.
Remove spindle (B) from pre-tensioning tool (No. 31 3 712) .
Remove press down tool (A) with mountings (C) out of pre-tensioning tool
(No. 31 3 712).
Remove stop pad (1) and bush (2).

Disengage pre-tensioning tool (No. 31 3 712) and relieve tension.

Loosen rubber retainer (A) and remove fork leg (1) from mounting (No. 31 3
715).

Remove spring (1).

Clamp fork leg (1) to brake caliper mounting (2) in a vice with vice jaw
protectors.
Remove bolt (3) with sealing ring (4), pressing damper unit (5) to prevent it
from rotating.
Remove damper unit (5) with centering plate (6) and drain damper unit (5)
by pumping.

(-) Removing fixed fork tube

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

052021 BMW Motorrad, UX-VA-4 2/7

BMW-Motorrad - F 850 GS
Loosen dust boot (1) with a suitable tool.
Loosen circlip (2).
Remove slider tube (3) from fixed fork tube (4) with a firm tug.

(-) Removing seal of fork leg

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Spread upper sliding bush (1) and lower sliding bush (2) slightly using a
suitable tool and remove them.
Remove support disc (3), fork sealing ring (4), circlip (5) and dust boot (6).

(-) Installing seal of fork leg

Oil the inner sealing lips of sealing ring (1) lightly.

Note the mounting orientation and while doing so, ensure that the protruding
sealing lip (Arrow) points in the direction of the dust boot.

Clean the slider tube.

Slip bag (1) over the slider tube so that the new sealing ring is not damaged
by sharp edges.
Slide dust boot (2) and circlip (3).
Slide sealing ring (4).
Remove bag (1).

052021 BMW Motorrad, UX-VA-4 3/7

BMW-Motorrad - F 850 GS

Lubricate components with fork oil.

Push the support disc (1) and the top sliding bush (2) onto slider tube (3).
Slightly spread the bottom sliding bush (4) and install in bead (Arrow) of
slider tube (3).

(-) Install the fixed tube

Carefully slide the fixed fork tube (1) onto the slider tube (2).
Install sliding bush (3), contact disc (4) and sealing ring (5) with impact bush
(No. 31 3 691).

Check circlip (1) for damage and corrosion, replace if required.

Lubricate circlip (1) and install and while doing so, ensure the correct
seating in the groove (Arrow) of fixed fork tube (2).

Lubricant
Acid-free friction-bearing grease 81 22 9 407 174

Turn impact bush (No. 31 3 691) over and install a new dust boot (3) into
the fixed fork tube (2).

(-) Pouring oil into right fork leg

Clean thread in bottom damper unit (5).

Position damper unit (5) with centering plate (6) in fork leg (1).

052021 BMW Motorrad, UX-VA-4 4/7

BMW-Motorrad - F 850 GS
Install bolt (3) with a new sealing ring (4).

Tightening torques
Damper unit to forkleg
M8 x 22 20 Nm
Thread-locking compound (Loctite
243, Medium strength)

Take out brake caliper mounting (2) of the fork leg (1) from vice.

Carefully lower fixed fork tube (1).

Fill oil slowly in slider tube (2).

Technical data
Fork oil, capacity of approx. 557 ml
right fork leg Telescopic fork oil (Telescopic fork oil, type 4)

Move the piston rod (3) of the damper unit up and down several times.
The damper unit is filled with oil and is bled.
Allow the oil to settle for a few minutes.
Repeat the procedure until the oil is free of bubbles and the oil level no
longer changes.
Lower piston rod (1).
Place the fork leg vertical.
Adjust the correct oil level on filler dipstick (No. 31 6 551), inserting filler
dipstick in the telescopic forks and draw off the excess fork oil.

Technical data
Level of fork oil in Forks fully 132 mm
right fork leg (air compressed
chamber) and damper
unit bled,
compression
spring
removed
Telescopic fork oil (Telescopic fork oil, type 4)

Install spring (1).

Position fork leg (1) on mounting (No. 31 3 715) and insert in pre-tensioning
tool(No. 31 3 712).
Secure fork leg (1) with rubber retainer (A).

052021 BMW Motorrad, UX-VA-4 5/7

BMW-Motorrad - F 850 GS

Position bush (1) with press-down tool (A) and mounting (C) in pre-
tensioning tool (No. 31 3 712).
Insert spindle (B) in pre-tensioning tool (No. 31 3 712).
Press bush (1) down with press-down tool (A) and spindle (B) out of pre-
tensioning tool (No. 31 3 712).
Pull piston rod (2) up with magnets.
Install support disc (3) with the curvature (arrow) facing down.
Install stop pad (4).

Check the O-ring (arrow) for damage; replace if necessary.

Lubricate O-ring (arrow).
Install lid (1) and lock with lock nut (2), counter-holding it to the lid with a
special wrench SW32 (No. 31 1 528) and mounting of the special wrench
(No. 31 1 529)c.

Tightening torques
Locknut to cover
20 Nm

Slowly relieve pressure on bush (1) with hold-down tool (A) and spindle (B)
from pre-tensioning tool (No. 31 3 712).
Make sure that bush (1) is correctly seated in lid (2).

Loosen knurled screws (C) and loosen mountings (B) from bore holes
(Arrows) of bush (1).

052021 BMW Motorrad, UX-VA-4 6/7

BMW-Motorrad - F 850 GS

Loosen rubber retainer (A).

Remove fork leg (1) from pre-tensioning tool (No. 31 3 712), noting
mounting (No. 31 3 715).

Lift fixed fork tube (2) and tighten lid (1) with special wrench SW32 (No. 31 1
528) and special wrench mounting (No. 31 1 529) in fixed fork tube (2) until
hand-tight.

052021 BMW Motorrad, UX-VA-4 7/7

BMW-Motorrad - F 850 GS

31 42 902 Changing fluid in telescopic forks (for maintenance)

Core activity
(-) Draining oil from left fork leg

Lower fixed fork tube completely.

052021 BMW Motorrad, UX-VA-4 1/10

BMW-Motorrad - F 850 GS

Loosen rubber retainer (A).

Remove fork leg (1) from pre-tensioning tool (No. 31 3 712), noting
mounting (No. 31 3 715).

Remove support disc (1), piston rod (2), spring (3), support disc (4) and
spacer pipe (5).

ATTENTION
Sharp-edged vent hole in the slider tube
Damage to the radial shaft seal in the fixed fork tube
Do not pull the slider tube out of the fixed fork tube past the as-installed
position.

Carefully turn around the fork leg and empty the oil into a suitable collection
container without exposing bore holes (arrows) of slider tube (1).

(-) Pouring oil into left fork leg

Carefully lower fixed fork tube (1).

Fill oil slowly in slider tube (2).

Technical data

052021 BMW Motorrad, UX-VA-4 2/10

BMW-Motorrad - F 850 GS
Fork oil, capacity of approx. 660 ml
left fork leg Telescopic fork oil (Telescopic fork oil, type 4)

Allow the oil to settle for a few minutes.

Place the fork leg vertical.

Adjust the correct oil level on filler dipstick (No. 31 6 551), inserting filler
dipstick in telescopic forks (1) and draw off the excess fork oil.

Technical data
Level of fork oil in left Fork fully 140 mm
fork leg (air chamber) compressed,
compression
spring and
spacer
removed
Telescopic fork oil (Telescopic fork oil, type 4)

Position support disc (1) on spacer pipe (2) and install in fork leg (3).
Shoulder (arrow) of support disc (1) shows the direction of fork leg (3).

Install spring (1), piston rod (2) and support disc (3) in fork leg (4).
Shoulder (arrow) of support disc (3) faces up.

Insert fork leg (1) in pre-tensioning tool (No. 31 3 712), positioning it on

mounting (No. 31 3 715).
Secure fork leg (1) with rubber retainer (A).

052021 BMW Motorrad, UX-VA-4 3/10

BMW-Motorrad - F 850 GS

Position piece of wood (1) between piston rod (2) and press-down tool (A).
Turn down spindle (B) with press-down tool (A) until snap ring (3) can be
inserted.
Install snap ring (3) with a suitable tool.
Remove piece of wood (1) between piston rod (2) and press-down tool (A).

Screw lock nut (1) up to the limit position on the piston rod (2).
Check the O-ring (arrow) for damage; replace if necessary.
Lubricate O-ring (arrow) with oil.
Install lid (3) and lock with lock nut (1).

Tightening torques
Locknut to cover
20 Nm

Lift fixed fork tube (4) and tighten lid (3) with special wrench SW32 (No. 31 1
528) and special wrench mounting (No. 31 1 529) in fixed fork tube (4) until
hand-tight.
Loosen rubber retainer (A).
Remove fork leg (1) from pre-tensioning tool (No. 31 3 712), noting
mounting (No. 31 3 715).

(-) Drain the oil from right fork leg

Firmly and repeatedly compress the fork leg to free any dirt that may be
inside.
Screw out lid (1) fully with special wrench (No. 31 1 528) SW32 and special
wrench mounting (No. 31 1 529) and carefully lower fixed fork tube (2).

052021 BMW Motorrad, UX-VA-4 4/10

BMW-Motorrad - F 850 GS
Empty the oil from the fork leg in a suitable collection container.

Install fixture (No. 31 3 715) into pre-tensioning tool (No. 31 3 712).

Insert fork leg (1) in pre-tensioning tool (No. 31 3 712).
Secure fork leg (1) with rubber retainer (A).

Rotate hold-down tool (A) out of pre-tensioning tool (No. 31 3 712)and

position it.
Position short mountings (B) in bore holes (arrows) of bush (1) with knurled
screws (C).

Press bush (1) down with press-down tool (A) and spindle (B) out of pre-
tensioning tool (No. 31 3 712).
Push lid (2) up and remove support disc (3).

Counter-hold lid (1) with special wrench (No. 31 1 528) SW32 and special
wrench mounting (No. 31 1 529) and loosen lock nut (2).
Remove the lid (1).

052021 BMW Motorrad, UX-VA-4 5/10

BMW-Motorrad - F 850 GS

Rotate hold-down tool (A) with spindle (B) out of pre-tensioning tool (No. 31
3 712) in the reverse direction.
Remove spindle (B) from pre-tensioning tool (No. 31 3 712) .
Remove press-down tool (A) with mountings (C) and bush (1) from pre-
tensioning tool (No. 31 3 712).

Disengage pre-tensioning tool (No. 31 3 712) and relieve tension.

Loosen rubber retainer (A) and remove fork leg (1) from mounting (No. 31 3
715).

Remove spring (1).

ATTENTION
Sharp-edged vent hole in the slider tube
Damage to the radial shaft seal in the fixed fork tube
Do not pull the slider tube out of the fixed fork tube past the as-installed
position.

052021 BMW Motorrad, UX-VA-4 6/10

BMW-Motorrad - F 850 GS
Carefully turn around the fork leg and empty the oil into a suitable collection
container without exposing bore holes (arrows) of slider tube (1).

(-) Pouring oil into right fork leg

Clean thread in bottom damper unit (5).

Position damper unit (5) with centering plate (6) in fork leg (1).
Install bolt (3) with a new sealing ring (4).

Tightening torques
Damper unit to forkleg
M8 x 22 20 Nm
Thread-locking compound (Loctite
243, Medium strength)

Take out brake caliper mounting (2) of the fork leg (1) from vice.
Carefully lower fixed fork tube (1).
Fill oil slowly in slider tube (2).

Technical data
Fork oil, capacity of approx. 557 ml
right fork leg Telescopic fork oil (Telescopic fork oil, type 4)

052021 BMW Motorrad, UX-VA-4 7/10

BMW-Motorrad - F 850 GS
Adjust the correct oil level on filler dipstick (No. 31 6 551), inserting filler
dipstick in the telescopic forks and draw off the excess fork oil.

Technical data
Level of fork oil in Forks fully 132 mm
right fork leg (air compressed
chamber) and damper
unit bled,
compression
spring
removed
Telescopic fork oil (Telescopic fork oil, type 4)

Install spring (1).

32 71 040 Renewing handlebar

+ 32 71 514

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Remove the left handlebar weight
Releasing handlebar fitting for clutch
removing left grip unit
Removing the right handlebar weight
Disengaging brake fitting for front wheel
Removing right multifunction switch
Removing the throttle twistgrip

Core activity
(-) Removing handlebars

Remove screws (1).

Remove clamping block (2).
Release handlebars (3).

Remove handlebars (1) from grip unit (2).

(-) Installing handlebars

Lubricate the rubber pad (arrow).

Installation tool
Silicone spray 83 19 2 208 609

Slide grip unit (1) onto handlebars (2), checking the rubber element (arrow).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Position handlebars (1) with clamping block (2).

Align handlebars (1) with the marks (arrows).
WARNING
Incorrect tightening sequence of the handlebar clamps.
Handlebars work loose when vehicle is ridden.
Tighten the handlebar clamps to the specified torque and in the specified
sequence.

Install screws (3).

Tightening torques
Handlebar clamping block to fork bridge
M8 x 35 Tightening
sequence: in the
forward direction of
travel, tighten until
seated
19 Nm

Follow-up work
Installing throttle twistgrip
Securing right multifunction switch
Securing brake fitting for front wheel
Installing right handlebar weight
Securing handlebar fitting for clutch
Securing left grip unit
Installing left handlebar weight
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

32 71 053 Replacing left hand protector

+ 32 71 553

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Core activity
(-) Removing left hand protector
Removing left mirror
Release the rubber cover (4).
Remove the left/right adapter (1) and the lock nut (3) with mirror (2).

Remove bolt (1).

Remove bushing (2).
Remove handlebar weight (3).

Remove hand protector(1).

(-) Installing left hand protector

Place hand protector (1) in position.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Install handlebar weight (1).

Install bush (2) with bolt (3).
Position hand protector (4).
Tighten screw (3) making sure that the hand protector (4) does not twist out
of position.

Tightening torques
Handlebar weight to handlebars
M10 x 50 38 Nm

Installing left mirror

Install complete left/right adapter (2) with mirror (3) and washer (4).

Tightening torques
Adapter to clamping block
M10 x 14 - 4.8 25 Nm

Slide rubber cover (1) over screw connection.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

32 72 001 Replacing throttle twistgrip

+ 32 72 620

Core activity
(-) Removing the throttle twistgrip

Remove bolt (1).

Remove throttle grip (2).

(-) Installing throttle twistgrip

Install throttle grip (2).

Install bolt (1).

Tightening torques
Throttle twistgrip to handlebar
M3.5 x 30 2 Nm

Follow-up work
Installing right multifunction switch
Installing right handlebar weight
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

32 72 065 Replacing handlebar fitting for clutch actuation

+ 32 72 626

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Loosen clutch cable from manual controls for clutch control
Removing the cover for wiring harness

Core activity
(-) Removing manual controls for clutch control

Disconnect connector (1) from clutch switch (2).

Remove bolts (3) , clamp (4) and clutch lever fitting (5) .

(-) Installing manual controls for clutch control

Hold clamp (1) and clutch lever fitting (2) in position. Install bolts (3), do not
tighten.
Adjust clutch lever fitting (2) with clamp (1) to mark (arrow).
Tighten the screws (3).

Tightening torques
Clutch lever fitting to handlebar
M6 x 20 Tightening
sequence: tighten
top until fully closed
8 Nm

Connect connector (4) with clutch switch (5).

Follow-up work
Secure clutch cable in manual controls for clutch control
Checking/adjusting clutch play
Installing the cover for wiring harness
Installing the cover for clutch switch
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

32 72 070 Replace clutch lever

+ 32 72 627

Core activity
(-) Removing the cover for clutch switch

Remove cover (1).

(-) Removing clutch lever

Insert adjusting screw (1) and lock nut (2) as far as possible and align it in
such a way that all the recesses align with clutch lever fitting (arrow) .
Remove nut (3) and bolt (4) .
Remove clutch lever (5) and detach clutch cable (6).

(-) Installing clutch lever

Lubricate clutch lever (5) and bolt (4).

Lubricant
Universal lubricant spray 81 22 9 407 711

Attach clutch cable (6) and position clutch lever (5).

Make sure that clutch cable (6) is routed in the recess of clutch lever fitting
(arrow), adjusting screw (1)and lock nut (2) is routed.
Install bolt (4) and new nut (3).

Tightening torques
Hand lever lever to clutch lever fitting
M6 x 30, Screw 6 Nm
052021 BMW Motorrad, UX-VA-4 1/4
BMW-Motorrad - F 850 GS
M6, Nut Tightening
Thread-locking compound sequence: Tighten
(mechanical) the nut, counter-
holding the bolt
8 Nm

Turn back lock nut (2) and adjusting screw (1) again.

(-) Checking/adjusting clutch play

Requirement
Engine is cold.

NOTICE
Before the adjustment of the clutch cable, it must be ensured that a correct
adjustment range is available on the coupling hand armature.

Adjusting the adjustment range (clutch cable) on clutch handlebar

fitting
Loosen lock nut (1)and adjust distance (A) using adjusting screw (2).

Technical data
Distance between 8.0+1.5 mm
adjusting screw and −1.5
locknut

If necessary, re-adjust clutch cable on engine.

If necessary, loosen nuts (1) and adjust clutch play until the adjustment
range on the clutch handlebar fitting is correct.
Tighten nuts (1) until hand-tight.

Technical data
Clutch cable play at the outer 3...5 mm
end of the
handlebar
052021 BMW Motorrad, UX-VA-4 2/4
BMW-Motorrad - F 850 GS
lever,
handlebars in
straight-
ahead
position,
engine cold

Result:
Clearance is out of tolerance.
Measure:
Adjusting clutch cable at engine housing
Loosen nuts (1) and adjust clutch play.

Technical data
Clutch cable play at the outer 3...5 mm
end of the
handlebar
lever,
handlebars in
straight-
ahead
position,
engine cold

Tighten nuts (1).

Measure the free travel/clutch play (B) between handlebar weight (2) and
clutch lever (1) again and if necessary, adjust on engine housing.

Technical data
Clutch cable play at the outer 3...5 mm
end of the
handlebar
lever,
handlebars in
straight-
ahead
position,
engine cold

(-) Installing the cover for wiring harness

Lightly lubricate detent pins (1).

Installation tool
Silicone spray 83 19 2 208 609

(-) Installing the cover for clutch switch

Install the cover (1).

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

32 72 076 Replacing lever for front-wheel brake

+ 32 72 576

Remove the nut (1).

Remove bolt (2).
Remove lever (3).

(-) Installing lever for front brake

Lubricate tyre tread (arrow) of brake lever (2).

Lubricant
Klüberplex BEM 34-132 31 42 7 713 934

Lubricate screw (1), leaving out the thread.

Lubricant
Klüberplex BEM 34-132 31 42 7 713 934

Insert lever (2).

Install bolt (1) and nut (3).

Tightening torques
Hand lever to handbrake fitting
M6 x 35, Screw 1 Nm
M6, Nut Tightening
sequence: Tighten
the nut, counter-
holding the bolt
6 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

32 72 078 Replacing brake handlebar fitting for front wheel

+ 32 72 578

Core activity
(-) Removing brake fitting for front wheel

Remove screws (1) and clamp (2) with mirror.

Remove complete brake fitting (3).

(-) Installing brake fitting for front wheel

Hold complete brake fitting (1) in position.

Attach clamp (2) with mirror and install screws (3), but do not tighten.
Align brake fitting (1) with clamp (2) to mark (arrow).
Tighten the screws (3).

Tightening torques
Handbrake fitting to handlebars
M6 x 20 Tightening
sequence: tighten
top until fully closed
8 Nm

+ 32 73 500

Core activity
(-) Removing clutch cable

Remove the straps (1).

Pull out clutch cable (2) from holder (3) .

Release clutch cable (1) from guide holder (2) and pull out between frame
brace and (3) exhaust duct (4) .

Work clutch cable (1) down between frame (2) and cylinder head (3) to
remove.

(-) Installing clutch cable

Work clutch cable (1) from below between frame (2) and cylinder head (3).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Work clutch cable (1) between frame brace (3) and exhaust duct (4) to the
front and insert in guide holder (2).

Feed clutch cable (2) in holder (3).

Secure straps (1).

Follow-up work
Secure the clutch cable
Secure clutch cable in manual controls for clutch control
Checking/adjusting clutch play
Installing the cover for wiring harness
Installing the cover for clutch switch
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

32 76 000 Replacing steering damper

+ 32 76 500

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Releasing fork partition

Core activity
(-) Removing steering damper

Remove bolt (1).

Release steering damper (2) and remove damping disc (3) with shouldered
bushing (4).

Remove bolt (1).

Remove steering damper (2) and damping disc (3) with shouldered bushing
(4).

(-) Installing steering damper

Clean the threads.

Install distance bush (4) with long side (arrow) downwards.
Hold steering damper (2) with distance bush (4) and damping disc (3) in
position.
Install bolt (1).

Tightening torques
Steering damper to frame
M8 x 55, Replace screw 24 Nm
Thread-locking compound (micro-
encapsulated)

Clean the threads.

Hold shouldered bushing (4) with damping disc (3) and steering damper (2)
in position.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Install bolt (1).

Tightening torques
Steering damper to fork bridge
M8 x 35, Renew screw 19 Nm
Thread-locking compound (micro-
encapsulated)

Follow-up work
Securing fork partition
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

33 35 000 Replacing rear wheel swinging arm

+ 33 35 501

Preparatory work
Placing motorcycle on rear-wheel stand
Installing engine lifter
Remove the rear wheel
Disengaging gearshift rod
Removing front left footrest plate
Removing chain guard
Releasing rear brake line
Releasing spring strut

Core activity
(-) Remove the swinging arm

+ 33 35 502

Core activity
(-) Remove the swinging-arm bearing
Removing left swinging-arm bearing
Remove bearing bush (1) with thrust washer (2).

Position short spindle (No. 36 5 552) with proper socket (1) on swinging arm
(2).
Attach disc with 37 mm thread (No. 36 5 553) to short spindle (No. 36 5
552).
Remove needle bearing (3) from swinging arm (2).

Removing right swinging-arm bearing

Remove bearing bush (1) with thrust washer (2).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

(-) Installing swinging-arm bearings

When installing needle sleeves (1), make sure that the labelling (arrow)
points outwards.

Install the right swinging-arm bearing

Lubricate needle bearings (1) and (2).

Lubricant
Acid-free friction-bearing grease 81 22 9 407 174

Position short spindle (No. 36 5 552) with 50 mm washer without thread (No.
36 5 554) and needle bearing (1).
Attach disc with 37 mm thread (No. 36 5 553) to short spindle (No. 36 5
552).
Install needle bearing (1) flush with swinging arm (3) .
Install needle bearing (2) in the same way, checking installation depth (A).

Technical data

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Installation depth A of Outer edge of 4.50 mm
the outer needle the needle
sleeves sleeve to the
outer edge of
the swinging
arm

Install bearing bush (1) with thrust washer (2).

Install the left swinging-arm bearing

Lubricate needle bearings (1) and (2).

Lubricant
Acid-free friction-bearing grease 81 22 9 407 174

Position short spindle (No. 36 5 552) with the 50 mm washer without thread
(No. 36 5 554) and needle bearing (1).
Attach disc with 37 mm thread (No. 36 5 553) to short spindle (No. 36 5
552).
Install needle bearing (1) flush with swinging arm (3) .
Install needle bearing (2) in the same way, checking installation depth (A).

Technical data
Installation depth A of Outer edge of 4.50 mm
the outer needle the needle
sleeves sleeve to the
outer edge of
the swinging
arm

Install bearing bush (1) with thrust washer (2).

Follow-up work

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Installing swinging arm
Securing spring strut
Secure the rear brake line
Installing chain guard
Installing front left footrest plate
Securing selector rod
Install the rear wheel
Bedding in brake pads
Removing engine lifter
Removing motorcycle from rear-wheel stand
Adjust chain sag
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

33 54 000 Replacing rear spring strut

+ 33 54 500

Additional billing items

33 54 502 Additional work for replacing rear spring strut (with ESA)

Core activity
(-) Removing spring strut

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Pull off hose (1) and work it up and clear of the vehicle.

Remove bolt (1) and bush (2).

Release rear wheel swinging arm (3) of spring strut (4).

Remove wedges (No. 36 5 521) below rear wheel (1) and lower the rear
wheel swinging arm.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Remove bolt (1) and bush (2).

Feed out spring strut (3) and remove.

(-) Installing spring strut

Clean the threads.

Lubricate bush (2) on the outside thinly .

Lubricant
Acid-free friction-bearing grease 81 22 9 407 174

Feed in spring strut (3) into place and hold it in position.

Install screw (1) with bush (2).

Tightening torques
Spring strut to frame
M12 x 1.5 x 75 - 10.9, Replace screw 100 Nm
Thread-locking compound (micro-
encapsulated)

Raise the rear wheel swinging arm, supporting the rear wheel (1) with
wedges (No. 36 5 521) while doing so.

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Lubricate bush (2) on the outside thinly .

Lubricant
Acid-free friction-bearing grease 81 22 9 407 174

Align rear wheel swinging arm (3) and spring strut (4) to each other.
Install screw (1) with bush (2).

Tightening torques
Spring strut to swinging arm
M12 x 1.5 x 75 - 10.9, Replace screw 100 Nm
Thread-locking compound (micro-
encapsulated)

Lubricate inner side of hose (1).

Installation tool
Silicone spray 83 19 2 208 609

Feed in and push hose (1).

Check routing of hoses (1).

If necessary, secure hoses (1) in holder (2).

Follow-up work
Remove wedges below rear wheel
Removing engine lifter
Installing chain guard
Installing left heel deflector
Installing left side cap
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

33 81 000 Replacing chainset

+ 33 81 500

ATTENTION
Changing an individual worn component of the chain set
Increased wear
Replace complete chain set and chain failure protection.

Preparatory work
Placing motorcycle on rear-wheel stand
Installing engine lifter
Disengaging gearshift rod
Removing front left footrest plate
Releasing pinion
Remove the rear wheel
Removing chain guard

Core activity
(-) Remove pinion with drive chain

Remove rear-wheel stand .

Remove pinion (1) with drive chain (2) from transmission output shaft (3).
Remove pinion (1) from drive chain (2).
Remove drive chain (2) from the rear wheel swinging arm (4).

(-) Removing chain drop guard

Remove bolt (1).

Remove chain failure protection (2).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

(-) Installing new chain failure protection

Installing the chain failure protection (2).

ATTENTION
Cable to the side-stand switch is trapped under chain drop guard
Component damage
Do not trap the cable under the chain drop guard.
From the front, work the chain into position between chain drop guard and
engine housing.

During installation, secure cable (4) for side-stand switch (3) (arrows).
Install bolt (1).

Secure hoses (1) in chain failure protection (2).

(-) Removing chain sprocket support and judder damper

Remove the spacer bush (1).

Remove chain sprocket support (2) and judder damper (3).

(-) Removing sprocket

Remove nuts (1).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Remove chain sprocket (2) from chain sprocket support (3).

(-) Installing sprocket

Install chain sprocket (2) to chain sprocket support (3) with labelling (arrow)
pointing outwards.
Install nut (1) and tighten crosswise.

Tightening torques
Chain sprocket to chain-sprocket carrier
M12 x 1.5 110 Nm
Thread-locking compound
(mechanical)

(-) Installing judder damper and sprocket carrier

Lubricate and install judder damper (3).

Installation tool
Silicone spray 83 19 2 208 609

Install chain sprocket support (2).

Install spacer bush (1).

(-) Installing pinion with drive chain

Lubricate gearing of the transmission output shaft (1).

Lubricant
MP 3 paste 07 55 9 062 476

Install pinion (2) so that the long collar (arrow) points outwards.
Thread in drive chain (3) on rear wheel swinging arm (4), while ensuring that
the rear wheel swinging arm (4) is not scratched.
Insert pinion (2) in drive chain (3).
Install pinion (2) with drive chain (3) on transmission output shaft (1).

Install rear-wheel stand .

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Follow-up work
Installing chain guard
Install the rear wheel
Securing pinion
Installing front left footrest plate
Securing selector rod
Adjust chain sag
Removing engine lifter
Removing motorcycle from rear-wheel stand
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

33 83 000 Adjusting chain tension

+ 33 83 500

Core activity
(-) Adjust chain sag

ATTENTION
Incorrect setting of chain tension
Overstretching of the chain
Adjust the chain at the point of least chain deflection.

Loosen nut (1).

Release adjusting screws (2) on the left and right.
ATTENTION
Rear wheel skewed at a slight angle because tensioning screws not
adjusted to same setting
Accelerated wear at rear wheel and chain drive
Make sure that the rear wheel is aligned to track correctly (same scale
reading on both sides of the rear wheel swinging arm).

Set the chain tension (A) through adjusting screws (2) on the left and right
while noting the correct toe adjustment (same scale value (Arrows) on both
sides of chain tensioner (3)).
NOTICE
After tightening the chains, tighten the adjusting screws only by hand in order
so that the setting does not change.

Technical data
Chain deflection Motorcycle 40...50 mm
with no
weight
applied,
supported on
its side stand

Tighten the nut (1).

Tightening torques
Rear quick-release axle in swinging arm
M24 x 1.5 100 Nm
Thread-locking compound
(mechanical)

Check if the washer (1) lies flush against screw head (2) and correct if
required.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Follow-up work
Lubricating drive chain
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

33 85 002 Replacing bearing for sprocket carrier

+ 33 85 502

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Remove the rear wheel

Core activity
(-) Removing bearings from sprocket carrier

Lever out the shaft seal (1).

Heat the hub.

Technical data
Release/mating 80 °C
temperature

Deflect the bearing (2) together with the bush (3) from the rear.

(-) Installing bearings in sprocket carrier

Insert the bush (3), the edge points to the bearing (2).
Heat the bearing seat.

Technical data
Release/mating 80 °C
temperature

ATTENTION
Installation not in compliance with correct procedure
Damage to roller bearings
When installing, apply pressure to the bearing outer race only.

Install the bearing (2) up to the limit position.

ATTENTION
Damage of the sealing lip due to incorrect tools
Damage to sealing ring
Only subject the sealing ring to load on the outer circumference, do not
press on the sealing lip.

Install the new shaft seal (1) up to the limit position, sealing lip points to
outer.

Follow-up work
Install the rear wheel
Adjust chain sag
Bedding in brake pads

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

33 85 007 Replacing chain drop guard

+ 33 85 507

Preparatory work
Placing motorcycle on rear-wheel stand
Installing engine lifter
Disengaging gearshift rod
Removing front left footrest plate

Core activity
(-) Removing chain drop guard

Remove bolt (1).

Remove chain failure protection (2).

(-) Installing chain drop guard

Position chain failure protection (2) while fastening cable (4) on side support
switch (3) (arrows).
Install bolt (1).

Tightening torques
Chain failure protection to crankcase
M6 x 45 8 Nm

Secure hoses (1) in chain failure protection (2).

Follow-up work
Installing front left footrest plate

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Securing selector rod
Removing engine lifter
Removing motorcycle from rear-wheel stand
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

33 85 012 Removing/installing sprocket carrier

+ 33 85 515

ATTENTION
Brake actuation with brake pads or brake calipers removed
Brake pistons pushed out
Do not operate brake.
Install brake pads and brake caliper or insert the piston resetting device.

Push brake caliper (1) against brake disc (2) to push back the piston.

Remove nut (1) with washer (2).

Loosen adjusting screws (3) and push both chain tensioners (4) along with
the rear wheel to the front.
Chain is slackened.
Remove chain (5) from chain sprocket (6) and move it aside, making sure
that the swinging arm is not scratched.

Remove quick-release axle (1).

ATTENTION
Removal of rear wheel not in accordance with correct procedure
Damage to wheel speed sensor
Note the wheel-speed sensor when rolling out the rear wheel.

Remove rear wheel (2), while paying attention to the brake caliper (3) and
push aside if required.

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS
Remove the left spacer bush (1).
Remove chain sprocket support (2) and judder damper (3).
Remove right spacer bush (4).

(-) Removing sprocket

Remove nuts (1).

Remove chain sprocket (2) from chain sprocket support (3).

(-) Installing sprocket

Install chain sprocket (2) to chain sprocket support (3) with labelling (arrow)
pointing outwards.
Install nut (1) and tighten crosswise.

Tightening torques
Chain sprocket to chain-sprocket carrier
M12 x 1.5 110 Nm
Thread-locking compound
(mechanical)

(-) Install the rear wheel

As applicable, clean the areas indicated (arrows) and lubricate.

Lubricant
Optimoly TA 18 21 9 062 599

Position brake caliper (1) in guide (2).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Lubricating the spacer bushes and radial shaft seal of chain sprocket
support
Remove all dirt and old lubricant from the components.
Lubricate the components at the areas indicated (arrows).

Lubricant
Unirex N3 83 19 2 160 349

Check judder damper (3) for damage, deformation or wear and replace, if
required..
Lubricate and install judder damper (3).

Installation tool
Silicone spray 83 19 2 208 609

Install right spacer bush (4).

Install chain sprocket support (2).
Install left spacer bush (1).

Clean and lubricate quick-release axle (1).

Lubricant
Unirex N3 83 19 2 160 349

ATTENTION
Installation of rear wheel not in accordance with correct procedure
Damage to wheel speed sensor
Note the wheel-speed sensor when rolling in the rear wheel.

Install rear wheel (2) noting that brake caliper (3) is seated in the guide
(Arrow).
Install quick-release axle (1).
Push rear wheel (1) forward and loop the chain (2) over the chain sprocket
(3).
Install nut (4) with washer (5), but do not tighten yet.

Follow-up work
052021 BMW Motorrad, UX-VA-4 3/4
BMW-Motorrad - F 850 GS
Adjust chain sag
Bedding in brake pads
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

33 85 504 Replacing chain slide rails (chain removed)

Core activity
(-) Remove the chain slide rail

Remove screws (1) with washers (2).

Remove chain slide rail (3), noting the locators (arrows).

(-) Installing chain slide rail

Install chain slide rail (3), noting the locators (arrows).

Install screws (1) with washers (2).

Tightening torques
Chain slide rail to rear wheel swinging arm
M6 x 14.5 8 Nm

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

34 00 010 Change brake fluid in entire system

+ 34 00 504

NOTICE
This description applies for brake filling and bleeding units with vacuum
extraction. If other devices are used, comply with the manufacturer's
instructions.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Core activity
(-) Changing brake fluid, front, and bleeding brake system

WARNING
Water ingress in the brake fluid due to air humidity
Decrease in the boiling point, formation of vapour bubbles reduces the
effectiveness of the brakes.
Use only fresh brake fluid from an unopened container.

Adjust brake lever (1) to maximum distance through knurled wheel (2).

Drain the brake fluid reservoir on handbrake lever fitting

ATTENTION
Brake fluid on painted surfaces, plastic and rubber components
Material damage
Do not allow brake fluid to come into contact with painted surfaces, plastic or
rubber components.
Wash components immediately with clear water if required.

Remove screws (1).

Remove reservoir cap (2).
Remove support plate (3).
Remove gaiter (4).
Draw off the brake fluid (5).

052021 BMW Motorrad, UX-VA-4 1/9

BMW-Motorrad - F 850 GS

◄
• Turn the handlebars to a position in which the brake fluid reservoir is
horizontal.
WARNING
Water ingress in the brake fluid due to air humidity
Decrease in the boiling point, formation of vapour bubbles reduces the
effectiveness of the brakes.
• Use only fresh brake fluid from an unopened container.

• Top up with fresh brake fluid (1) up to the upper edge (arrow).

Hydraulic fluid
Brake fluid, DOT4 I
• Turn the handlebars to a position in which air can rise through outlet hole
(3).
• Vent the brake system by several small strokes on brake lever (1).
• Repeat this operation until air bubbles (2) cease to escape from outlet hole
(3) and a clear pressure point is perceptible.

• Operate brake lever (1) by approximately half of the lever travel and secure
there using suitable auxiliary materials (arrow).

K81_R34043b

• Connect hose (1) from bleeder unit to bleeder screw (2) from left brake
caliper (3).
• Slightly open the bleeder screw (2).

052021 BMW Motorrad, UX-VA-4 2/9

BMW-Motorrad - F 850 GS
• Push brake caliper (3) against brake disc (4), pressing the brake fluid
through hose (1) while doing so.
>> The pistons are pushed back.
• Close the bleeder screw (2).

• Connect hose (1) from bleeder unit to bleeder screw (2) from right brake
caliper (3).
• Slightly open the bleeder screw (2).
• Push brake caliper (3) against brake disc (4), pressing the brake fluid
through hose (1) while doing so.
>> The pistons are pushed back.
• Close the bleeder screw (2).

• Remove auxiliary materials (arrow).

K81_R34043c

• Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
WARNING
Water ingress in the brake fluid due to air humidity
Decrease in the boiling point, formation of vapour bubbles reduces the
effectiveness of the brakes.
• Use only fresh brake fluid from an unopened container.

• Top up with fresh brake fluid (1) up to the upper edge (arrow).

Hydraulic fluid
Brake fluid, DOT4 I
• Connect the bleeder unit to right brake caliper (1).
• Slightly open the bleeder screw (2).
WARNING
Diminished braking effect
052021 BMW Motorrad, UX-VA-4 3/9
BMW-Motorrad - F 850 GS
Ingress of air into brake system
• The outlet hole must always be covered with brake fluid, top up brake fluid if
required.

• Keep drawing off brake fluid until escape of new brake fluid is visible.
• Close the bleeder screw (2).

• Connect the bleeder unit to left brake caliper (1).

• Slightly open the bleeder screw (2).
• Draw off brake fluid until it is seen that new brake fluid exits or the require
amount of fluid has passed through.
• Close the bleeder screw (2).

· End vacuum extraction.

• Operate the brake lever several times until the brake pads are bedded.

• Operate brake lever several times until a pressure point can be felt.
• Route vent hose (1) up.
>> Rising air bubbles can be observed in a better way.
• Operate brake lever till the pressure point and open bleeder screw (2) for a
short time.
• Pull brake lever till the grip and close bleeder screw (2).
lllrNOTICE
Always open bleeder screw wide and pull through lever wide in order to
increase the flow rate of the brake fluid.

• Release the brake lever.

• Operate brake lever until a pressure point can be felt and bleed again.
• Repeat the process until no air bubbles (arrow) escape and a clearly
noticeable pressure point is reached with the bleeder screw (2) closed.
• Tighten bleeder screw (2).

••""Tightening torques
Bleed screw to brake caliper, front
114 Nm
I
• Operate brake lever several times until a pressure point can be felt.
• Route vent hose (1) up.
>> Rising air bubbles can be observed in a better way.
• Operate brake lever till the pressure point and open bleeder screw (2) for a
short time.

052021 BMW Motorrad, UX-VA-4 4/9

BMW-Motorrad - F 850 GS
• Pull brake lever till the grip and close bleeder screw (2).
.-NOTICE
Always open bleeder screw wide and pull through lever wide in order to
increase the flow rate of the brake fluid.

'" Release the brake lever.

"",Tightening torques
Bleed screw to brake caliper, front
I 14 Nm I
WARNING
Diminished braking effect
Ingress of air into brake system
• The outlet hole must always be covered with brake fluid, top up brake fluid if
required.

• Position handlebar such that air can rise through the outlet hole (Arrow) in
the handbrake fitting (1).

• Vent the brake system by several small strokes on brake lever (1).
• Repeat this operation until air bubbles (2) cease to escape from outlet hole
(3) and a clear pressure point is perceptible.

• Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
• Pour in fresh brake fluid (1) until level reaches the upper edge (arrow) of the
mark.

.-ATTENTION
Escaping brake fluid

052021 BMW Motorrad, UX-VA-4 5/9

BMW-Motorrad - F 850 GS
Component damage
• Carefully clean the sealing faces before installing the diaphragm in the brake
-fluid reservoir.

• Clean the rim of the reservoir (arrow), support plate (3), gaiter (4) and
reservoir cap (2).
• Position gaiter (4), support plate (3) and reservoir cap (2).
• Install screws (1).

Check

• Check brake pressure by operating the brakes.

Result:
• Low brake pressure
Measure:
• Repeat the bleeding process without vacuum extraction.

(-) Changing brake fluid, rear, and bleeding brake system

► Releasing brake-fluid reservoir, rear
• Remove bolt (1).
• Ease brake fluid tank (2) aside, making sure that it does not tilt or hang
down.

◄
► Emptying the rear brake fluid tank
.- ATTENTION
Brake fluid on painted surfaces, plastic and rubber components
Material damage
• Do not allow brake fluid to come into contact with painted surfaces, plastic or
rubber components.
• Wash components immediately with clear water if required.

• Remove reservoir cap (1).

• Remove lock washer (2).
• Remove gaiter (3).
• Draw off the brake fluid and clean the expansion tank (4).
◄
• Connect hose (1) from bleeder unit to bleeder screw (2).
• Slightly open the bleeder screw (2).

052021 BMW Motorrad, UX-VA-4 6/9

BMW-Motorrad - F 850 GS
Push brake caliper (3) against brake disc (4), pressing the brake fluid
through hose (1) while doing so.
>> The brake piston is pushed back.
• Close the bleeder screw (2).

WARNING
Water ingress in the brake fluid due to air humidity
Decrease in the boiling point, formation of vapour bubbles reduces the
effectiveness of the brakes.
• Use only fresh brake fluid from an unopened container.

• Top up the brake fluid tank (1) up to the maximum mark (2).

Hydraulic fluid
Brake fluid, DOT4 I
• Connect the brake bleeding device.
• Slightly open the bleeder screw (1).
WARNING
Diminished braking effect
Ingress of air into brake system
• The outlet hole must always be covered with brake fluid, top up brake fluid if
required.

• Keep drawing off brake fluid until the leakage of new brake fluid is detected
or the full amount of fluid has flown through.

!] Technical data
Amount of liquid for around three fillings
changing/bleeding of brake fluid
the brake system reservoir

• Close the bleeder screw (1).

• End vacuum extraction.

• Operate the footbrake lever several times until the brake pads are bedded.

• Route vent hose (1) up.

>> Rising air bubbles (arrow) can be observed better in this way.
• Operate footbrake lever till pressure point and open bleeder screw (2) for a
short time.
• Press footbrake lever till limit position and close bleeder screw (2).
•NOTICE
Always open bleeder screw wide and pull through lever wide in order to
increase the flow rate of the brake fluid.

052021 BMW Motorrad, UX-VA-4 7/9

BMW-Motorrad - F 850 GS
• Operate footbrake lever until a pressure point can be traced and bleed
again.
• Repeat the process until no air bubbles(arrow) escape and a clearly
noticeable pressure point is reached with the bleeder screw(2) closed.
• Tighten bleeder screw(2).

�
Tightening torques
Bleed screw to brake caliper, rear
I 14 Nm I

" Top up the brake fluid tank(1) up to the maximum mark(2).

Hydraulic fluid
Brake fluid, DOT4 I
• Clean the rim of the reservoir(arrow), gaiter(1), lock washer(2) and
reservoir cap(3).
• Install gaiter and(1) and lock washer(2).
• Install reservoir cap(3).

► Securing rear brake-fluid reservoir

• Position brake fluid tank(2).
• Install bolt(1).

�
Tightening torques
Brake fluid tank to side cover
M6 x 16, Replace screw 2.4 Nm
Thread-locking compound
(mechanical)

◄
• Perform a functional check of the brake system.

Check

• Check brake pressure by operating the brakes.

052021 BMW Motorrad, UX-VA-4 8/9

BMW-Motorrad - F 850 GS
Result:
• Low brake pressure
Measure:
• Repeat the bleeding process without vacuum extraction.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 9/9

BMW-Motorrad - F 850 GS

34 00 048 Changing brake fluid, front brakes

+ 34 00 548

NOTICE
This description applies for brake filling and bleeding units with vacuum
extraction. If other devices are used, comply with the manufacturer's
instructions.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Core activity
(-) Changing brake fluid, front, and bleeding brake system

Adjust brake lever (1) to maximum distance through knurled wheel (2).

Drain the brake fluid reservoir on handbrake lever fitting

Remove screws (1).

Remove reservoir cap (2).
Remove support plate (3).
Remove gaiter (4).
Draw off the brake fluid (5).

052021 BMW Motorrad, UX-VA-4 1/6

BMW-Motorrad - F 850 GS

• Top up with fresh brake fluid (1) up to the upper edge (arrow).

• Operate brake lever (1) by approximately half of the lever travel and secure
there using suitable auxiliary materials (arrow).

K81_R34043b

• Connect hose (1) from bleeder unit to bleeder screw (2) from left brake
caliper (3).
• Slightly open the bleeder screw (2).

052021 BMW Motorrad, UX-VA-4 2/6

BMW-Motorrad - F 850 GS
• Push brake caliper (3) against brake disc (4), pressing the brake fluid
through hose (1) while doing so.
>> The pistons are pushed back.
• Close the bleeder screw (2).

• Remove auxiliary materials (arrow).

K81_R34043c

• Turn the handlebars to a position in which the brake fluid reservoir is

• Top up with fresh brake fluid (1) up to the upper edge (arrow).

Hydraulic fluid
Brake fluid, DOT4 I
• Connect the bleeder unit to right brake caliper (1).
• Slightly open the bleeder screw (2).
WARNING
Diminished braking effect
052021 BMW Motorrad, UX-VA-4 3/6
BMW-Motorrad - F 850 GS
Ingress of air into brake system
• The outlet hole must always be covered with brake fluid, top up brake fluid if
required.

• Keep drawing off brake fluid until escape of new brake fluid is visible.
• Close the bleeder screw (2).

• Connect the bleeder unit to left brake caliper (1).

• Slightly open the bleeder screw (2).
• Draw off brake fluid until it is seen that new brake fluid exits or the require
amount of fluid has passed through.
• Close the bleeder screw (2).

· End vacuum extraction.

• Operate the brake lever several times until the brake pads are bedded.

• Release the brake lever.

052021 BMW Motorrad, UX-VA-4 4/6

'" Release the brake lever.

• Position handlebar such that air can rise through the outlet hole (Arrow) in
the handbrake fitting (1).

• Vent the brake system by several small strokes on brake lever (1).
• Repeat this operation until air bubbles (2) cease to escape from outlet hole
(3) and a clear pressure point is perceptible.

• Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
• Pour in fresh brake fluid (1) until level reaches the upper edge (arrow) of the
mark.

.-ATTENTION
Escaping brake fluid

052021 BMW Motorrad, UX-VA-4 5/6

BMW-Motorrad - F 850 GS
Component damage
• Carefully clean the sealing faces before installing the diaphragm in the brake
-fluid reservoir.

• Clean the rim of the reservoir (arrow), support plate (3), gaiter (4) and
reservoir cap (2).
• Position gaiter (4), support plate (3) and reservoir cap (2).
• Install screws (1).

Check

• Check brake pressure by operating the brakes.

Result:
• Low brake pressure
Measure:
• Repeat the bleeding process without vacuum extraction.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 6/6

BMW-Motorrad - F 850 GS

34 00 049 Changing brake fluid, rear brakes

+ 34 00 549

NOTICE
This description applies for brake filling and bleeding units with vacuum
extraction. If other devices are used, comply with the manufacturer's
instructions.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Core activity
(-) Changing brake fluid, rear, and bleeding brake system
Releasing brake-fluid reservoir, rear

Remove bolt (1).

Ease brake fluid tank (2) aside, making sure that it does not tilt or hang
down.

Emptying the rear brake fluid tank

Remove reservoir cap (1).

Remove lock washer (2).
Remove gaiter (3).
Draw off the brake fluid and clean the expansion tank (4).

Connect hose (1) from bleeder unit to bleeder screw (2).

Slightly open the bleeder screw (2).
Push brake caliper (3) against brake disc (4), pressing the brake fluid
through hose (1) while doing so.
The brake piston is pushed back.
Close the bleeder screw (2).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Top up the brake fluid tank (1) up to the maximum mark (2).

Hydraulic fluid
Brake fluid, DOT4

Connect the brake bleeding device.

Slightly open the bleeder screw (1).
WARNING
Diminished braking effect
Ingress of air into brake system
The outlet hole must always be covered with brake fluid, top up brake fluid if
required.

Keep drawing off brake fluid until the leakage of new brake fluid is detected
or the full amount of fluid has flown through.

Technical data
Amount of liquid for around three fillings
changing/bleeding of brake fluid
the brake system reservoir

Close the bleeder screw (1).

End vacuum extraction.
Operate the footbrake lever several times until the brake pads are bedded.
Route vent hose (1) up.
Rising air bubbles (arrow) can be observed better in this way.
Operate footbrake lever till pressure point and open bleeder screw (2) for a
short time.
Press footbrake lever till limit position and close bleeder screw (2).
NOTICE
Always open bleeder screw wide and pull through lever wide in order to
increase the flow rate of the brake fluid.

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Operate footbrake lever until a pressure point can be traced and bleed
again.
Repeat the process until no air bubbles (arrow) escape and a clearly
noticeable pressure point is reached with the bleeder screw (2) closed.
Tighten bleeder screw (2).

Tightening torques
Bleed screw to brake caliper, rear
14 Nm

Top up the brake fluid tank (1) up to the maximum mark (2).

Hydraulic fluid
Brake fluid, DOT4

Clean the rim of the reservoir (arrow), gaiter (1), lock washer (2) and
reservoir cap (3).
Install gaiter and (1) and lock washer (2).
Install reservoir cap (3).

Securing rear brake-fluid reservoir

Position brake fluid tank (2).
Install bolt (1).

Tightening torques
Brake fluid tank to side cover
M6 x 16, Replace screw 2.4 Nm
Thread-locking compound
(mechanical)

Perform a functional check of the brake system.

Check

Check brake pressure by operating the brakes.

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Result:
Low brake pressure
Measure:
Repeat the bleeding process without vacuum extraction.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

34 00 514 Bleeding rear brake system (for replacing component)

NOTICE
This description applies for brake filling and bleeding units with vacuum
extraction. If other devices are used, comply with the manufacturer's
instructions.

Core activity
(-) Bleeding brake system

Top up the brake fluid tank (1) up to the maximum mark (2).

Hydraulic fluid
Brake fluid, DOT4

During the bleeding procedure, make sure that the brake fluid level does not
fall below the minimum mark (3) and top up the brake fluid if necessary.
Operate the footbrake lever several times until the brake pads are bedded.
Connect vent hose (1) to bleeder screw (2).
Route vent hose (1) up.
Rising air bubbles (arrow) can be observed better in this way.
Operate footbrake lever and open bleeder screw (2), tighten bleeder screw
after lever operation (2).
NOTICE
Always open bleeder screw wide and pull through lever wide in order to
increase the flow rate of the brake fluid.

Repeat the process until no air bubbles (arrow) escape.

Tighten bleeder screw (2).

Tightening torques
Bleed screw to brake caliper, rear
14 Nm

Clean the rim of the reservoir (arrow), gaiter (1), lock washer (2) and
reservoir cap (3).
Install gaiter and (1) and lock washer (2).
Install reservoir cap (3).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Securing rear brake-fluid reservoir

Position brake fluid tank (2).
Install bolt (1).

Tightening torques
Brake fluid tank to side cover
M6 x 16, Replace screw 2.4 Nm
Thread-locking compound
(mechanical)

Check operation of the brake system.

Check

Check brake pressure by operating the brakes.

Result:
Low brake pressure
Measure:
Repeat the brake-bleeding process.

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

34 00 515 Bleeding front brake system (for replacing component)

NOTICE
This description applies for brake filling and bleeding units with
vacuum extraction. If other devices are used, comply with the
manufacturer's instructions.

Core activity
(-) Bleeding brake system

Adjust brake lever (1) to maximum distance through knurled wheel

(2).

Remove screws (1).

Remove reservoir cap (2).
Remove support plate (3).
Remove gaiter (4).
Draw off the brake fluid (5).

Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
Pour in fresh brake fluid (1) until level reaches the upper edge
(arrow) of the mark.

Hydraulic fluid
Brake fluid, DOT4

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

WARNING
Diminished braking effect
Ingress of air into brake system
The outlet hole must always be covered with brake fluid, top up
brake fluid if required.

Position handlebar such that air can rise through the outlet hole
(Arrow) in the handbrake fitting (1).

Vent the brake system by several small strokes on brake lever (1).
Repeat this operation until air bubbles (2) cease to escape from
outlet hole (3) and a clear pressure point is perceptible.

Operate brake lever several times until a pressure point can be felt.
Connect vent hose (1) to bleeder screw (2).
Route vent hose (1) up.
Rising air bubbles can be observed in a better way.
Operate brake lever and open bleeder screw (2).
NOTICE
Always open bleeder screw wide and pull through lever wide in order
to increase the flow rate of the brake fluid.

Repeat the process until no air bubbles (arrow) escape.

Tighten bleeder screw (2).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

Tightening torques
Bleed screw to brake caliper, front
14 Nm

Repeat the process until no air bubbles (arrow) escape.

Tighten bleeder screw (2).

Tightening torques
Bleed screw to brake caliper, front
14 Nm

Vent the brake system by several small strokes on brake lever (1).
Repeat this operation until air bubbles (2) cease to escape from
outlet hole (3) and a clear pressure point is perceptible.

Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
Pour in fresh brake fluid (1) until level reaches the upper edge
(arrow) of the mark.

ATTENTION
Escaping brake fluid
Component damage

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Carefully clean the sealing faces before installing the diaphragm in

the brake-fluid reservoir.

Clean the rim of the reservoir (arrow), support plate (3), gaiter (4)
and reservoir cap (2).
Position gaiter (4), support plate (3) and reservoir cap (2).
Install screws (1).

Check operation of the brake system.

Check

Check brake pressure by operating the brakes.

Result:
Low brake pressure
Measure:
Repeat the brake-bleeding process.

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

34 00 583 Draining/filling/bleeding front brake system

NOTICE
This description applies for brake filling and bleeding units with vacuum
extraction. If other devices are used, comply with the manufacturer's
instructions.

Core activity
(-) Draining front brake system
Drain the brake fluid reservoir on handbrake lever fitting

Remove screws (1).

Remove reservoir cap (2).
Remove support plate (3).
Remove gaiter (4).
Draw off the brake fluid (5).

Press the brake caliper (1) against the brake disc (2) with your hand.
The brake pistons are pushed back.

052021 BMW Motorrad, UX-VA-4 1/6

BMW-Motorrad - F 850 GS

Draw off the excess brake fluid and clean the brake fluid expansion tank (1).

Connect the bleeder unit to right brake caliper (1).

Slightly open the bleeder screw (2).
Draw off brake fluid until it ceases to emerge.
Tighten bleeder screw (2).

Connect the bleeder unit to left brake caliper (1).

Slightly open the bleeder screw (2).
Draw off brake fluid until it ceases to emerge.
Tighten bleeder screw (2).
NOTICE
Drain the brake system only to the extent necessary for the tasks in question
to be performed.

(-) Filling and bleeding front brake system

WARNING
Water ingress in the brake fluid due to air humidity
Decrease in the boiling point, formation of vapour bubbles reduces the
effectiveness of the brakes.

052021 BMW Motorrad, UX-VA-4 2/6

BMW-Motorrad - F 850 GS
Use only fresh brake fluid from an unopened container.

Adjust brake lever (1) to maximum distance through knurled wheel (2).

Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
WARNING
Water ingress in the brake fluid due to air humidity
Decrease in the boiling point, formation of vapour bubbles reduces the
effectiveness of the brakes.
Use only fresh brake fluid from an unopened container.

Top up with fresh brake fluid (1) up to the upper edge (arrow).

Hydraulic fluid
Brake fluid, DOT4

Connect the bleeder unit to right brake caliper (1).

Slightly open the bleeder screw (2).
WARNING
Diminished braking effect
Ingress of air into brake system
The outlet hole must always be covered with brake fluid, top up brake fluid if
required.

Keep drawing off brake fluid until new brake fluid visibly escapes.
Tighten bleeder screw (2).

Connect the bleeder unit to left brake caliper (1).

Slightly open the bleeder screw (2).
Keep drawing off brake fluid until new brake fluid visibly escapes.
Tighten bleeder screw (2).

WARNING

052021 BMW Motorrad, UX-VA-4 3/6

BMW-Motorrad - F 850 GS
Air bubbles difficult to recognise in brake fluid drawn off by vacuum
extraction
Braking power is reduced due to insufficient brake system bleeding.
In the final step, bleed the system manually (without vacuum extraction) until
the fluid emerging is bubble-free.

Position handbrake fitting (1) such that air can rise through the outlet hole
(arrow).

Vent the brake system by several small strokes on brake lever (1).
Air bubbles (2) cease to escape from outlet hole (3).

Operate brake lever several times until a pressure point can be felt.
Route vent hose (1) up.
Rising air bubbles can be observed in a better way.
Operate brake lever till the pressure point and open bleeder screw (2) for a
short time.
Pull brake lever till the grip and close bleeder screw (2).
NOTICE
Always open bleeder screw wide and pull through lever wide in order to
increase the flow rate of the brake fluid.

Release the brake lever.

Operate brake lever until a pressure point can be felt and bleed again.
Repeat the process until no air bubbles (arrow) escape and a clearly
noticeable pressure point is reached with the bleeder screw (2) closed.
Tighten bleeder screw (2).

Tightening torques
Bleed screw to brake caliper, front
14 Nm

052021 BMW Motorrad, UX-VA-4 4/6

BMW-Motorrad - F 850 GS
Always open bleeder screw wide and pull through lever wide in order to
increase the flow rate of the brake fluid.

Release the brake lever.

Tightening torques
Bleed screw to brake caliper, front
14 Nm

Bedding in brake pads

WARNING
Brake pads not lying against the brake disc
Risk of accident due to delayed braking effect.
Before driving, check that the brakes respond without delay.

After completing work, operate the brake several times until the brake pads
are bedded.

Vent the brake system by several small strokes on brake lever (1).
Repeat this operation until air bubbles (2) cease to escape from outlet hole
(3).

Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
Pour in fresh brake fluid (1) until level reaches the upper edge (arrow) of the
mark.

ATTENTION
Escaping brake fluid
Component damage
Carefully clean the sealing faces before installing the diaphragm in the brake
-fluid reservoir.

052021 BMW Motorrad, UX-VA-4 5/6

BMW-Motorrad - F 850 GS
Clean the rim of the reservoir (arrow), support plate (3), gaiter (4) and
reservoir cap (2).
Position gaiter (4), support plate (3) and reservoir cap (2).
Install screws (1).

Check

Check brake pressure by operating the brakes.

Result:
Low brake pressure
Measure:
On completion of all work place the motorcycle on its side stand and
repeatedly short-pull the brake lever to expel the residual air from the
handbrake cylinder.

052021 BMW Motorrad, UX-VA-4 6/6

BMW-Motorrad - F 850 GS

34 00 584 Draining/filling/bleeding rear brake system

NOTICE
This description applies for brake filling and bleeding units with vacuum
extraction. If other devices are used, comply with the manufacturer's
instructions.

Core activity
(-) Draining rear brake system
Releasing brake-fluid reservoir, rear
Remove bolt (1).
Ease brake fluid tank (2) aside, making sure that it does not tilt or hang
down.

Emptying the rear brake fluid tank

Remove reservoir cap (1).

Remove lock washer (2).
Remove gaiter (3).
Draw off the brake fluid and clean the expansion tank (4).

Press the brake caliper (1) against the brake disc (2) with your hand.
The brake piston is pushed back.

Draw off the brake fluid that has flowed back and clean reservoir (1).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Connect the brake bleeding device.

Slightly open the bleeder screw (1).
Draw off brake fluid until it ceases to emerge.
Close the bleeder screw (1).

(-) Filling and bleeding rear brake system

Top up brake fluid expansion tank (1) with fresh brake fluid till the (MAX)
mark (2).

Hydraulic fluid
Brake fluid, DOT4

Connect bleeder unit to bleeder screw (1).

Slightly open the bleed screw.
WARNING
Diminished braking effect
Ingress of air into brake system
The outlet hole must always be covered with brake fluid, top up brake fluid if
required.

Continue bleeding the brake system until fresh brake fluid emerges.
Close the bleeder screw (1).

End vacuum extraction.

Operate the footbrake lever several times until the brake pads are bedded.
Route vent hose (1) up.

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Rising air bubbles (arrow) can be observed better in this way.
Operate footbrake lever till pressure point and open bleeder screw (2) for a
short time.
Press footbrake lever till limit position and close bleeder screw (2).
NOTICE
Always open bleeder screw wide and pull through lever wide in order to
increase the flow rate of the brake fluid.

Operate footbrake lever until a pressure point can be traced and bleed
again.
Repeat the process until no air bubbles (arrow) escape and a clearly
noticeable pressure point is reached with the bleeder screw (2) closed.
Tighten bleeder screw (2).

Tightening torques
Bleed screw to brake caliper, rear
14 Nm

Filling rear brake fluid expansion tank

Top up the brake fluid tank (1) up to the maximum mark (2).

Hydraulic fluid
Brake fluid, DOT4

Clean the rim of the reservoir (arrow), gaiter (1), lock washer (2) and
reservoir cap (3).
Install gaiter and (1) and lock washer (2).
Install reservoir cap (3).

Securing rear brake-fluid reservoir

Position brake fluid tank (2).

Install bolt (1).

Tightening torques
Brake fluid tank to side cover
M6 x 16, Replace screw 2.4 Nm

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Thread-locking compound
(mechanical)

Check

Check brake pressure by operating the brakes.

Result:
Low brake pressure
Measure:
Repeat the bleeding process without vacuum extraction.

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

34 11 002 Replacing front left sealing kit for brake calliper (without bleeding)
+ 34 11 845

CAUTION
Handling harmful operating fluids
Damage to health
Observe safety regulations/safety data sheets, use personal protective
equipment (e.g., gloves, safety goggles) where required.

ATTENTION
Damage to surfaces due to sharp-edged tools
Component damage
Use wooden or plastic tools to remove sealing rings from the brake calliper.
Use plastic or wooden tools to clean the sealing ring grooves.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Securing the brake lever
Removing front left brake calliper
Removing brake pads

Core activity
(-) Removing seals set for brake calliper

Requirement
Thoroughly clean the brake calliper and remove all traces of foreign matter.

Pull off brake calliper (1) from brake-calliper support (2).

CAUTION
Sudden shooting out of a brake piston
Danger of injury
Secure brake piston, e.g. with wooden part.
Catch brake piston on a padded surface.

Insert wooden strip (1) or similar in brake calliper.

Position air gun (2) with a suitable rubber adapter (arrow) on the brake line
connection and push the brake pinion (3) out with it.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Remove small sealing ring (1) and large sealing ring (2), and in doing so, do
not damage the brake cylinder (arrow).
Clean brake cylinder (arrow).

Cleaner
Brake cleaner 83 19 2 154 780

(-) Installing seals set for brake calliper

Lubricate large sealing rings (2) and small sealing rings (1) (with groove
(arrow)) with provided lubricant.
Install sealing rings (2) and (1).

Install bake piston (1) observing sealing rings (2) and (3).
Install brake piston (4) in the same manner.
Push brake piston back completely and remove emerged lubricant/brake
fluid.

Check gaiters (1) and (2), replace if necessary.

Clean and thinly lubricate bolts (3).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Lubricant
Optimoly TA 18 21 9 062 599

Slide brake calliper (4) onto brake-calliper support (5).

Make sure gaiters (1) and (2) are sealing correctly.

Follow-up work
Installing brake pads
Installing front left brake caliper
Release the brake lever

=> Bleeding front brake system (for replacing component)

(Description in item: 34 00 515, Billed as a separate item)
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

34 11 008 Replacing front brake pads

+ 34 11 832

Press the brake caliper (1) against the brake disc (2) with your hand.
The brake pistons are pushed back.

Remove split-pin keeper (1) and locking pin (2).

Remove screws (3).
Release retaining plate (4) and brake caliper (5).
ATTENTION
Brake actuation with brake pads or brake calipers removed
Brake pistons pushed out
Do not operate brake.
Install brake pads and brake caliper or insert the piston resetting device.

Remove brake pads (6).

Clean brake caliper (5).

(-) Installing front brake pads

Check spring (1) for correct fit.

The mark (Arrow) points in the direction of rotation of the front wheel.
Check that plate (2) is correctly seated.

Install brake pads (6).

Check locking pin (2) before installation; replace attachment set as needed:
Damage, such as grooves

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
-Wear
- Corrosion
• Insert locking pin (2).
• Secure retaining plate (4) and brake caliper (5) with screws (3).

�Tightening torques
Brake caliper to telescopic fork
M10 x 45 138 Nm I
• Drive in locking pin (2) to limit position.
• Install the split-pin keeper (1).

(-) Bedding in brake pads

WARNING
Brake pads not lying against the brake disc
Risk of accident due to delayed braking effect.
• Before driving, check that the brakes respond without delay.

• After completing work, operate the brake several times until the brake pads
are bedded.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

34 11 060 Replacing front brake caliper (without bleeding brakes)

+ 34 11 560

CAUTION
Handling harmful operating fluids
Damage to health
Observe safety regulations/safety data sheets, use personal protective
equipment (e.g., gloves, safety goggles) where required.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Securing the brake lever

Core activity
(-) Removing front left brake calliper

Remove banjo bolt (1) with sealing rings (2).

Remove brake hoses (3) and spacer clip (4).
Use suitable auxiliary materials to seal the brake hoses (3).
Remove screws (5) and brake calliper (6), noting sensor cable (7).

(-) Replacing brake caliper

Remove split-pin keeper (1).

Remove locking pin (2).
Remove brake pads (3).

Pay attention to the mounting orientation of the spring (1). The mark (arrow)
indicates the correct direction of rotation of the wheel.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Install brake pads (3) (renew worn brake pads).

Serve in locking pin (2) up to limit position and install split-pin keeper (1).

(-) Installing front left brake caliper

Position brake caliper (1) noting the sensor cable (2).

Position retaining plate (3) and install screws (4).

Tightening torques
Brake caliper to telescopic fork
M10 x 45 38 Nm

Position brake hose (5) with new sealing rings (6) and spacer clip (7).
Install banjo bolt (8).

Tightening torques
Double banjo bolt to brake calliper
M10 x 1 24 Nm

Follow-up work
Release the brake lever

=> Bleeding front brake system (for replacing component)

(Description in item: 34 00 515, Billed as a separate item)
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

34 11 220 Removing/installing front brake discs

+ 34 11 840

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Installing front-wheel stand
Removing left brake caliper
Remove the right brake caliper
Removing front wheel

Core activity
(-) Remove the front left brake disc

Remove screws (1).

Remove the brake disc (2).

(-) Removing front right brake disc

Remove screws (1).

Remove the brake disc (2).

(-) Install the front left brake disc

Clean the threads.

Place brake disc (1) on the wheel rim with the broad pressure discs to the
outside and position.
Install screws (2).

Tightening torques
Brake disc to front wheel
M8 x 27 - 10.9, Replace screw Tightening
Thread-locking compound (micro- sequence: tighten in
encapsulated)
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
diagonally opposite
sequence
19 Nm

(-) Install the front right brake disc

Clean the threads.

Place brake disc (1) on the wheel rim with the broad pressure discs to the
outside and position.
Install screws (2).

Tightening torques
Brake disc to front wheel
M8 x 27 - 10.9, Replace screw Tightening
Thread-locking compound (micro- sequence: tighten in
encapsulated) diagonally opposite
sequence
19 Nm

Follow-up work
Install the front wheel
Measuring brake-disc run-out
Securing right brake caliper
Securing left brake caliper
Removing front-wheel stand
Bedding in brake pads
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

34 21 005 Replacing sealing kit for brake calliper (without bleeding)

+ 34 21 505

CAUTION
Handling harmful operating fluids
Damage to health
Observe safety regulations/safety data sheets, use personal protective
equipment (e.g., gloves, safety goggles) where required.

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Releasing rear wheel-speed sensor
Removing rear brake pads
Operating and holding footbrake lever in position
Releasing brake-fluid reservoir, rear
Emptying the rear brake fluid tank

Core activity
(-) Removing rear brake caliper

Remove banjo bolt (1) with sealing rings (2).

Remove brake hose (3).

Remove nut (1) with washer (2).

Loosen adjusting screws (3) and push both chain tensioners (4) along with
the rear wheel to the front.

052021 BMW Motorrad, UX-VA-4 1/5

BMW-Motorrad - F 850 GS
Chain is slackened.
Remove chain (5) from chain sprocket (6) and move it aside, making sure
that the swinging arm is not scratched.

Remove quick-release axle (1).

Remove rear wheel (2) and brake caliper (3).

(-) Removing seals set for brake calliper

Requirement
Thoroughly clean the brake calliper and remove all traces of foreign matter.

CAUTION
Sudden shooting out of brake pistons
Danger of injury
Do not reach into the brake calliper.
Catch brake piston on a padded surface.

Pull off brake calliper (1) from brake-calliper support (2).

CAUTION
Sudden shooting out of a brake piston
Danger of injury
Secure brake piston, e.g. with wooden part.
Catch brake piston on a padded surface.

052021 BMW Motorrad, UX-VA-4 2/5

BMW-Motorrad - F 850 GS
Insert wooden strip (1) or similar in brake calliper.
Position air gun (2) with a suitable rubber adapter (arrow) on the brake line
connection and push the brake pinion (3) out with it.

Remove small sealing ring (1) and large sealing ring (2), and in doing so, do
not damage the brake cylinder (arrows).
Clean brake cylinder (arrows).

Cleaner
Brake cleaner 83 19 2 154 780

(-) Installing seals set for brake calliper

Lubricate large sealing ring (2) and small sealing ring (1) lightly with lubricant
provided (4).
Install large sealing ring (2).
Install small sealing ring (1) with groove (arrow).

Lubricate brake piston (1) and sealing rings (2) and (3) lightly with lubricant
provided (3).
Install bake piston (1) observing sealing rings (2) and (3).
Push brake piston (1) back completely and remove emerged lubricant.

Check gaiters (1) and (2), replace if necessary.

Clean and thinly lubricate bolts (3).

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS

Lubricant
Never Seez Compound (brake-pad 83 19 2 158 852
paste)

Slide brake calliper (4) onto brake-calliper support (5).

Make sure gaiters (1) and (2) are sealing correctly.

Clean brake calliper carefully.

(-) Installing rear brake caliper

As applicable, clean the areas indicated (arrows) and lubricate.

Lubricant
Optimoly TA 18 21 9 062 599

Position brake caliper (1) in guide (2).

Ensure that the spacer bush (1) is installed.

Lubricate quick-release axle (1).

052021 BMW Motorrad, UX-VA-4 4/5

BMW-Motorrad - F 850 GS

Lubricant
Unirex N3 83 19 2 160 349

Install rear wheel (2) noting that brake caliper (3) is seated in the guide
(Arrow).
Install quick-release axle (1).

Push rear wheel (1) forward and loop the chain (2) over the chain sprocket
(3).
Install nut (4) with washer (5), do not tighten.

Position brake hose (3).

Install banjo bolt (1) with new sealing rings (2).

Tightening torques
Banjo bolt for brake hose to components
M10 x 1 24 Nm

Follow-up work
Disengaging footbrake lever
Installing rear brake pads
Securing rear wheel-speed sensor
Adjust chain sag

=> Bleeding rear brake system (for replacing component)

(Description in item: 34 00 514, Billed as a separate item)
Final check of work performed

052021 BMW Motorrad, UX-VA-4 5/5

BMW-Motorrad - F 850 GS

34 21 060 Replacing rear brake caliper (without bleeding brakes)

+ 34 21 560

CAUTION
Handling harmful operating fluids
Damage to health
Observe safety regulations/safety data sheets, use personal protective
equipment (e.g., gloves, safety goggles) where required.

Core activity
(-) Removing rear brake caliper

Remove banjo bolt (1) with sealing rings (2).

Remove brake hose (3).

Remove nut (1) with washer (2).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Remove quick-release axle (1).

Remove rear wheel (2) and brake caliper (3).

(-) Replacing rear brake caliper

Remount reusable small parts to the new part (1) and replace them if
necessary.
1 x cap
1 x bleeder screw
1 x spring
1 x clamp

(-) Installing rear brake caliper

As applicable, clean the areas indicated (arrows) and lubricate.

Lubricant
Optimoly TA 18 21 9 062 599

Position brake caliper (1) in guide (2).

Ensure that the spacer bush (1) is installed.

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

Ensure that the spacer bush (1) is installed.

Lubricate quick-release axle (1).

Lubricant
Unirex N3 83 19 2 160 349

Install rear wheel (2) noting that brake caliper (3) is seated in the guide
(Arrow).
Install quick-release axle (1).

Push rear wheel (1) forward and loop the chain (2) over the chain sprocket
(3).
Install nut (4) with washer (5), do not tighten.

Position brake hose (3).

Install banjo bolt (1) with new sealing rings (2).

Tightening torques
Banjo bolt for brake hose to components
M10 x 1 24 Nm

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Follow-up work
Disengaging footbrake lever
Installing rear brake pads
Securing rear wheel-speed sensor
Adjust chain sag

=> Bleeding rear brake system (for replacing component)

(Description in item: 34 00 514, Billed as a separate item)
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

34 21 200 Replacing rear brake pads

+ 34 21 769

Press the brake caliper (1) against the brake disc (2) with your hand.
The brake pistons are pushed back.

Remove split-pin keeper (1) and locking pin (2).

ATTENTION
Brake actuation with brake pads or brake calipers removed
Brake pistons pushed out
Do not operate brake.
Install brake pads and brake caliper or insert the piston resetting device.

Remove brake pads (3).

(-) Installing rear brake pads

Check spring (1) for correct fit.

Install brake pads (3).

Check locking pin (2) before installation; replace attachment set as needed:
Damage, such as grooves
Wear

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Corrosion
Drive in locking pin (2) to limit position.
Install the split-pin keeper (1).

Follow-up work
Bedding in brake pads
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

34 21 301 Removing/installing rear brake disc

+ 34 21 772

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Remove the rear wheel

Core activity
(-) Removing brake disc

Remove screws (1).

Remove the brake disc (2).

(-) Installing rear brake disc

Clean the threads and mating faces.

Position brake disc (1) with shoulder (arrow) upwards.
Install screws (2).

Tightening torques
Brake disc to rear wheel
M8 x 15.5, Replace screw Tightening
Thread-locking compound (micro- sequence: tighten
encapsulated) by stages in
diagonally opposite
sequence
30 Nm

(-) Checking rear brake disc for runout with brake disc removed

Requirement
No burrs or scoring on brake disc, brake disc thickness above minimum.
Brake disc has been cleaned.

Align balancing jig (No. 36 3 601) with knurled screws (1) and bubble level
(2).
Insert balancing shaft (No. 36 5 571) in rear-wheel adapter and secure it
with tensioner (No. 36 5 572), making sure that rear-wheel bearing is lightly
preloaded.
Position the rear wheel on the balancing and install stops (No. 36 5 573) to
prevent it slipping out of position.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Insert dial gauge (No. 00 2 510) in a suitable dial gauge holder (1) and
install measuring shoe (No. 34 2 510).
Align dial gauge in such a way that the tip is in contact with the brake disc
close to the outer edge (arrow) and the dial gauge is slightly preloaded.

Check

Set the dial gauge to "0".

Slowly turn the wheel through at least one complete revolution and
observe the dial gauge reading.
The sum of the positive and negative dial-gauge readings is the total run-
out.

Technical data
Brake disc lateral installed, at max 0.15 mm
runout, rear outside
circumference,
component
cooled
removed, at max 0.10 mm
outside
circumference,
component
cooled

Result:
Lateral run-out is excessive.
Measure:
Check positioning of the brake disc/wheel rim.
Check the wheel rim for damage.
If necessary, check the brake disc.
See the "Diagnosis tree, braking torque fluctuations" overview for further
information.

Follow-up work

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Install the rear wheel
Adjust chain sag
Bedding in brake pads
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

34 31 002 Replacing footbrake cylinder (without bleeding brakes)

+ 34 31 502

Preparatory work
Removing right heel deflector
Releasing brake-fluid reservoir, rear
Emptying the rear brake fluid tank

Core activity
(-) Removing footbrake cylinder

Release clip (1).

Release hose (2) from footbrake cylinder (3), catch any escaping brake fluid.

Remove cable strap (arrow).

Remove banjo bolt (1) with sealing rings (2).
Release brake hose (3), catch any escaping brake fluid if necessary.
Use suitable auxiliary materials to seal brake hose (3).

Unclip bolt (1) from pushrod (2) and remove it from pushrod (2) and
footbrake lever (3).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Remove bolt (1).

Remove footbrake cylinder (2).

(-) Installing footbrake cylinder

Position footbrake cylinder (2).

Install bolt (1).

Tightening torques
Footbrake cylinder to footrest plate
M6 x 20 8 Nm

Hold pushrod (2) in position on footbrake lever (3).

Install bolts (1) and clip onto pushrod (2).

Remove the seal from brake hose (3).

Position brake hose (3) with new sealing rings (2).
Install banjo bolt (1).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

Tightening torques
Banjo bolt for brake hose to components
M10 x 1 24 Nm

Secure the cable strap (arrow).

Connect new clamp (1) to hose (2).

Connect hose (2) to footbrake cylinder (3).
Secure clamp (1) with pliers (No. 13 1 500).

Top up the brake fluid tank (1) up to the maximum mark (2).

Hydraulic fluid
Brake fluid, DOT4

Press the brake calliper (1) against the brake disc (2) with your hand.
The brake piston is pressed back and the new footbrake cylinder is bled.

(-) Adjust blow-by clearance at piston rod

Insert feeler gauge (1) in the direction of travel between footrest plate (2)
and brake lever (3).

Technical data

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Blow-by clearance of On the limit 1.9...2.1 mm
the footbrake lever position for
the footbrake
lever on the
footrest plate.

Slacken nut (1) on pushrod (2).

Turn pushrod (2) until all play on the pushrod (2) is taken up.
Lock nut (1) on pushrod (2).

Tightening torques
Pushrod, footbrake cylinder
M6, Locknut 6 Nm

Remove the feeler gauge.

Secure nut (1) with thread-locking sealant.

Follow-up work
Installing right heel deflector

=> Bleeding rear brake system (for replacing component)

(Description in item: 34 00 514, Billed as a separate item)
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

34 32 040 Replacing front brake line to pressure modulator (without bleeding brakes)
+ 34 32 640

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

=> Draining/filling/bleeding front brake system (Description

in item: 34 00 583, Billed as a separate item)
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Disengaging tank vent valve
Remove the intake air silencer

Core activity
(-) Removing front brake line to pressure modulator

Remove cable strap (arrow).

Remove tensioning strap (1).

Open holder (1) and release brake line (2).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Remove banjo bolt (1) with sealing rings (2).

Release brake line (3) from brake fitting (4) and collect any escaping brake
fluid if necessary.

Remove banjo bolt (1) with sealing ring (2) and collect escaping brake fluid if
required.
Release brake line (3).
Remove sealing ring (4).

First feed out brake line (1) at rear and then at the front and remove.

(-) Installing front brake line to pressure modulator

First feed brake line (1) in to the front and then to the rear and position.

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

Clean sealing surface (Arrow) of pressure modulator (1).

Position a new sealing ring (2).
Insert brake line (3).
Position brake line (3) with new sealing ring (4) and banjo bolt (5).
Tighten the banjo bolt (5).

Tightening torques
Banjo bolt for brake hose to components
M10 x 1 24 Nm

Position brake line (1) with new sealing rings (2), noting the banjo bolt (3) on
brake fitting (4) and while doing so, note the torsional stop (arrow).
Tighten the banjo bolt (3).

Tightening torques
Banjo bolt for brake hose to components
M10 x 1 24 Nm

Secure brake line (2) in holders (1).

Secure the cable strap (arrow).

Install tensioning straps (1).

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Follow-up work
Install the intake air silencer
Securing tank vent valve
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

34 32 044 Replacing front brake line from pressure modulator (without bleeding brakes)
+ 34 32 644

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

=> Draining/filling/bleeding front brake system (Description

Core activity
(-) Removing front brake line from pressure modulator

Release brake line (1) from holders (2) and (3) .

Release brake line (1) from holders (2).

052021 BMW Motorrad, UX-VA-4 1/5

BMW-Motorrad - F 850 GS

Remove bolt (1).

Release brake-hose distributor (2).

Remove the cable straps (arrows).

Release brake hose (1).

Remove banjo bolt (1) with sealing rings (2).

Remove brake hoses (3) and spacer clip (4).
Seal brake hoses (3) with suitable auxiliary materials.

Remove cable strap (arrow).

Open holder (1) and release brake line (2).

052021 BMW Motorrad, UX-VA-4 2/5

BMW-Motorrad - F 850 GS

Remove banjo bolt (1) with sealing ring (2) and collect escaping brake fluid if
required.
Release brake line (3).
Remove sealing ring (4).

Release brake line (1) from the holder (Arrow).

First feed out brake line (1) at rear, then feed through to the front under the
steering head and remove.

(-) Install the front brake line from pressure modulator

Feed the brake line (1) from the front under the steering head, feed in at rear
and position.
Secure the brake line (1) in the bracket (arrow).

Clean the sealing surface (arrow) on the pressure modulator (1).

Place the new sealing ring (2) into position.
Insert the brake line (3).
Fit the brake line (3) with the new sealing ring (4) and banjo bolt (5).

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS
Tighten the banjo bolt (5).

Tightening torques
Banjo bolt for brake hose to components
M10 x 1 24 Nm

Secure brake line (2) in holder (1).

Secure the cable strap (arrow).

Position brake hose (3) with new sealing rings (2) and spacer clip (4).
Install banjo bolt (1).

Tightening torques
Double banjo bolt to brake calliper
M10 x 1 24 Nm

Route brake hose (1).

Close the cable strap (arrows).

Position brake-hose distributor (2).

Install bolt (1).

Tightening torques
Brake-hose distributor to fork clamp
M6 x 16 8 Nm

052021 BMW Motorrad, UX-VA-4 4/5

BMW-Motorrad - F 850 GS

Secure the brake line (1) in the brackets (2).

Secure the brake line (1) in the brackets (2) and (3).

052021 BMW Motorrad, UX-VA-4 5/5

BMW-Motorrad - F 850 GS

34 32 050 Replacing rear brake line to pressure modulator (without bleeding brakes)
+ 34 32 650

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

=> Draining/filling/bleeding rear brake system (Description in

item: 34 00 584, Billed as a separate item)
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Disengaging tank vent valve
Removing right side cover
Removing right heel deflector

Core activity
(-) Removing rear brake pipe to pressure modulator

Remove cable strap (arrow).

Remove banjo bolt (1) with sealing rings (2).
Release brake line (3), collect any escaping brake fluid if necessary.

Remove cable strap (arrow).

Remove banjo bolt (1) with sealing ring (2) and collect escaping brake fluid if
required.
Release brake line (3) and remove to the side.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Remove sealing ring (4).

(-) Install the rear brake line to pressure modulator

Clean sealing surface of pressure modulator (1).

Position a new sealing ring (2).
Insert brake line (3).
Position brake line (3) with new sealing ring (4) and banjo bolt (5).
Tighten the banjo bolt (5).

Tightening torques
Banjo bolt for brake hose to components
M10 x 1 24 Nm

Secure the cable strap (arrow).

Position brake line (1) with banjo bolt (2) and new sealing rings (3).
Tighten the banjo bolt (2).

Tightening torques
Banjo bolt for brake hose to components
M10 x 1 24 Nm

Secure the cable strap (arrow).

Follow-up work
Installing right heel deflector
Installing right side cover
Securing tank vent valve
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
052021 BMW Motorrad, UX-VA-4 2/3
BMW-Motorrad - F 850 GS
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

34 32 051 Replacing rear brake line from pressure modulator (without bleeding brakes)
+ 34 32 651

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

=> Draining/filling/bleeding rear brake system (Description in

Core activity
(-) Removing rear brake line from pressure modulator

Remove screws (1).

Release brake line (2) with holders (3).

Release brake line (1) from holders (2).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Remove cable strap (arrow).

Release brake line (1) from holders (2).

Remove banjo bolt (1) with sealing rings (2).

Release brake line (3), collect any escaping brake fluid if necessary.

Remove banjo bolt (1) with sealing ring (2) and collect escaping brake fluid if
required.
Release brake line (3) and remove to the rear.
Remove sealing ring (4).

(-) Installing rear brake line from pressure modulator

Clean sealing surface (Arrow) of pressure modulator (1).

Position a new sealing ring (2).
Position brake line (3).
Position brake line (3) with new sealing ring (4) and banjo bolt (5).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Tighten the banjo bolt (5).

Tightening torques
Banjo bolt for brake hose to components
M10 x 1 24 Nm

Position brake line (1) with banjo bolt (2) and new sealing rings (3).
Tighten the banjo bolt (2).

Tightening torques
Banjo bolt for brake hose to components
M10 x 1 24 Nm

Secure brake line (1) in holders (2).

Secure the cable strap (arrow).

Secure brake line (1) in holders (2).

Route brake line (1) and position it with holders (2) in bore holes (Arrow).
Install screws (3).

Tightening torques
Brake-line holder to swinging arm
M6 x 16 8 Nm

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Follow-up work
Installing right side cover
Securing tank vent valve
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

34 32 499 Replacing hose, rear, to reservoir

+ 34 32 525

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Releasing brake-fluid reservoir, rear

Remove bolt (1).

Ease brake fluid tank (2) aside, making sure that it does not tilt or hang
down.

(-) Emptying the rear brake fluid tank

Remove reservoir cap (1).

Remove lock washer (2).
Remove gaiter (3).
Draw off the brake fluid and clean the expansion tank (4).

(-) Removing right heel deflector

Release the brake hose (1) from holder (2).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Remove screws (1) and (2).

Remove heel deflector (3).

(-) Removing rear brake hose to reservoir

Open the clamps (1).

Wrap cloths around the port of the brake cylinder.
Release and remove the brake hose (2).

(-) Installing rear brake hose to reservoir

Slide the new clamps (1) onto the brake hose (2).
Install the brake hose (2) and fasten the clamps (1) with pliers (No. 13 1
500).

(-) Installing right heel deflector

Position heel deflector (3).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Install bolts (1) and (2).
Tighten the screw (2).

Tightening torques
Footbrake cylinder with heel guard to footrest plate
M6 x 35 8 Nm

Tighten the screw (1).

Tightening torques
Heel guard to footrest plate
M6 x 20 8 Nm

Secure brake hose (1) in holder (2).

(-) Filling rear brake fluid expansion tank

Slowly top up the brake-fluid reservoir with brake fluid, making sure that the
air escapes from the brake hose.

Hydraulic fluid
Brake fluid, DOT4

Lightly tap the brake hose to enable the residual air to escape from the hose
into the reservoir.
Check
Check brake pressure by operating the brakes.
Result:
Low brake pressure
Measure:
Repeat the brake-bleeding process.

Top up the brake fluid tank (1) up to the maximum mark (2).
Clean the rim of the reservoir (arrow), gaiter (1), lock washer (2) and
reservoir cap (3).
Install gaiter and (1) and lock washer (2).
052021 BMW Motorrad, UX-VA-4 3/4
BMW-Motorrad - F 850 GS
Install reservoir cap (3).

(-) Securing rear brake-fluid reservoir

Position brake fluid tank (2).

Install bolt (1).

Tightening torques
Brake fluid tank to side cover
M6 x 16, Replace screw 2.4 Nm
Thread-locking compound
(mechanical)

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

34 51 011 Replacing pressure modulator (without bleeding/testing software/ programming)

+ 34 51 511

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

=> Draining/filling/bleeding front brake system (Description

in item: 34 00 583, Billed as a separate item)

=> Draining/filling/bleeding rear brake system (Description in

item: 34 00 584, Billed as a separate item)
Removing seat
Disconnect battery from vehicle
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Disengaging tank vent valve
Removing right side cover
Disconnecting brake lines from pressure modulator
Removing left heel deflector
Removing chain guard
Removing left side cap
Removing starter relay
Removing the holder of the carbon canister

Core activity
(-) Removing pressure modulator

Press lock (Arrow) and fold open retaining clip (1).

Disconnect connector (2) for pressure modulator.

052021 BMW Motorrad, UX-VA-4 1/5

BMW-Motorrad - F 850 GS

Remove bolt (1).

Loosen holder (2).

Release holder (1) with pressure modulator from bore hole (2).
Remove cable strap (arrow).

Feed holder (1) with pressure modulator under rear frame (2) and remove.

(-) Replacing pressure modulator

Remove bolt (1).

Release holder (2) from pressure modulator (3), checking catch (arrow).

052021 BMW Motorrad, UX-VA-4 2/5

BMW-Motorrad - F 850 GS

Install pressure modulator (3) on holder (2), checking catch (arrow).

Install bolt (1).

Tightening torques
Pressure modulator to bracket
M6 x 20 8 Nm

(-) Installing pressure modulator

Insert cable strap (Arrow) in holder (1) but do not close.

Feed holder (1) with pressure modulator under rear frame (2) and position.

Secure the cable strap (arrow).

Insert holder (1) with pressure modulator in bore hole (2).

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS

Align holder (2).

Install screw (1), but do not tighten.

Connect connector (2) for pressure modulator.

Close retaining clip (1) while ensuring that the lock (Arrow) engages.

Follow-up work
Installing the holder of the carbon canister
Installing starter relay
Installing left side cap
Installing chain guard
Installing left heel deflector
Connect the brake lines to pressure modulator
Installing right side cover
Securing tank vent valve
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
052021 BMW Motorrad, UX-VA-4 4/5
BMW-Motorrad - F 850 GS
Installing top front-wheel cover
Installing front spray guard
Connect battery with vehicle
Checking, if necessary correcting date
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 5/5

BMW-Motorrad - F 850 GS

35 21 000 Removing/installing or replacing footbrake lever

+ 35 21 531

Unclip bolt (1) from pushrod (2) and remove from pushrod (2) and footbrake
lever (3) .

Remove bolt (1), counter-holding it at two-flats (arrows) of shouldered

bushing (2) .
Release footbrake lever (3) from footrest plate (4) .

Detach footbrake lever (1) from return spring (2) and remove together with
shouldered bushing (3) and thrust washer (4) .

(-) Installing footbrake lever

ATTENTION
Damage of the bearing due to lubricants.
Component damage, stiff movement
Lubricants can damage the coating chemically.
Lubricant bind dirt particles and increase the wear by this.
052021 BMW Motorrad, UX-VA-4 1/3
BMW-Motorrad - F 850 GS
A PTFE-bearing is maintenance free; do not lubricate the bearing.

Insert shouldered bushing (3) and thrust washer (4) into the brake pedal (1).
Attach brake pedal (1) together with shouldered bushing (3) and thrust
washer (4) in release spring (2). Note thrust washer (4).

Hold brake pedal (3) in position on the footrest plate (4).

Install screw (1), counter-holding it at two-flats (arrows) of shouldered
bushing (2) while doing so.

Tightening torques
Brake pedal to footrest plate
M8 x 20 19 Nm

Hold fork of pushrod (2) in position at footbrake lever (3).

Install bolts (1) and clip onto pushrod (2).

(-) Adjust blow-by clearance at piston rod

Insert feeler gauge (1) in the direction of travel between footrest plate (2)
and brake lever (3).

Technical data
Blow-by clearance of On the limit 1.9...2.1 mm
the footbrake lever position for
the footbrake
lever on the
footrest plate.

Slacken nut (1) on pushrod (2).

Turn pushrod (2) until all play on the pushrod (2) is taken up.
Lock nut (1) on pushrod (2).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Tightening torques
Pushrod, footbrake cylinder
M6, Locknut 6 Nm

Remove the feeler gauge.

Secure nut (1) with thread-locking sealant.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

36 20 510 Replacing RDC control unit (without checking software/programming)

Equipment trim-level variant:

0530 - Tyre pressure control (RDC)OE

Preparatory work
Removing luggage carrier
Removing rear carrier

Core activity
(-) Remove RDC control unit

Remove expanding rivet (1).

Release RDC control unit (2) from fixture (arrow).
Disconnect connector (3).

(-) Install RDC control unit

Connect connector (3).

Clasp and position the RDC control unit (2) in fixture (arrow).
Install expanding rivet (1).

Follow-up work
Installing rear carrier
Installing luggage carrier

=> Testing software (Description in item: 61 00 502, Billed as

a separate item)

=> Programming control units of vehicle (along with testing

software) (Description in item: 61 00 510, Billed as a
separate item)

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

36 20 554 Replacing front RDC sensor (tyre removed)

Equipment trim-level variant:

0530 - Tyre pressure control (RDC)OE

Core activity
(-) Removing RDC sensor

Remove the nut (1).

Remove RDC sensor (2) and valve (3).

(-) Installing RDC sensor

Clean the seat for RDC sensor.

Insert valve (1), RDC sensor (2) and new nut (3).
If necessary, note the distance from the rim flange (arrows) and tighten nut
(3).

Tightening torques
Tyre pressure monitoring (RDC) sensor to wheel rim
M8 x 1, Replace nut 7 Nm

Follow-up work
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle
Teaching in RDC sensor at control unit
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

36 20 555 Replacing rear RDC sensor (tyre removed)

Equipment trim-level variant:

0530 - Tyre pressure control (RDC)OE

Core activity
(-) Removing RDC sensor

Remove the nut (1).

Remove RDC sensor (2) and valve (3).

(-) Installing RDC sensor

Clean the seat for RDC sensor.

Insert valve (1), RDC sensor (2) and new nut (3).
If necessary, note the distance from the rim flange (arrows) and tighten nut
(3).

Tightening torques
Tyre pressure monitoring (RDC) sensor to wheel rim
M8 x 1, Replace nut 7 Nm

Follow-up work
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle
Teaching in RDC sensor at control unit
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

36 23 001 Replacing wheel-speed sensor, front

+ 36 23 601

Core activity
(-) Removing front wheel-speed sensor

Remove bolt (1).

Release wheel speed sensor (2).

Release cable (1) from clamp (2) and cable clip (3) .

Release cable (1) from cable clip (2) .

Core activity
(-) Removing rear wheel-speed sensor

Remove cable strap (arrow).

Disconnect and remove plug connection (1) for wheel speed sensor.
Work cable (2) down, detaching at tab (3) .

Release cable (1) from cable clip (2) .

Remove cable strap (arrow).

Release cable (1) from cable clip (2) .

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Remove bolt (1).

Release wheel speed sensor (2).
Remove bolt (3) and cable clip (4) .
Remove wheel speed sensor (2).

(-) Installing rear wheel-speed sensor

Clean the threads.

Position wheel speed sensor (1) and install bolt (2).

Tightening torques
Wheel-speed sensor, rear, to brake caliper carrier
M6 x 16, Replace screw 8 Nm
Thread-locking compound (micro-
encapsulated)

Position cable clip(3) in bore hole (Arrow) of brake-caliper support (4) and
install bolt (5).

Tightening torques
Cable clip for wheel-speed sensor to brake-caliper support
M5 x 10 - 10.9, Replace screw 4.6 Nm
Thread-locking compound (micro-
encapsulated)

Secure cable (1) in cable clip (2).

Secure the cable strap (arrow).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Secure cable (1) in cable clip (2).

Route cable (2) upwards, attaching it to tab (3).

Install plug connection (1) for wheel speed sensor and connect.
Secure the cable strap (arrow).

Follow-up work
Installing bracket for fuel tank
Secure support for seat bench
Securing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

36 23 003 Replacing sensor ring, front

+ 36 23 603

Core activity
(-) Removing front sensor ring

Remove screws (1).

Remove sensor ring (2).

(-) Installing front sensor ring

Position sensor ring (2).

Install screws (1).

Tightening torques
Sensor ring to front wheel
M5 x 10 5 Nm

Follow-up work
Install the front wheel
Securing right brake caliper
Securing left brake caliper
Removing front-wheel stand
Bedding in brake pads
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

36 23 004 Replacing sensor ring, rear

+ 36 23 604

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Remove the rear wheel

Core activity
(-) Removing rear sensor ring

Remove screws (1).

Remove sensor ring (2).

(-) Installing rear sensor ring

Position sensor ring (2).

Install screws (1).

Tightening torques
Sensor ring to rear wheel
M5 x 10 5 Nm

Follow-up work
Install the rear wheel
Adjust chain sag
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

36 30 300 Removing/installing front wheel

+ 36 30 628

Core activity
(-) Removing front wheel

Release clamping screws (1) on left and right.

Remove screws (1), counter-holding with the hexagon head (No. 36 3 691) if
necessary.
Pull out quick-release axle (2) with hexagon head (No. 36 3 691).
ATTENTION
Removal of front wheel not in compliance with correct procedure
Damage to wheel speed sensor
Note the wheel-speed sensor when rolling out the front wheel.

Remove front wheel (3).

(-) Install the front wheel

Clean and lubricate spacer bush (1), If necessary.

Install spacer bush (1).

Lubricant
Unirex N3 83 19 2 160 349

Clean and lubricate quick-release axle (2).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Lubricant
Unirex N3 83 19 2 160 349

ATTENTION
Front wheel installed wrong way round
Risk of accident
Note direction-of-rotation arrows on tyre or rim.

ATTENTION
Installation of front wheel not in compliance with correct procedure
Damage to wheel speed sensor
Note the wheel-speed sensor when rolling in the front wheel.

Position front wheel (3).

Install quick-release axle (2).
Install bolt (1) and tighten, counter-hold the quick-release axle on the right
side with the hexagon head (No. 36 3 691) while doing so.

Tightening torques
Axle screw in front quick-release axle
M20 x 1.5 50 Nm

Compress the telescopic forks several times to avoid twisting, lower front-
wheel stand, if required.
Tighten clamping bolts (1) on left and right.

Tightening torques
Clamp of quick-release axle
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence

19 Nm

Follow-up work
Securing right brake caliper
Securing left brake caliper
Removing front-wheel stand
Bedding in brake pads
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

36 30 320 Removing/installing rear wheel

+ 36 30 629

ATTENTION
Brake actuation with brake pads or brake calipers removed
Brake pistons pushed out
Do not operate brake.
Install brake pads and brake caliper or insert the piston resetting device.

Push brake caliper (1) against brake disc (2) to push back the piston.

Remove nut (1) with washer (2).

Remove quick-release axle (1).

ATTENTION
Removal of rear wheel not in accordance with correct procedure
Damage to wheel speed sensor
Note the wheel-speed sensor when rolling out the rear wheel.

Remove rear wheel (2), while paying attention to the brake caliper (3) and
push aside if required.

052021 1/3
BMW-Motorrad - F 850 GS
Remove the left spacer bush (1).
Remove chain sprocket support (2) and judder damper (3).
Remove right spacer bush (4).

(-) Install the rear wheel

As applicable, clean the areas indicated (arrows) and lubricate.

Lubricant
Optimoly TA 18 21 9 062 599

Position brake caliper (1) in guide (2).

Lubricating the spacer bushes and radial shaft seal of chain sprocket
support
Remove all dirt and old lubricant from the components.
Lubricate the components at the areas indicated (arrows).

Lubricant
Unirex N3 83 19 2 160 349

Check judder damper (3) for damage, deformation or wear and replace, if
required..
Lubricate and install judder damper (3).

Installation tool
Silicone spray 83 19 2 208 609

Install right spacer bush (4).

Install chain sprocket support (2).
Install left spacer bush (1).

Clean and lubricate quick-release axle (1).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Lubricant
Unirex N3 83 19 2 160 349

ATTENTION
Installation of rear wheel not in accordance with correct procedure
Damage to wheel speed sensor
Note the wheel-speed sensor when rolling in the rear wheel.

Follow-up work
Adjust chain sag
Bedding in brake pads
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

36 30 508 Balancing front wheel (statically) (wheel removed)

Core activity
(-) Static balancing of front wheel

Align the balancing jig (No. 36 3 601) with knurled screw (1) and bubble
level (2).
Check the carrier axle for runout and damage.
Install adapter axle (No. 36 5 571) with conical adapter (No. 36 5 572) in the
front-wheel bearing and tension.
Position adapter axle (No. 36 5 571) with the front wheel on balancer (No.
36 3 601).
Allow the front wheel to settle to a stop.
Clean the attachment points for the adhesive weights.
Affix the adhesive weights uniformly spaced on both sides of the rim
opposite the wheel's heaviest point.

Technical data
Permissible front- max 5 g
wheel imbalance
Balance weight for max 80 g
front wheel
Weights have to be
affixed with one half
on the left and one
half on the right, in
other words centred
on the rim

Repeat the balancing procedure as a check.

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

36 30 518 Balancing rear wheel (statically) (wheel removed)

Core activity
(-) Removing mounting for judder damper

Remove screws (1).

Remove mounting (2).
Remove the spacer bush (3).

(-) Static balancing of rear wheel

Align the balancing jig (No. 36 3 601) with knurled screw (1) and bubble
level (2).
Check the carrier axle for runout and damage.
Install adapter axle (No. 36 5 571) with conical adapter (No. 36 5 572) in the
rear-wheel bearing and tension.
Position adapter axle (No. 36 5 571) with the rear wheel on balancer (No. 36
3 601).
Allow the rear wheel to settle to a stop.
Clean the attachment points for the adhesive weights.
Affix the adhesive weights uniformly spaced on both sides of the rim
opposite the wheel's heaviest point.

Technical data
Permissible rear- max 5 g
wheel imbalance
Balance weight for max 80 g
rear wheel
Weights have to be
affixed with one half
on the left and one
half on the right, in
other words centred
on the rim

Repeat the balancing procedure as a check.

(-) Installing mounting for judder damper

Position spacer bush (3).

Position mounting (2).
Install screws (1).

Tightening torques
Mounting for judder damper to wheel hub
M10 x 30 - 10.9 56 Nm
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

36 30 601 Replacing rim for front wheel (wheel removed)

Core activity
(-) Remove the front left brake disc

Remove screws (1).

Remove the brake disc (2).

(-) Removing front sensor ring

Remove screws (1).

Remove sensor ring (2).

(-) Removing front right brake disc

Remove screws (1).

Remove the brake disc (2).

(-) Removing front tyre

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Remove the tyre with commercially available tools.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
(-) Installing front tyre

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Install the tyre in accordance with the manufacturer's instructions, using

commercially available tools. Make sure that the direction-of-rotation arrows
on tyre and rim point in the same direction.
Manufacturer-specific tyre mark for imbalance must be toward the valve.

Check

Inflate the tyre to test pressure and check the valve for leaks.

Technical data
Wheel valve test 4 bar
pressure

Result:
Valve leaking
Measure:
Replace the valve insert.
Result:

Valve leaktight
Measure:
Adjust the air pressure

Technical data
Tyre pressure, front One-up, tyre 2.2 bar
cold
Two-up 2.5 bar
and/or with
luggage, tyre
cold

Check the tyre and make sure the line is at a uniform distance from the rim
flange all the way round.

(-) Install the front right brake disc

Place brake disc (1) on the wheel rim with the broad pressure discs to the
outside and position.
Install screws (2).

Tightening torques
Brake disc to front wheel
M8 x 27 - 10.9, Replace screw Tightening
Thread-locking compound (micro- sequence: tighten in
encapsulated) diagonally opposite
sequence
19 Nm

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
(-) Install the front left brake disc

Place brake disc (1) on the wheel rim with the broad pressure discs to the
outside and position.
Install screws (2).

Tightening torques
Brake disc to front wheel
M8 x 27 - 10.9, Replace screw Tightening
Thread-locking compound (micro- sequence: tighten in
encapsulated) diagonally opposite
sequence
19 Nm

(-) Installing front sensor ring

Position sensor ring (2).

Install screws (1).

Tightening torques
Sensor ring to front wheel
M5 x 10 5 Nm

(-) Static balancing of front wheel

Repeat the balancing procedure as a check.

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

36 30 611 Replacing rim for rear wheel (wheel removed)

Core activity
(-) Removing brake disc

Remove screws (1).

Remove the brake disc (2).

(-) Removing rear sensor ring

Remove screws (1).

Remove sensor ring (2).

(-) Removing rear tyre

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Remove the tyre with commercially available tools.

(-) Installing rear tyre

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Install the tyre in accordance with the manufacturer's instructions, using

commercially available tools. Make sure that the direction-of-rotation arrows
on tyre and rim point in the same direction.
Manufacturer-specific tyre mark for imbalance must be toward the valve.

Check

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS
Inflate the tyre to test pressure and check the valve for leaks.

Technical data
Wheel valve test 4 bar
pressure

Result:
Valve leaking
Measure:
Replace the valve insert.
Result:
Valve leaktight
Measure:
Correct the tyre pressure.

Technical data
Tyre pressure, rear One-up, tyre 2.5 bar
cold
Two-up 2.9 bar
and/or with
luggage, tyre
cold

Check the tyre and make sure the line is at a uniform distance from the rim
flange all the way round.

(-) Installing rear sensor ring

Position sensor ring (2).

Install screws (1).

Tightening torques
Sensor ring to rear wheel
M5 x 10 5 Nm

(-) Installing rear brake disc

Position brake disc (1) with shoulder (arrow) upwards.

Install screws (2).

Tightening torques
Brake disc to rear wheel
M8 x 15.5, Replace screw Tightening
Thread-locking compound (micro- sequence: tighten
encapsulated) by stages in
diagonally opposite
sequence
30 Nm

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
(-) Checking rear brake disc for runout with brake disc removed

Requirement
No burrs or scoring on brake disc, brake disc thickness above minimum.
Brake disc has been cleaned.

Check

Set the dial gauge to "0".

Slowly turn the wheel through at least one complete revolution and
observe the dial gauge reading.
The sum of the positive and negative dial-gauge readings is the total run-
out.

Technical data
Brake disc lateral installed, at max 0.15 mm
runout, rear outside
circumference,
component
cooled
removed, at max 0.10 mm
outside
circumference,
component
cooled

Result:
Lateral run-out is excessive.
Measure:
Check positioning of the brake disc/wheel rim.
Check the wheel rim for damage.
052021 BMW Motorrad, UX-VA-4 3/4
BMW-Motorrad - F 850 GS
If necessary, check the brake disc.
See the "Diagnosis tree, braking torque fluctuations" overview for further
information.

(-) Static balancing of rear wheel

Align the balancing jig (No. 36 3 601) with knurled screw (1) and bubble
level (2).
Check the carrier axle for runout and damage.
Install adapter axle (No. 36 5 571) with conical adapter (No. 36 5 572) in the
rear-wheel bearing and tension.
Position adapter axle (No. 36 5 571) with the rear wheel on balancer (No. 36
3 601).
Allow the rear wheel to settle to a stop.
Clean the attachment points for the adhesive weights.
Affix the adhesive weights uniformly spaced on both sides of the rim
opposite the wheel's heaviest point.

Repeat the balancing procedure as a check.

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

36 31 510 Replacing spokes for front wheel (tyre removed)

Core activity
(-) Replacing spokes

NOTICE
Before exchanging the spokes, determine the cause of the spoke break and
check rim for plastic deformation.
The rim should be within the permissible tolerance for side and radial runout or
within a tolerance range with centering capability, whereby the runout should
be distributed to a larger size.
In case of plastic deformations on the rim or runouts in a small area of the rim
circumference, the rim should be replaced for reasons of safety.
In case of more than one loose or damaged spoke, the rim should be replaced
or completely equipped with new spokes by a professional for reasons of
safety.

Slacken set screw (1).

Remove spoke nipple (2) and spoke (3).
Insert a new spoke (3).
Install spoke nipple (2).

Tightening torques
Nipple on spoke
M4.5 x 0.75 3.5 Nm

Tighten set screw (1).

Tightening torques
Thread locking compound for spoke nipples
Grubscrew, M4 2 Nm

(-) Checking runout of front wheel rim

Align balancing jig (No. 36 3 601) with knurled screws (1) and bubble level
(2).
Insert balancing shaft (No. 36 5 571) in front-wheel bearing and secure it
with tensioner (No. 36 5 572), making sure that front-wheel bearing is lightly
preloaded.
Push stops (No. 36 5 573) on to balancing shaft (No. 36 5 571) and seat the
front wheel in the balancer.

Move limit positions (No. 36 5 573) against belt pulleys (1) and tighten.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Check
Set dial gauge (No. 00 2 510) with measuring adapter (No. 34 2 510) on the
machined inner face and check lateral runout.

Technical data
Lateral runout, front max 2 mm
wheel

Result:
Permissible lateral runout is exceeded.
Measure:
Replace the wheel rim.

Check

Set dial gauge (No. 00 2 510) with measuring adapter (No. 34 2 510) on the
machined inner face and check vertical runout.

Technical data
Vertical runout, front max 2 mm
wheel

Result:
Permissible vertical runout is exceeded.
Measure:
Replace the wheel rim.

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

36 31 511 Replacing spokes for rear wheel (tyre removed)

Core activity
(-) Removing mounting for judder damper

Remove screws (1).

Remove mounting (2).
Remove the spacer bush (3).

(-) Replacing spokes

Slacken set screw (1).

Remove spoke nipple (2) and spoke (3).
Insert a new spoke (3).
Install spoke nipple (2).

Tightening torques
Nipple on spoke
M4.5 x 0.75 3.5 Nm

Tighten set screw (1).

Tightening torques
Thread locking compound for spoke nipples
Grubscrew, M4 2 Nm

(-) Check the runout of rear wheel rim

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Push stops (No. 36 5 573) on to balancing shaft (No. 36 5 571) and seat the
front wheel in the balancer.

Move limit positions (No. 36 5 573) against belt pulleys (1) and tighten.

Check
Set dial gauge (No. 00 2 510) with measuring adapter (No. 34 2 510) on the
machined inner face and check lateral runout.

Technical data
Lateral runout, rear max 2 mm
wheel

Result:
Permissible lateral runout is exceeded.
Measure:
Replace the wheel rim.

Check

Set dial gauge (No. 00 2 510) with measuring adapter (No. 34 2 510) on the
machined inner face and check vertical runout.

Technical data
Vertical runout, rear max 2 mm
wheel

Result:
Permissible vertical runout is exceeded.
Measure:
Replace the wheel rim.

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
(-) Installing mounting for judder damper

Position spacer bush (3).

Position mounting (2).
Install screws (1).

Tightening torques
Mounting for judder damper to wheel hub
M10 x 30 - 10.9 56 Nm

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

36 31 851 Renewing front wheel bearing (wheel removed)

Preparatory work
Removing spacing bushing for front wheel
Removing shaft sealing rings

Core activity
(-) Removing wheel bearings of front wheel
Reassemble internal puller and reaction support
Install internal puller (No. 00 8 573) in reaction support (No. 00 8 562).

Place support ring (No. 31 6 500) on the wheel hub on the right-hand side of
the wheel and lay the wheel flat.
Install reaction support (No. 00 8 572) and internal puller (No. 00 8 573).
Heat the bearing seat.

Technical data
Release/mating 100 °C
temperature

Remove wheel bearing (1) .

Remove the spacer bush (2).

Heat the left bearing seat.

Technical data
Release/mating 100 °C
temperature

Drive out the left wheel bearing (1) with drift (No. 11 6 733) from the inside.
Allow the wheel hub to cool down.
Degrease and clean the bearing seats and the spacing bushing.

(-) Installing wheel bearings of front wheel

Installing left wheel bearing
Introduce wheel bearing (1) into the bearing seat.
Install spindle with pull-in nut (No. 36 5 551), washer (A) (dia. 47 mm)
without thread (No. 36 5 554), washer (B) (dia. 25 mm) and (C) (dia. 47 mm)
with thread (No. 36 5 553).
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Pull in wheel bearing (1) until seated.
Remove washer (A) and pull-in nut.

Installing right wheel bearing

Install spacer bush (2).
Spacing bushing (2) sits flat and square on wheel bearing (1).
Introduce wheel bearing (3) into the bearing seat.
Install washer (A) and pull-in nut.
Pull in wheel bearing (3) until seated against spacing bushing (2).
Remove spindle with pull-in nut (No. 36 5 551) and washers (A), (B) and (C).

Follow-up work
Installing shaft sealing rings
Installing spacing bushing for front wheel

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

36 31 861 Replace wheel bearing for rear wheel (wheel removed)

Preparatory work
Removing mounting for judder damper
Removing shaft sealing ring with circlip

Core activity
(-) Removing wheel bearings of rear wheel

Remove wheel bearing (1) with reaction support (No. 00 8 562), internal
puller (No. 00 8 563), and support ring (No. 36 6 640) .
Remove the tubular spacer (2).

Remove wheel bearing (1) with reaction support (No. 00 8 562), internal
puller (No. 00 8 563), and support ring (No. 36 6 640) .

(-) Installing wheel bearings of rear wheel

Clean the bearing seats.

Installing right rear-wheel bearing
Install bearing (1) with the open face in the bearing seat. Install long spindle
with pull-in nut (No. 36 5 551) washer without thread (No. 36 5 554) and
washers with thread (No. 36 5 553):
Washer (A) without thread, dia. 52 mm
Washer (B) with thread, dia. 28 mm
Washer (C) with thread, dia. 52 mm
Pull in bearing (1) up to the limit position.
Remove washer (A) and pull-in nut.

Installing left rear-wheel bearing

Install spacer bush (2).
Spacer bush (2) sits flat and without tilting on bearing (1).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Install bearing (3) with the open face in the bearing seat. Install long spindle
with pull-in nut (No. 36 5 551) washer without thread (No. 36 5 554) and
washers with thread (No. 36 5 553):
Washer (A) without thread, dia. 52 mm
Washer (B) with thread, dia. 28 mm
Washer (C) with thread, dia. 52 mm
Pull in bearing (3) until seated against the spacer bush (2).

Follow-up work
Installing shaft sealing ring with circlip
Installing mounting for judder damper

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

36 32 501 Renewing front tyre (wheel removed)

Core activity
(-) Removing front tyre

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Remove the tyre with commercially available tools.

(-) Installing front tyre

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Install the tyre in accordance with the manufacturer's instructions, using

commercially available tools. Make sure that the direction-of-rotation arrows
on tyre and rim point in the same direction.
Manufacturer-specific tyre mark for imbalance must be toward the valve.

Check

Inflate the tyre to test pressure and check the valve for leaks.

Technical data
Wheel valve test 4 bar
pressure

Result:
Valve leaking
Measure:
Replace the valve insert.
Result:

Valve leaktight
Measure:
Adjust the air pressure

Technical data
Tyre pressure, front One-up, tyre 2.2 bar
cold
Two-up 2.5 bar
and/or with
luggage, tyre
cold

Check the tyre and make sure the line is at a uniform distance from the rim
flange all the way round.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
(-) Static balancing of front wheel

Repeat the balancing procedure as a check.

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

36 32 511 Removing rear tyre (wheel removed)

Core activity
(-) Removing rear tyre

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Remove the tyre with commercially available tools.

(-) Installing rear tyre

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Install the tyre in accordance with the manufacturer's instructions, using

commercially available tools. Make sure that the direction-of-rotation arrows
on tyre and rim point in the same direction.
Manufacturer-specific tyre mark for imbalance must be toward the valve.

Check

Inflate the tyre to test pressure and check the valve for leaks.

Technical data
Wheel valve test 4 bar
pressure

Result:
Valve leaking
Measure:
Replace the valve insert.
Result:

Valve leaktight
Measure:
Correct the tyre pressure.

Technical data
Tyre pressure, rear One-up, tyre 2.5 bar
cold
Two-up 2.9 bar
and/or with
luggage, tyre
cold

Check the tyre and make sure the line is at a uniform distance from the rim
flange all the way round.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
(-) Removing mounting for judder damper

Remove screws (1).

Remove mounting (2).
Remove the spacer bush (3).

(-) Static balancing of rear wheel

Align the balancing jig (No. 36 3 601) with knurled screw (1) and bubble
level (2).
Check the carrier axle for runout and damage.
Install adapter axle (No. 36 5 571) with conical adapter (No. 36 5 572) in the
rear-wheel bearing and tension.
Position adapter axle (No. 36 5 571) with the rear wheel on balancer (No. 36
3 601).
Allow the rear wheel to settle to a stop.
Clean the attachment points for the adhesive weights.
Affix the adhesive weights uniformly spaced on both sides of the rim
opposite the wheel's heaviest point.

Repeat the balancing procedure as a check.

(-) Installing mounting for judder damper

Position spacer bush (3).

Position mounting (2).
Install screws (1).

Tightening torques
Mounting for judder damper to wheel hub
M10 x 30 - 10.9 56 Nm

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

36 32 528 Checking wheel rims for deformations, dents (tyres removed)

Core activity
(-) Checking runout of front wheel rim

Move limit positions (No. 36 5 573) against belt pulleys (1) and tighten.

Check
Set dial gauge (No. 00 2 510) with measuring adapter (No. 34 2 510) on the
machined inner face and check lateral runout.

Technical data
Lateral runout, front max 2 mm
wheel

Result:
Permissible lateral runout is exceeded.
Measure:
Replace the wheel rim.

Check

Set dial gauge (No. 00 2 510) with measuring adapter (No. 34 2 510) on the
machined inner face and check vertical runout.

Technical data
max 2 mm

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Vertical runout, front
wheel

Result:
Permissible vertical runout is exceeded.
Measure:
Replace the wheel rim.

(-) Removing mounting for judder damper

Remove screws (1).

Remove mounting (2).
Remove the spacer bush (3).

(-) Check the runout of rear wheel rim

Move limit positions (No. 36 5 573) against belt pulleys (1) and tighten.

Check
Set dial gauge (No. 00 2 510) with measuring adapter (No. 34 2 510) on the
machined inner face and check lateral runout.

Technical data
Lateral runout, rear max 2 mm
wheel

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Result:
Permissible lateral runout is exceeded.
Measure:
Replace the wheel rim.

Check

Set dial gauge (No. 00 2 510) with measuring adapter (No. 34 2 510) on the
machined inner face and check vertical runout.

Technical data
Vertical runout, rear max 2 mm
wheel

Result:
Permissible vertical runout is exceeded.
Measure:
Replace the wheel rim.

(-) Installing mounting for judder damper

Position spacer bush (3).

Position mounting (2).
Install screws (1).

Tightening torques
Mounting for judder damper to wheel hub
M10 x 30 - 10.9 56 Nm

052021 BMW Motorrad, UX-VA-4 3/3

Frames - Fairing

Repair Guide

BMW Motorrad
BMW-Motorrad - F 850 GS

46 51 050 Replacing rear frame

+ 46 51 563

Preparatory work
Removing seat
Removing battery
Removing luggage carrier
Removing rear carrier
Removing number-plate carrier
Removing left side cap
Releasing brake-fluid reservoir, rear
Removing right side cover
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Removing support for seat bench
Removing bracket for fuel tank
Loosening holder for main fuse
Removing lock bearing with lock barrel
Removing eccentric seat bench
Removing rear left footrest bracket
Removing rear right footrest bracket
Loosening holder for control units
Removing cover for voltage regulator with spray guard
Release the wiring harness from the rear-wheel cover
Removing rear-wheel cover

Core activity
(-) Removing rear frame

Release brake hose (1) with holder (2).

Remove screws (1).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

46 51 120 Removing/installing frame

+ 46 51 575

Preparatory work
Placing motorcycle on rear-wheel stand
Removing seat
Removing battery
Removing luggage carrier
Removing rear carrier
Removing number-plate carrier
Removing left side cap
Removing right side cover
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Remove the intake air silencer
Removing throttle-valve assembly
Removing windscreen
Removing centre slipstream deflector
Remove the windscreen adjuster
Removing left slipstream deflector
Removing right slipstream deflector
Removing instrument panel
Removing headlight
Removing the fork partition
Removing front panel carrier
Draining front brake system
Draining rear brake system
Draining coolant
Removing the cover for wiring harness
Loosen clutch cable from manual controls for clutch control
Remove the left handlebar weight
Removing left handlebar grip
Release the wiring harness front section
Loosen brake line from brake fitting for front wheel
Releasing the front brake line from the brake caliper
Removing steering damper
Removing top fork bridge
Installing engine lifter
Removing the bottom fork bridge with the front suspension
052021 BMW Motorrad, UX-VA-4 1/10
BMW-Motorrad - F 850 GS

• Release the vent hose (1) from the bracket (2).

• Release the cable (1) for the alternator from the bracket (2).

• Feed the wiring harnesses (1) from the trailing arm and front panel carrier
through the frame (2) and let them hang under the steering head (arrow).

®
\

KB2....R61019b

• Set the wiring harness (1) from the rear area with the control units (2) aside
towards the front on the engine.

052021 BMW Motorrad, UX-VA-4 3/10

BMW-Motorrad - F 850 GS

KB2...R61021b

• Remove screws (1).

• Slacken collar nuts (2) .
• Unscrew the threaded bush (3) to the limit position.

• Remove screws (1).

• Swivel the footrest plate (1) to the side.

• Remove screws (2).

KB2...R46046b

• Remove screws (1).

• Release the frame (2).

052021 BMW Motorrad, UX-VA-4 4/10

BMW-Motorrad - F 850 GS

• Release the fixtures (arrows) of the cable duct (1) from the frame and set
the cable duct (1) on the engine.
• Pry off, feed out and remove the frame (2).

(-) Installing frame

• Feed in and fit the frame (2).

• Position the cable duct (1).
• Secure the fixtures (arrows) of the cable duct (1) in the frame.

• Make sure the cable (1) for the alternator is routed above the engine screw
connection (2), correct if applicable.

• Align the frame (2) and install the screws (1), do not tighten.

052021 BMW Motorrad, UX-VA-4 5/10

BMW-Motorrad - F 850 GS

• Swivel the footrest plate (1) to the side.

• Install screws (2), but do not tighten.

• Install screws (1), but do not tighten.

• Tighten screws (1).

�Tightening torques
Frame to engine
M12 x 40 - 10.9 1100 Nm
I

• Lubricate threaded bushes (3).

Lubricant
Optimoly TA I1a 21 9 062 599

052021 BMW Motorrad, UX-VA-4 6/10

BMW-Motorrad - F 850 GS
Align threaded bushes (3) and collar nuts (2) with cylinder head with a
suitable tool.
• Tighten threaded bushes (3) and collar nuts (2), install bolts (1).

• Swivel the footrest plate (1) to the side.

• Tighten the screws (2).

�Tightening torques
Frame to engine
M12 x 40-10.9 1100 Nm
I

• Set the wiring harness (1) from the rear area with the control units (2) aside
towards the rear.

• Feed the wiring harness (1) from the trailing arm and front panel carrier
through the apertures (arrows) of the frame (2) towards the front.

• Secure cable (1) for the alternator in the bracket (2).

052021 BMW Motorrad, UX-VA-4 7/10

BMW-Motorrad - F 850 GS

• Secure the vent hose (1) in the bracket (2).

• Install the line clip (4) for the clutch cable (1).
• Secure the clutch cable (1) in the brackets (2) and (3).

• Insert the brake line (2) and secure in bracket (4).

• Install the brake line (1).
• Secure brake lines (1) and (2) in brackets (3).
• Secure the cable strap (arrow).

Follow-up work
Installing the bracket complete with pressure modulator and starter
motor relay
Mount carbon canister with holder
Installing rear swinging arm

052021 BMW Motorrad, UX-VA-4 8/10

BMW-Motorrad - F 850 GS
Connect the brake lines to pressure modulator
Securing tank vent valve
Installing pinion with drive chain
Installing front left footrest plate
Securing selector rod
Installing rear frame
Installing rear-wheel cover
Secure the wiring harness to the rear-wheel cover
Installing cover for voltage regulator with spray guard
Securing holders for control units
Installing eccentric seat bench
Installing lock bearing with lock barrel
Securing holder for main fuse
Installing bracket for fuel tank
Installing support for seat bench
Installing the exhaust duct
Installing radiator
Installing the bottom fork bridge with the front suspension
Installing top fork bridge with the trailing arm
Securing steering damper
Securing the front brake line to the brake caliper
Secure brake line to brake fitting for front wheel
Secure the wiring harness front section
Installing left handlebar grip
Installing left handlebar weight
Secure clutch cable in manual controls for clutch control
Checking/adjusting clutch play
Installing the cover for wiring harness
Filling cooling system
Filling and bleeding front brake system
Filling and bleeding rear brake system
Removing engine lifter
Installing front panel carrier
Installing the fork partition
Installing headlight
Installing instrument panel
Installing left slipstream deflector
Install the right slipstream deflector
Install the windscreen adjuster
Installing centre slipstream deflector
Instal I the windscreen
Installing throttle-valve assembly
Install the intake air silencer
Installing fuel tank

052021 BMW Motorrad, UX-VA-4 9/10

BMW-Motorrad - F 850 GS
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing right side cover
Installing left side cap
Installing number-plate carrier
Installing rear carrier
Installing luggage carrier
Installing battery
Removing motorcycle from rear-wheel stand
Adjust chain sag
Connect the BMW Motorrad diagnostic system to the vehicle
Performing vehicle test with BMW Motorrad diagnostic system
Checking, if necessary correcting date
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Checking headlight beam throw
Final check of work performed

052021 BMW Motorrad, UX-VA-4 10/10

BMW-Motorrad - F 850 GS

46 51 520 Replacing frame (frame removed)

Core activity
(-) Replacing frame

Render the VIN on the old part invalid and dispose of the old part in
accordance with national regulations.
If necessary, use foil to mask off vehicle identification number on new part.
Convert the stop pad (1).
Convert the collar nuts (2) and the threaded bushes (3).
Screw in the threaded bushes (3) to the limit position.
Clean the area and attach a new type plate (4) on the new part.

Follow-up work
Installing outer races for top and bottom steering-head bearings
Installing top steering-head bearing
Removing inner race for bottom steering-head bearing
Installing inner race for bottom steering-head bearing

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

46 52 009 Removing/installing or cleaning/ lubricating centre stand

+ 46 52 509
Equipment trim-level variant:

0636 - Centre standOE

Preparatory work
Placing motorcycle on rear-wheel stand
Installing engine lifter

Core activity
(-) Removing tension springs for centre stand

CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Wear safety goggles.
Carefully relieve and, as applicable, apply spring tension.

Pretension centre-stand springs (1) and spring plates (2) with basic unit (No.
46 5 741) and fixture (No. 46 5 746).
Spread spring plates (2) apart until they can be removed from retaining bolts
(arrows).
Lower centre stand (3).

(-) Removing centre stand

Remove screws (1) and remove right retaining plate (2).

Pull centre stand (3) out of left retaining plate (4) and remove.

(-) Installing centre stand

ATTENTION
Damage of the bearing due to lubricants.
Component damage, stiff movement
Lubricants can damage the coating chemically.
Lubricant bind dirt particles and increase the wear by this.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
A PTFE-bearing is maintenance free; do not lubricate the bearing.

Clean bearing seats (arrows), , but do not lubricate.

Insert centre stand (1) in left retaining plate (2).
Hold right retaining plate (3) in position and install screws (4).

Tightening torques
Retaining panel for centre stand to right footrest plate
M8 x 20 19 Nm

(-) Installing tension springs for centre stand

If applicable, hook new tension springs (1) into spring plates (2).
Position basic unit (No. 46 5 741) and mount (No. 46 5 746) on spring plates
(2).
Pretension tension springs (1).

As applicable, clean the retaining pins (arrows) and lubricate.

Lubricant
Unirex N3 83 19 2 160 349

Spread spring plates (2) apart until they can be installed on the retaining
bolts (arrows).
Lift centre stand (3) and position spring plates (2) on the retaining pins
(arrows).
Install tension springs (1) with basic unit (No. 46 5 741) and fixture (No. 46 5
746).
Remove the tools.

Follow-up work
Removing engine lifter
Removing motorcycle from rear-wheel stand
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 52 011 Renewing tension spring for centre stand

+ 46 52 503
Equipment trim-level variant:

0636 - Centre standOE

Preparatory work
Placing motorcycle on rear-wheel stand
Installing engine lifter

Core activity
(-) Removing tension springs for centre stand

CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Wear safety goggles.
Carefully relieve and, as applicable, apply spring tension.

(-) Installing tension springs for centre stand

If applicable, hook new tension springs (1) into spring plates (2).
Position basic unit (No. 46 5 741) and mount (No. 46 5 746) on spring plates
(2).
Pretension tension springs (1).

As applicable, clean the retaining pins (arrows) and lubricate.

Lubricant
Unirex N3 83 19 2 160 349

Spread spring plates (2) apart until they can be installed on the retaining
bolts (arrows).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Lift centre stand (3) and position spring plates (2) on the retaining pins
(arrows).
Install tension springs (1) with basic unit (No. 46 5 741) and fixture (No. 46 5
746).
Remove the tools.

Follow-up work
Removing engine lifter
Removing motorcycle from rear-wheel stand
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 52 510 Removing and installing the rear-wheel stand special tool (motorcycles without centre
stand)

Core activity
(-) Placing motorcycle on rear-wheel stand

Insert mounts (No. 36 3 974) into basic stand (No. 36 3 971), use the pins to
adjust the height.
Manoeuvre the rear-wheel stand into position, making sure that the axle is
not blocked.
Seat mounts (No. 36 3 974) against the swinging arm and tighten the
clamping screws to secure.
ATTENTION
Vehicle toppling to side
Risk of damage to parts if vehicle topples
Make sure that the vehicle is secured so that it cannot topple sideways.

Hold the motorcycle upright and at the same time press the stand down until
the motorcycle is level and the handle of the rear-wheel stand is on the
ground.
Block the front brake, e.g. with a rubber band.
Secure the motorcycle using tensioning straps.

(-) Removing motorcycle from rear-wheel stand

Extend the side stand.

ATTENTION
Vehicle toppling to side
Risk of damage to parts if vehicle topples
Make sure that the vehicle is secured so that it cannot topple sideways.

If applicable, remove the straps.

Secure the vehicle to ensure that it cannot topple and slowly lower it,
remove rear-wheel stand (No. 36 3 971).
Place the motorcycle on its side stand.
Release the front brake.

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

46 53 000 Removing/installing or replacing side stand

+ 46 53 601

Core activity
(-) Removing side stand

CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Wear safety goggles.
Carefully relieve and, as applicable, apply spring tension.

Remove springs (1) with hook (No. 46 5 721).

Remove bolts (2).
Remove the side stand (3).

(-) Installing side stand

Clean shouldered bushings (4), check them for damage and replace them if
necessary.
Clean the threads.
Hold side stand (3) in position.
Install bolts (2).

Tightening torques
Side stand to pivot mount
M10 x 1 41 Nm
Thread-locking compound (micro-
encapsulated)
or, Thread-locking compound (Loctite
243, Medium strength)

CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Wear safety goggles.
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Carefully relieve and, as applicable, apply spring tension.

Install the springs (1) with hooks (No. 46 5 721).

Follow-up work
Securing side-stand switch
Installing engine guard
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 53 007 Replacing side stand pivot

+ 46 53 507

Core activity
(-) Removing side stand with bearing

CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Wear safety goggles.
Carefully relieve and, as applicable, apply spring tension.

Remove springs (1) with hook (No. 46 5 721).

Remove bolts (2).
Remove the side stand (3).
Using a suitable tool, remove bearing bushings (4).

(-) Installing side stand with bearing

Install shouldered bushings (4) with suitable tool.

Clean the threads.
Hold side stand (3) in position.
Install bolts (2).

Tightening torques
Side stand to pivot mount
M10 x 1 41 Nm
Thread-locking compound (micro-
encapsulated)
or, Thread-locking compound (Loctite
243, Medium strength)

CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Wear safety goggles.
Carefully relieve and, as applicable, apply spring tension.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Install the springs (1) with hooks (No. 46 5 721).

Follow-up work
Securing side-stand switch
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 53 010 Replacing pivot-bearing mount for side stand

+ 46 53 510

Core activity
(-) Removing pivot mount with side stand

Remove screws (1) and (2).

Remove bearing support (3) with side stand .

(-) Replacing pivot mount for side stand

Remove bolt (1) and side stand (2) from bearing support (2).

Install new bearing bushes (1) in bearing support (2).

Clamp the bearing support (3) with vice jaw protectors in vice.

052021 1/2
BMW-Motorrad - F 850 GS
Clean the threads.
Secure side stand (2) with bolt (1).

Tightening torques
Side stand to pivot mount
M10 x 1 41 Nm
Thread-locking compound (micro-
encapsulated)
or, Thread-locking compound (Loctite
243, Medium strength)

(-) Installing pivot mount with side stand

Position bearing support (3) with side stand .

Install screws (1), and (2).

Tightening torques
Bearing support for side stand to crankcase
M10 x 35 38 Nm
Footrest plate with side-stand bearing support on crankcase
M10 x 50 38 Nm

Follow-up work
Installing tension springs for side stand
Securing side-stand switch
Securing lower gearshift rod
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 53 011 Renewing tension spring for prop stand

+ 46 53 602

CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Wear safety goggles.
Carefully relieve and, as applicable, apply spring tension.

Remove springs (1) with hook (No. 46 5 721).

(-) Installing tension springs for side stand

CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Wear safety goggles.
Carefully relieve and, as applicable, apply spring tension.

Install the springs (1) with hooks (No. 46 5 721).

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

46 54 200 Removing/installing or replacing luggage carrier

+ 46 54 505

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing luggage carrier

Remove screws (1).

Remove luggage carrier (2).

(-) Replacing luggage carrier

Remove screws (1) and remove luggage carrier (2) from lower section of
luggage carrier (3).
Secure the lower section of the luggage carrier (3) on new part.

Tightening torques
Lower section of luggage carrier to luggage carrier
M6 x 16, Replace screw 3 Nm
Thread-locking compound (micro-
encapsulated)

(-) Installing luggage carrier

Clean the threads.

Position luggage carrier (2).
Install screws (1).

Tightening torques
Luggage carrier to rear frame
M8 x 40, Replace screw 19 Nm
Thread-locking compound (micro-
encapsulated)

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

46 54 330 Replace case holder

+ 46 54 512
Equipment trim-level variant:

0661 - Storage shelf with case holderOE

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat

Core activity
(-) Removing rear footrest bracket/left case holder

Remove the bolts (2) and footrest bracket/case holder (1).

(-) Removing rear footrest bracket/right case holder

Remove the bolts (2) and rear footrest bracket/case holder (1).

(-) Installing left rear footrest/case carrier

Clean the threads.

Secure rear footrest/case carrier (1) with screws (2).

Tightening torques
Rear footrest holder to rear frame
M8 x 30 - 10.9, Replace screw 28 Nm
Thread-locking compound (micro-
encapsulated)

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
(-) Installing right rear footrest/case carrier

Clean the threads.

Secure rear footrest/case carrier (1) with screws (2).

Tightening torques
Rear footrest holder to rear frame
M8 x 30 - 10.9, Replace screw 28 Nm
Thread-locking compound (micro-
encapsulated)

(-) Removing luggage carrier

Remove screws (1) and (2).

Remove luggage carrier (3).

(-) Installing luggage carrier

Clean the threads.

Position luggage carrier (3).
Install screws (1), and (2).

Tightening torques
Luggage carrier to rear frame
M8 x 30, Replace screw 19 Nm
Thread-locking compound (micro-
encapsulated)
M8 x 50, Replace screw 19 Nm
Thread-locking compound (micro-
encapsulated)

Follow-up work
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 61 030 Remove/install or replace top front wheel cover

+ 46 61 505

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing front spray guard

Remove screws (1).

Remove spray guard (2) , thereby releasing it from retaining lugs (arrows) of
front-wheel cover above(3).

(-) Removing top front-wheel cover

Release top front-wheel cover (1) to retaining lugs (arrows) of left fairing side
panel (2) and right fairing side panel (3), noting the locators (4).
Remove top front-wheel cover (1).

(-) Installing top front-wheel cover

Secure top front-wheel cover (1) in retaining lugs (arrows) of left fairing side
panel (2) and right fairing side panel (3), noting the locators (4).

(-) Installing front spray guard

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Position spray guard (2) , thereby securing it in retaining lugs (arrows) of
front-wheel cover above(3).
Install long screws (1).

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 61 037 Removing/installing front-wheel cover, bottom

+ 46 61 506

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing bottom front-wheel cover

Remove screws (1).

Release brake hose (2) from line clip (3).
Lay brake hoses (2) and (4) to one side.

Remove screws (1).

Lay brake hose (2) to one side.
Remove front-wheel cover (3).

(-) Installing bottom front-wheel cover

Clean the threads.

Position front-wheel cover (1).
Route brake hose (2), securing it in locator (arrow).
Install screws (3).

Tightening torques
Front-wheel cover to telescopic fork
M6 x 16, Replace screw 3 Nm
Thread-locking compound (micro-
encapsulated)

Clean the threads.

Route brake hose (1), securing it in locator (arrow).
Secure brake hose (2) in line clip (3).
Install screws (4).
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS

Tightening torques
Front-wheel cover to telescopic fork
M6 x 16, Replace screw 3 Nm
Thread-locking compound (micro-
encapsulated)

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 62 000 Replacing rear-wheel cover

+ 46 62 502

Preparatory work
Removing seat
Removing battery
Removing luggage carrier
Removing rear carrier
Removing number-plate carrier
Removing rear-light unit
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank
Removing support for seat bench
Removing bracket for fuel tank
Loosening holder for main fuse
Removing lock bearing with lock barrel
Removing eccentric seat bench
Loosening holder for control units
Removing cover for voltage regulator with spray guard
Removing voltage regulator
Releasing the wiring harness from the rear-wheel cover

Core activity
(-) Removing rear-wheel cover

Remove expanding rivet (1).

Remove screws (2).

Remove screws (1).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Pull rear-wheel cover (1) to the rear and remove.

(-) Replacing rear-wheel cover

Remount the small parts from the old to the new rear-wheel cover (1), renew
them if necessary.
8 x flat nut
3 x cable holder
3 x grommets
2 x seal plugs

Clean the adhesive surfaces and attach the sign in accordance with the
national specifications.

(-) Installing rear-wheel cover

Feed in rear-wheel cover (1) and position.

Install screws (1).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

Tightening torques
Rear-wheel cover to rear frame
M6 x 16 8 Nm

Install screws (2).

Tightening torques
Rear-wheel cover to rear frame
M6 x 16 8 Nm

Install expanding rivet (1).

Follow-up work
Securing the wiring harness to the rear-wheel cover
Installing voltage regulator
Installing cover for voltage regulator with spray guard
Securing holders for control units
Installing eccentric seat bench
Installing lock bearing with lock barrel
Securing holder for main fuse
Installing bracket for fuel tank
Installing support for seat bench
Securing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing rear-light unit
Installing number-plate carrier
Installing rear carrier
Installing luggage carrier
Installing battery
Installing seat

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
Checking, if necessary correcting date
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

46 62 050 Renewing number plate carrier

+ 46 62 508

Preparatory work
Removing seat

Core activity
(-) Removing number-plate carrier

Release bulb socket (1) for the number plate light.

Loosen cable (2) from holder (3).

Remove cable strap (arrow) and set plug (1) aside.

Remove screws (1) and screws (2).

Release locators (arrows) of number plate carrier (3) from rear-wheel cover
(4) and release number plate carrier (3).

Guide out cables (1) and (2) for the turn indicator.
Guide out cable (3) with the bulb socket from number plate carrier (4).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

(-) Replacing number-plate carrier

Remove screws (1).

Unhook and remove left turn indicator (2) and right turn indicator (3).
Remove nuts (4).

Remove nuts (1).

Remove number plate light (2).

Remount the small parts from the old to the new number plate carrier (1).
1 x cable holder
1 x reflector
3 x expansion nut

Install number plate light (2).

Install nuts (1).

Tightening torques

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Number-plate light to number-plate carrier
M5 2 Nm

Install nuts (4).

Guide in, position and hook right turn indicator (2) and left turn indicator (3).
Install screws (1).

Tightening torques
Flashing turn indicator to number-plate carrier
M6 x 20 3 Nm

(-) Installing number-plate carrier

Guide cable (3) with the bulb socket in number plate carrier (4).
Guide in cables (1) and (2) for the turn indicator.

Engage locators (arrows) of number plate carrier (3) in rear-wheel cover (4)
and hold number plate carrier (3) in position, taking care not to pinch cable
legs from turn indicator and rear light while doing so.
Install screws (1) and screws (2).

Connect connector (3) for the left turn indicator and secure it.
Connect connector (2) for the right turn indicator and secure it.
Position connector (1) and secure the cable strap (arrow).

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Install bulb socket (1) for the number plate light.

Secure the clutch cable (2) in holder (3).

Follow-up work
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

46 62 055 Replacing rear section

+ 46 62 509

Preparatory work
Removing seat
Removing luggage carrier

Core activity
(-) Removing rear carrier

Remove screws (1) with long shouldered bushings (2).

Remove screws (3) with short shouldered bushings (4).
Remove rear carrier (5).

(-) Installing rear carrier

Pay attention to the correct mounting location and mounting orientation of

the buffer case hanging system (1), (2), (3) and (4) in rear carrier (5).
Arrow (6) on underside of the buffer points in the forward direction of travel.

Clean the threads.

Hold rear carrier (5) in position.
Install screws (3) with short shouldered bushings (4) hand-tight.
Install screws (1) with long shouldered bushings (2) hand-tight.
Tighten screws (1) and screws (3).

Tightening torques
Rear carrier to rear frame
front, M8 x 40, Replace screw 19 Nm
Thread-locking compound (micro-
encapsulated)
rear, M8 x 25, Replace screw 19 Nm
Thread-locking compound (micro-
encapsulated)

Follow-up work

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Installing luggage carrier
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 63 018 Replacing left badge carrier

+ 46 63 713

Core activity
(-) Removing the fairing side panel from the left badge holder

Release the brackets (arrow) and remove the fairing side panel (1) from the
badge holder (2).

(-) Replacing badge carrier, left

Remount the small parts on the new part, renew if applicable.

1 x BMW badge
2 x slip-in retainer
2 x C-clip nut

(-) Assemble the fairing side panel and the left badge holder

Place the fairing side panel (1) on the badge holder (2) and secure with the
brackets (arrow).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Follow-up work
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 63 025 Replacing left radiator cowl

+ 46 63 526

Remove screws (1).

Remove radiator cowl (2) while noting the mounting clips (Arrows).

(-) Replacing left radiator cowl

Remount the small parts on the new part, renew if applicable:

2 x C-clip nut

(-) Installing left radiator cowl

Install radiator cowl (2) while noting the mounting clips (Arrows).
Install long screws (1).

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

46 63 031 Replacing windscreen

+ 46 63 830

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing windscreen

Remove screws (1).

Remove windscreen (2).

(-) Install the windscreen

Assembling the windscreen
Install rubber grommets (1) and shouldered bushings (2).

Position windscreen (2).

Install screws (1).

Tightening torques
Windscreen to windscreen holder
M5 x 20 4 Nm

Follow-up work
Final check of work performed
052021 BMW Motorrad, UX-VA-4 1/1
BMW-Motorrad - F 850 GS

46 63 039 Removing/installing windscreen holder

+ 46 63 836

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing windscreen

Remove screws (1).

Remove windscreen (2).

(-) Removing centre slipstream deflector

Remove body-bound rivets (1).

Remove slipstream deflector (2).

(-) Removing windscreen holder

Remove screws (1).

Remove windscreen holder (2) .

(-) Installing windscreen holder

Position windscreen holder (2).

052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Install screws (1).

Tightening torques
Windscreen holder to front panel carrier
M6 x 20 5 Nm

(-) Installing centre slipstream deflector

Position slipstream deflector (2).

Install expanding rivets (1).

(-) Install the windscreen

Make sure that rubber grommets (1) and shouldered bushings (2) are
installed.

Position windscreen (2).

Install screws (1).

Tightening torques
Windscreen to windscreen holder
M5 x 20 4 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 63 059 Replacing front panel carrier

+ 46 63 733

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing front spray guard
Removing top front-wheel cover
Removing windscreen
Removing centre slipstream deflector
Removing windscreen holder
Removing left slipstream deflector
Removing right slipstream deflector
Removing headlight
Removing instrument panel

Core activity
(-) Removing front panel carrier

Remove bolt (1).

Cut through the cable straps (arrows).

Release air temperature sensor (1).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Cut through the cable ties (1).

Release the cable (arrows).

Remove screws (1) on left and right.

Remove front panel carrier (2).

(-) Replacing front panel carrier

Remount the small parts on the new part (1), renew if applicable.
3 x rubber grommet
2 x slip-in retainer
2 x C-clip nut M5
4 x C-clip nut M6
2 x cable holder
1 x connector holder

(-) Installing front panel carrier

Clean the threads.

Insert front panel carrier (2).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Install screws (1) on left and right.

Tightening torques
Front panel carrier to frame
M6 x 25, Replace screw 8 Nm
Thread-locking compound (micro-
encapsulated)

Secure air temperature sensor (1).

Close the cable strap (arrows).

Secure cable (arrows).

Secure cable strap (1).

Install bolt (1).

052021 BMW Motorrad, UX-VA-4 3/4

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 63 333 Replacing side panel, left

+ 46 63 900

Core activity
(-) Removing the fairing side panel from the left badge holder

Release the brackets (arrow) and remove the fairing side panel (1) from the
badge holder (2).

(-) Replacing side panel, left

Remount the small parts on the new part, renew if applicable.

3 x slip-in retainer
3 x C-clip nut

(-) Assemble the fairing side panel and the left badge holder

Place the fairing side panel (1) on the badge holder (2) and secure with the
brackets (arrow).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

46 71 200 Replacing front left footplate

+ 46 71 821

Preparatory work
Placing motorcycle on rear-wheel stand
Installing engine lifter
Removing front left footrest
Disengaging gearshift rod
Removing left heel deflector

Core activity
(-) Removing front left footrest plate

Remove bolt (1) from swinging arm axle.

If necessary, turn away the gearshift lever.

Remove bolt (1).
Remove screws (2) and screws (3).
Remove footrest plate (4) with mounted parts, feeding out the lug (arrow).

(-) Replacing the front left footrest plate

Remove screw (1), counter-holding shouldered bushing (2) while doing so.
Remove shouldered bushing (2), gearshift lever (3) and washer(4) from
footrest plate (5).

ATTENTION
Damage of the bearing due to lubricants.
052021 BMW Motorrad, UX-VA-4 1/3
BMW-Motorrad - F 850 GS
Component damage, stiff movement
Lubricants can damage the coating chemically.
Lubricant bind dirt particles and increase the wear by this.
A PTFE-bearing is maintenance free; do not lubricate the bearing.

Clean sliding surfaces of shouldered bushing (2) and gearshift lever (3).
Install shouldered bushing (2) in gearshift lever (3) and with washer (4) hold
it in position on the new footrest plate (5).
Install screw (1), counter-holding shouldered bushing (2) while doing so.

Tightening torques
Gearshift lever to footrest plate
M8 x 25 19 Nm

(-) Installing front left footrest plate

Hold footrest plate (4) with mounted parts in position, while feeding in the lug
(arrow).
Install screws (3), screws (2) and screws (1), but do not tighten.

Install screw (1) of the swinging arm axle and tighten.

Tightening torques
Rear wheel swinging arm to frame
M20 x 1.5, Replace screw 200 Nm

Tighten the screws (2).

Tightening torques
Footrest plate with side-stand bearing support on crankcase
M10 x 50 38 Nm

Tighten the screw (1).

Tightening torques
Retaining panel for centre stand to left footrest plate
M10 x 35 38 Nm

Tighten the screws (3).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Tightening torques
Left footrest plate to crankcase
M8 x 45 - 10.9 28 Nm

Follow-up work
Installing left heel deflector
Install the front left footrest
Securing selector rod
Removing engine lifter
Removing motorcycle from rear-wheel stand
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

46 71 204 Replacing front right footplate

+ 46 71 822

NOTICE
When removing the grooved drive studs, damage to the microswitch is
probable.
Do not transfer the microswitch to the new part. Instead, install a new
microswitch with new grooved drive studs.

Preparatory work
Placing motorcycle on rear-wheel stand
Support rear wheel with wedges
Installing engine lifter
Disengaging gearshift rod
Removing front left footrest plate
Removing right heel deflector
Releasing footbrake cylinder
Removing front right footrest
Releasing right footrest plate

Core activity
(-) Removing front right footrest plate

NOTICE
To facilitate subsequent re-assembly, when removing the swinging-arm axle
secure the swinging arm in position in the frame/engine.
When removing, insert a length of pipe of suitable diameter, or a second
swinging-arm axle, to hold the swinging arm in position.

Prepare suitable pipe (1) of length (A) and diameter (B) .

Technical data
Dimension A (length approx. 90 mm
of pipe)
Dimension B 24 mm
(diameter of suitable
pipe/swinging arm
axle)

Pull out swinging arm axle (1) with footrest plate (2) from swinging arm (3)
and frame (4) a little.
Insert prepared pipe (5) from the other side until the swinging arm (3) is
secured.
Remove swinging arm axle (1) with footrest plate (2) .

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Remove swinging arm axle (1) from footrest plate (2) .

(-) Replacing front right footrest plate

Disengage spring (1).

Remove screw (2), counter-holding shouldered bushing (3) while doing so.
Remove shouldered bushing (3), footbrake lever (4) and washer (5) from
footrest plate (6).

Fasten microswitch (2) with new grooved drive studs (1) on new footrest
plate (3).

ATTENTION
Damage of the bearing due to lubricants.
Component damage, stiff movement
Lubricants can damage the coating chemically.

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Lubricant bind dirt particles and increase the wear by this.
A PTFE-bearing is maintenance free; do not lubricate the bearing.

Clean sliding surfaces of shouldered bushing (3) and footbrake lever (4).
Install shouldered bushing (3) in footbrake lever (4) and with washer (5) hold
it in position on the new footrest plate (6).
Install screw (2), counter-holding shouldered bushing (3) while doing so.

Tightening torques
Brake pedal to footrest plate
M8 x 20 19 Nm

Engage spring (1).

(-) Install front right footrest plate

Install swinging arm axle (1) in footrest plate (2).

Install swinging arm axle (1) with footrest plate (2), pulling out pipe (3).

Follow-up work
Secure the right footrest plate
Installing front right footrest
Securing footbrake cylinder
Installing right heel deflector
Installing front left footrest plate
Securing selector rod
Removing engine lifter
Remove wedges below rear wheel
Removing motorcycle from rear-wheel stand
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

46 71 208 Replacing rear left foot support

+ 46 71 823

Remove the bolts (1) and footrest bracket (2).

(-) Replacing the rear left footrest bracket

Remove lock washer (1) and bolts (2).

Remove footrest (3).

Fit the footrest (3) on the new footrest bracket.

Install bolts (2) and lock washer (1).

(-) Installing rear left footrest bracket

Fit the footrest bracket (2) and install the screws (1).

Tightening torques

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Footrest plate to retaining panel for centre stand
M10 x 35 38 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

51 14 002 Renew decal or inscription in paint

+ 51 14 502

NOTICE
This is an exemplary description for replacing and labelling decor or inscription
in paint.
The alignment and placement on the vehicle results from the used part or
catalog figures.
The foil is to be positioned in such a way that there is an even distance to
component edges around it.
The rounded area of the foil should be aligned with the component rounded
area.

Core activity
(-) Pull off decor or inscription

ATTENTION
Overheating of plastic parts and paint
Damage to paint and plastic parts
Do not overheat plastic part and paint, do not use any hot air blower.

Heat the foil (1) and surface using a blow dryer, pull off starting from one
corner (arrow).
Remove possible adhesive residues.

(-) Surface treatment

NOTICE
Bonding on freshly painted surfaces can be done after a drying period of at
least 24 hours.

The surface must be clean and dust free.

Clean surface with isopropanol, allow for sufficient air drying time.

Cleaner
Solvent cleaner R2, Cleaning agent 83 19 0 417 324
and installation aids containing
isopropanol

(-) Labelling decor or inscription

Label bigger foils in the wet bonding procedure.

Coat surface with corresponding water.

Technical data
Washing-up liquid approx. 0.5 %
concentration in
water

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Pull off backing film.
Align label on the edge (arrow) and glue it.

To protect the surface of the foil better when squeegeeing, wrap the doctor
blade with a microfiber cloth.
Press down top edge with the doctor blade.

Press down front and bottom edge with the doctor blade.
Push out enclosed air using doctor blade to the edge.

Heat up cavity in the marked area with blow dryer until creases visibly
disappear.

ATTENTION
Component damage
Decor or inscription is undone
The foil reaches its integrated heating control after approx. 24 hours.
Do not wash or polish vehicle beforehand as far as possible.

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Allow label to cool down. Stick cavity from front to back with fingers, then
press down again with the doctor blade.
Coat and pull off the existing protective paper with fluid as may be the case.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

51 16 044 Replacing left mirror

+ 51 16 554

Release the rubber cover (4).

Remove the left/right adapter (1) and the lock nut (3) with mirror (2).

(-) Installing left mirror

Install left/right adapter (1).

Tightening torques
Adapter to clamping block
M10 x 14 - 4.8 25 Nm

Install the mirror (2) and align.

Tighten the lock nut (3).

Tightening torques
Mirror (locknut) to clamping piece
M10 x 1.25 Left-hand thread,
22 Nm

Slide rubber cover (4) over screw connection.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

51 25 020 Replacing lock barrel for fuel tank

+ 51 25 591

WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.

Open fuel filler cap (1).

Cover the fuel filler neck.
ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Push the latching tab (arrow) down using a suitable tool until holes (2) are
aligned.
Secure the latching tab (arrow) using drill (3) into fuel filler cap (1).

Technical data
Drill-bit diameter 2 mm

Turn key (4) to the "Open" position and remove lock barrel (5).

(-) Installing lock barrel for fuel filler cap

Open fuel filler cap (1).

Cover the fuel filler neck.
ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Push the latching tab (arrow) down using a suitable tool until holes (2) are
aligned.
Secure the latching tab (arrow) using drill (3) into fuel filler cap (1).

Technical data
Drill-bit diameter 2 mm

Lubricate the lock barrel (5).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Lubricant
MI-Setral-43 N 83 23 2 152 082

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

51 25 038 Replace lock cylinder in ignition/steering lock

+ 51 25 538

Core activity
(-) Removing lock barrel from ignition lock

Insert ignition key (1) and turn it to the ON position.

Press in retainer (2) through the bore hole (arrow) using a suitable tool (3)
such as a stiff wire.
Pull out lock barrel (4) with ignition key (1) from steering-lock housing (5) .

(-) Install the lock barrel for ignition lock

Lubricate the lock barrel (1).

Lubricant
MI-Setral-43 N 83 23 2 152 082

Use ignition key (2) to install lock barrel (1) in the ON position.
Press down lock barrel (1) until retainer (3) engages in lock barrel (1).
Turn ignition key (2) to the "OFF" position; the key can now be removed.

Follow-up work
Installing top fork bridge
Securing handlebars
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

51 25 044 Replace handlebar-lock housing

+ 51 25 544

Core activity
(-) Replacing steering-lock housing

Punch-mark shear screws (1) in the centre (arrows).

First pre-drill shear screws (1) with a small drill and then drill them out with
a larger drill.

Technical data
Ignition (Pilot) hole min 10 mm
switch/steering lock - diameter 2 mm
drilling depth for
drilling out tamper- Hole 10 mm
proof shear screws diameter 5 mm

Heat the area around the thread of shear screws (1) without overheating the
ignition steering lock.

Technical data
Release/mating 80 °C
temperature

Remove shear screws (1) with a suitable screw extractor.

Remove ignition steering lock (2).

Position ignition steering lock (1) on new fork bridge (2).

Install shear screws (3) and tighten until the tool engagement (arrow) tears
off head (4).

Tightening torques
Ignition/steering lock to fork bridge
M8 x 18, Replace screw Tighten bolt until tool
Thread-locking compound (micro- handle shears off.
encapsulated)

(-) Transferring lock barrel, steering lock housing

Insert the ignition key (1) and turn it to the ON position.

Push in the retainer (2) by inserting a length of stiff wire (3) or similar as far
to the outside as possible into the hole (arrow).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Pull out lock barrel (4) with ignition key (1).
Lubricate the lock barrel (4).

Lubricant
MI-Setral-43 N 83 23 2 152 082

Use the ignition key (1) to insert the lock barrel (4) in the ON position into the
new steering-lock housing (5).
Push the lock barrel (4) down.
Fuse (2) engages.
Turn the ignition key (1) to the OFF position.

Follow-up work
Installing top fork bridge
Securing handlebars
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

51 25 050 Removing/installing or replacing seat lock

+ 51 25 595

Preparatory work
Removing seat
Removing battery
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank

Core activity
(-) Remove the seat lock

Remove screws (1).

Release support (2) and detach from eccentric (3) (swing support arm (4) to
the rear and press spring (5) downwards).
Remove support (2) for seat lock.

(-) Installing seat lock

Position support (2) for the seat lock, attaching it to eccentric (3).
Install screws (1).

Tightening torques
Seat retainer bridge to rear frame
M6 x 20 8 Nm

(-) Removing lock barrel

Remove locking ring (1).

Push the key into the lock barrel.
Press the lock (arrow) and pull lock barrel (2) from lock strip (3).

(-) Installing case lock barrel

Insert lock barrel (2) into lock strip (3), making sure that the lock (arrow) slips
over the angled face into the bore hole.
Install locking ring (1).

(-) Installing lock strip

Position lock strip (3) and install bolts (1) and (2).

Tightening torques

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

51 25 090 Replacing lock barrel for case

+ 51 25 601

Core activity
(-) Removing lock strip

Open case/topcase.
Remove screws (1) and (2).
Remove lock strip (3).

(-) Removing lock barrel

Remove locking ring (1).

Push the key into the lock barrel.
Press the lock (arrow) and pull lock barrel (2) from lock strip (3).

(-) Installing case lock barrel

Insert lock barrel (2) into lock strip (3), making sure that the lock (arrow) slips
over the angled face into the bore hole.
Install locking ring (1).

(-) Installing lock strip

Position lock strip (3) and install bolts (1) and (2).

Tightening torques

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

51 25 091 Install a single key locking system set

+ 51 25 605

Core activity
(-) Replacing steering-lock housing

Punch-mark shear screws (1) in the centre (arrows).

First pre-drill shear screws (1) with a small drill and then drill them out with
a larger drill.

Technical data
Ignition (Pilot) hole min 10 mm
switch/steering lock - diameter 2 mm
drilling depth for
drilling out tamper- Hole 10 mm
proof shear screws diameter 5 mm

Heat the area around the thread of shear screws (1) without overheating the
ignition steering lock.

Technical data
Release/mating 80 °C
temperature

Remove shear screws (1) with a suitable screw extractor.

Remove ignition steering lock (2).

Position ignition steering lock (1) on new fork bridge (2).

Install shear screws (3) and tighten until the tool engagement (arrow) tears
off head (4).

Tightening torques
Ignition/steering lock to fork bridge
M8 x 18, Replace screw Tighten bolt until tool
Thread-locking compound (micro- handle shears off.
encapsulated)

(-) Transferring lock barrel, steering lock housing

Insert the ignition key (1) and turn it to the ON position.

052021 BMW Motorrad, UX-VA-4 1/4
BMW-Motorrad - F 850 GS
Push in the retainer (2) by inserting a length of stiff wire (3) or similar as far
to the outside as possible into the hole (arrow).
Pull out lock barrel (4) with ignition key (1).
Lubricate the lock barrel (4).

Lubricant
MI-Setral-43 N 83 23 2 152 082

(-) Removing lock barrel for fuel filler cap

Open fuel filler cap (1).

Cover the fuel filler neck.
ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Push the latching tab (arrow) down using a suitable tool until holes (2) are
aligned.
Secure the latching tab (arrow) using drill (3) into fuel filler cap (1).

Technical data
Drill-bit diameter 2 mm

Turn key (4) to the "Open" position and remove lock barrel (5).

(-) Installing lock barrel for fuel filler cap

Open fuel filler cap (1).

Cover the fuel filler neck.
ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Push the latching tab (arrow) down using a suitable tool until holes (2) are
aligned.
Secure the latching tab (arrow) using drill (3) into fuel filler cap (1).

Technical data
Drill-bit diameter 2 mm

Lubricate the lock barrel (5).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

Lubricant
MI-Setral-43 N 83 23 2 152 082

(-) Removing lock barrel from seat lock

Remove screws (1).

Remove the cover (2) for the lock barrel.

Insert the ignition key (1).

Press the tab (arrow) and remove the lock barrel (2) from the cover (3).

(-) Installing lock barrel for seat lock

Use the ignition key (1) (3) to install lock barrel (2) in the cover.
The tab (Arrow) engages.

Fit the cover (1) for the lock barrel, and check for intervention by driver
(arrow) in eccentric (2).
Install screws (3).

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Follow-up work
Installing top fork bridge
Securing handlebars
Installing battery
Connect the BMW Motorrad diagnostic system to the vehicle
Programming the vehicle control, control unit with BMW Motorrad
diagnosis system
Checking, if necessary correcting date
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

Electrical System

Repair Guide

BMW Motorrad
BMW-Motorrad - F 850 GS

61 00 002 Testing software

+ 61 00 502

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat

Core activity
(-) Connect the BMW Motorrad diagnostic system to the vehicle

Connect the BMW Motorrad battery charger.

NOTICE
When carrying out diagnosis and programming, use a battery charger with 30
A approved by BMW Motorrad that ensures an on-board system voltage of
13 V.

Loosen diagnostic connector (1) from holder (2).

Connect diagnostic connector (1) with connecting cable (3) for diagnosis
system.
NOTICE
See the information about the BMW Motorrad diagnostic system for all further
instructions.

(-) Checking the software with the BMW Motorrad diagnosis

system

Start the diagnosis system.

Read out the software release.
Perform diagnosis. Rectify faults, if found, before starting
programming/coding.

=> Programming control units of vehicle (along with testing software)

(Description in item: 61 00 510, Billed as a separate item)
(-) Disconnecting BMW Motorrad diagnostic system from vehicle

Close all diagnostic programs and switch off the ignition.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Follow-up work
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

61 00 003 Resetting/learning adaptation values (with replacing component)

+ 61 00 503

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat

Core activity
(-) Connect the BMW Motorrad diagnostic system to the vehicle

Connect the BMW Motorrad battery charger.

NOTICE
When carrying out diagnosis and programming, use a battery charger with 30
A approved by BMW Motorrad that ensures an on-board system voltage of
13 V.

Loosen diagnostic connector (1) from holder (2).

Connect diagnostic connector (1) with connecting cable (3) for diagnosis
system.
NOTICE
See the information about the BMW Motorrad diagnostic system for all further
instructions.

(-) Performing vehicle test with BMW Motorrad diagnostic system

and resetting the adaptation values

NOTICE
When working with the BMW Motorrad diagnostic system, always follow the
instructions it issues.

Perform the vehicle test with the BMW Motorrad diagnostic system and
read out the fault memory.
Perform all requisite repair work.
Reset the adaptation values.

This is the only way of ensuring correct operation of the vehicle.

Cut out the defective plug or length of cable, if possible making the cut at
some point along a straight run where the wiring harness can be firmly
secured.
Cut the individual cores staggered along the length of a shrink-on hose (1)
so that the repaired points are not beside each other.
Correlate the numbered cores of the repair kit with the corresponding cable
colours of the original plug and cut them back to the appropriate staggered
lengths.
NOTICE
The cables are not colour-coded; instead, they have code numbers to ensure
the universal usability of the repair kits.

Set stripping pliers (No. 61 0 511) to the correct wire diameter.

Use stripping pliers (No. 61 0 511) to strip the ends of the wires.

Slip shrink-on hoses (1) into position.

Insert the ends of the wires into the corresponding crimp connectors (2),
note that insulation and core must both be secured (detail).
Secure crimp connectors (2) with pliers (No. 61 4 342) with crimping head
(No. 61 4 343) to the stripped ends of the wires, noting the cable cross-
section.

Slip shrink-on hose (1) into position over the repair and heat the hose.
Shrink-on hose (1) contracts to a tight fit.
Hot glue (arrows) escapes between shrink-on hose (1) and wire (2).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Wrap fibre-reinforced insulating tape (No. 61 0 631) around the repair.

ATTENTION
Electrical wiring not routed in compliance with correct procedure
Open circuit and chafing
Carefully route electrical wiring correctly.
Make sure that no lines can chafe or are kinked on installation.

Secure the repair to the vehicle.

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

61 11 100 Removing/installing or replacing main wiring harness

+ 61 11 509

NOTICE
Tightening the cable ties has to be the last step in the process; this is in order
to ensure that the wiring harness can be positioned correctly and that there is
no strain on the cable legs with plugs.

NOTICE
The wiring harness is delivered pre-assembled with cable duct.
Engine and chassis wiring harness not available as separate components.
Auxiliary cable of optional equipment may have to be installed in the cable
duct.

Preparatory work
Installing engine lifter
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing windscreen
Removing centre slipstream deflector
Removing left slipstream deflector
Removing right slipstream deflector
Removing instrument panel
Removing headlight
Releasing brake-fluid reservoir, rear
Removing right side cover
Removing left side cap
Removing fuel tank
Remove the intake air silencer
Disengaging hoses for tank ventilation
Releasing throttle-valve assembly
Removing luggage carrier
Removing rear carrier
Removing battery
Loosening holder for main fuse
Removing holder for control unit
Disconnecting wiring harness from control unit of engine control
Removing support for seat bench
Removing bracket for fuel tank
Removing the cover for wiring harness
052021 BMW Motorrad, UX-VA-4 1/19
BMW-Motorrad - F 850 GS
Removing lock bearing with lock barrel
Removing eccentric seat bench
Disconnecting the connector for DWA preparation
Removing number-plate carrier
Removing cover for voltage regulator with spray guard
Disconnecting connector for the voltage regulator and working it clear
Removing right heel deflector
Releasing chain guard
Removing spring strut
Disengaging gearshift rod
Removing front left footrest plate
Remove the left handlebar weight
removing left grip unit

Core activity
(-) Releasing left and right wiring harness for left multifunction
switch

Unclip the retaining tabs (arrows).

Remove cover (1).

Disconnect connector (1) for the multifunction switch.

Remove 2-pin connector (2) with the blanking plug.

Press the releases (arrows) at front and back and disconnect connector (1)
for the throttle grip.

052021 BMW Motorrad, UX-VA-4 2/19

BMW-Motorrad - F 850 GS

Remove bolt (1).

Pull cover (2) down slightly.

Push cover (1) forward and up to remove, noting retaining catches (2).

Disconnect 2-pin connector (1) with blanking cap.

Disconnect connector (2) for the multifunction switch.

(-) Disengage wiring harness for front carrier

Release connectors (1) for navigation and the cable (arrows).

Disconnect the connector (2) for temperature sensor.
Remove cable straps (3).

052021 BMW Motorrad, UX-VA-4 3/19

BMW-Motorrad - F 850 GS

Remove the cable strap (arrows).

Remove the straps (1).
Disconnect connector (2) for the ignition steering lock.
Remove cable clips (3) and (4).

Remove cable straps (1).

Release connectors (2) for accessories and the cable (arrow).

Remove the cable strap (arrows).

Release the wiring harness from retaining bracket (1).

(-) Releasing wiring harness from engine

Remove cable strap (arrow).

Disconnect plug (1) for the horn.
Remove the protective cap (2).
Remove nut (3) and disconnect positive wire (4) for starter.

052021 BMW Motorrad, UX-VA-4 4/19

BMW-Motorrad - F 850 GS
Lay wiring harness (5) to one side.

Disconnect plug connection (1) for fan.

Release lid from starter motor relay.

Disconnect connector (1).
Remove nuts (2) and release cables (3) and (4) from starter motor relay (5).

Remove the cable straps (arrows).

Disconnect plug (1) for crankshaft sensor.
Remove screw (2) and disconnect ground line (3).
Disconnect plug (4) for the potentiometer for the gear indicator.
Lay wiring harness to one side.

(-) Disconnecting connector for side-stand switch

Remove screw (1) from chain failure protection (2).

052021 BMW Motorrad, UX-VA-4 5/19

BMW-Motorrad - F 850 GS

Disconnect connector (1) for side-stand switch.

Release cable (2) behind chain drop guard (3).

(-) Releasing wiring harness from frame

Remove cable straps (1).

Disconnect the connector (2) for the front speed sensor.
Open locks (arrows) to cable channel (3).

Remove the cable straps (arrows).

Release cable (1) for alternator from cable clip (2).
Disconnect connector (3) for coolant temperature sensor.

Disconnect connector (1) for the tank vent valve.

Disconnect connector (2) for the throttle-valve assembly.

052021 BMW Motorrad, UX-VA-4 6/19

BMW-Motorrad - F 850 GS

Information on disconnecting vibration-resistant plug

ATTENTION
Disconnection of the connector not in compliance with correct
procedure
Damage to locking tab
Push the connector away from the locking tab, do not lift or bend the locking
tab.

Unlock locking tab (1) in direction of arrow (arrow 1).

Press down locking tab (1) in direction of arrow (arrow 2) and disconnect
connector (2).

Disconnect connector (1) for direct ignition coils.

Disconnect connector (1) for oxygen sensor and release cable (2) (arrow).

Disconnect connector (1) for camshaft sensor.

Remove screw (2) and disconnect ground line (3).
Lay wiring harness (4) to one side.

052021 BMW Motorrad, UX-VA-4 7/19

BMW-Motorrad - F 850 GS

Remove cable straps (1).

Open cable hose locks (arrow).
Release the wiring harness from retaining bracket (2).
Disconnect connector (3) for the rear speed sensor.
Lift throttle valve assembly (4) carefully and feed out wiring harness (5) to
the rear.

(-) Release wiring harness, right

Remove cable strap (arrow).

Press lock and fold out retaining clip (1).
Disconnect the connector (2) for the pressure modulator.

Remove the cable straps (arrows).

Disconnect connector (1) for the brake light switch and work it up and clear
of the vehicle.

Remove cable strap (arrow).

Unlock the main relay (1) (press the release tab for the relay) and pull off in
an upward direction.

052021 BMW Motorrad, UX-VA-4 8/19

BMW-Motorrad - F 850 GS

(-) Releasing the wiring harness from the rear-wheel cover and
number plate carrier

Disconnect connector (1) for rear light.

Remove the cable straps (arrows).

Release the wiring harness (1) from the rear-wheel cover (2).
Feed the wiring harness (3) for the number plate light out of the rear-wheel
cover (2).

(-) Remove the wiring harness

Release wiring harness (1) from vehicle and remove.

(-) Removing cable duct

052021 BMW Motorrad, UX-VA-4 9/19

BMW-Motorrad - F 850 GS
Release the fixtures (arrows) of the cable duct (1) from the frame (2).
Remove cable duct (1).

(-) Installing cable duct with wiring harness

Feed in cable duct (1) with wiring harness in frame (2) and position it.
Secure the fixations (arrows) in the frame.

Insert wiring harness (1) into vehicle.

(-) Securing wiring harness to engine

Position cables (3) and (4) on starter motor relay (5).

Install nuts (2).

Tightening torques
Wiring harness to starter relay
M6, Replace nut 6 Nm
Thread-locking compound
(mechanical)

Connect connector (1).

Secure lid.
Secure grounding cable (2) with bolt (1).

052021 BMW Motorrad, UX-VA-4 10/19

BMW-Motorrad - F 850 GS

Tightening torques
Wiring harness (ground) to engine
M6 x 10 8 Nm

Close the cable strap (arrows).

Route the wiring harness (5).

Connect plug (1) for the horn.
Connect positive wire (4) for starter and install nut (3).

Tightening torques
Positive wire to starter motor
M6, Replace nut 5 Nm
Thread-locking compound
(mechanical)

Install protective cap (2).

Secure the cable strap (arrow).
Connect plug connection (1) for fan.

(-) Connecting connector for side-stand switch

Secure cable (2) behind chain drop guard (3).

Connect connector (1) for side-stand switch.

Fasten chain failure protection (2) with screw (1).

052021 BMW Motorrad, UX-VA-4 11/19

BMW-Motorrad - F 850 GS

(-) Securing the wiring harness to the rear-wheel cover and

number plate carrier

Route the wiring harness (1).

Route wiring harness (3) for the number plate light into the rear-wheel cover
(2).
Close the cable strap (arrows).

Connect connector (1) for rear light.

(-) Securing wiring harness, right

Route connector (1) for brake light switch down and connect.
Close the cable strap (arrows).

Connect the connector (2) for the pressure modulator.

Close the retaining clip (1), while making sure that the lock engages.

052021 BMW Motorrad, UX-VA-4 12/19

BMW-Motorrad - F 850 GS
Secure the cable strap (arrow).

Secure main relay (1).

Secure the cable strap (arrow).

ATTENTION
Screws overtightened past the specified value
Component damage
Tighten the screws only to their specified tightening torque.

Install bolt (1).

Tightening torques
Lid to right multifunction switch
Screw for plastic, PT2.5 x 15 0.4 Nm

Connect connector (1) for throttle grip.

(-) Secure wiring harness to front panel carrier

Secure connectors (1) for navigation and the cable (arrows).

Connect connector (2) for temperature sensor.
Secure cable strap (3).

052021 BMW Motorrad, UX-VA-4 16/19

BMW-Motorrad - F 850 GS

Connect plug (2) for the ignition steering lock.

Close the cable strap (arrows).
Secure straps (1).
Secure cable clips (3) and (4).

Secure connectors (2) for accessories and the cable (arrows).

Secure cable strap (1).

Close the cable strap (arrows).

Secure wiring harness in retaining bracket (1).

Follow-up work
Securing left grip unit
Installing front left footrest plate
Securing selector rod
Installing spring strut

052021 BMW Motorrad, UX-VA-4 17/19

BMW-Motorrad - F 850 GS
Securing chain guard
Installing right heel deflector
Connecting plug for voltage regulator
Installing cover for voltage regulator with spray guard
Installing number-plate carrier
Securing connector for DWA preparation
Installing right side cover
Securing rear brake-fluid reservoir
Installing left side cap
Installing eccentric seat bench
Installing lock bearing with lock barrel
Installing bracket for fuel tank
Installing support for seat bench
Connect main wiring harness to control unit for engine control
Installing holder for control units
Securing holder for main fuse
Installing battery
Installing rear carrier
Installing luggage carrier
Secure the throttle valve system
Securing hoses for tank ventilation
Install the intake air silencer
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing left handlebar weight
Installing headlight
Installing instrument panel
Installing left slipstream deflector
Install the right slipstream deflector
Installing centre slipstream deflector
Install the windscreen
Installing top front-wheel cover
Installing the cover for wiring harness
Installing front spray guard
Connect the BMW Motorrad diagnostic system to the vehicle
Performing vehicle test with BMW Motorrad diagnostic system and
resetting the adaptation values
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Removing engine lifter

052021 BMW Motorrad, UX-VA-4 18/19

BMW-Motorrad - F 850 GS
Final check of work performed

052021 BMW Motorrad, UX-VA-4 19/19

BMW-Motorrad - F 850 GS

61 21 005 No-load current test, complete vehicle

+ 61 21 505

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat

Core activity
(-) Measuring battery voltage

NOTICE
Battery voltage and standby current can be measured with various devices
(observe respective operating instructions):
Conventional multimeter
BMW Motorrad MBOX (Measurement Box)
ICOM Next

Set expected voltage range on the measuring device (1).

Position gauge tip (2) on positive terminal (3) of the battery and position
gauge tip (4) on negative terminal (5) of the battery.
Enter the measured battery voltage in the measured-data record.
Check
Check the battery voltage.

Result:

Measured battery voltage < 12.5 V.

Measure:
Charge battery fully, note charging date on battery (label).

(-) Idle-current measurement

Requirement
Motorcycle's ignition is switched OFF.
Battery is fully charged.

NOTICE
To prevent activation of the control units, do not disconnect the battery from
the wiring harness. A cable jumper must ensure the current flow when
connecting/disconnecting.

Wait until the ZFE control unit has switched off before starting measurement.

Technical data
30...60 s

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Deactivation delay, if no
Central Vehicle consumers
Electronics are active

Connect cable jumper (1) on the negative terminal of the battery (2) and on
the cable shoe of the wiring harness (3).
This is to prevent a reset of the electronic control units when the battery is
disconnected.

Remove bolt (4) and take off cable (3).

Set ammeter (5) to highest measuring range, connect terminals (6) to

battery negative terminal (2) and cable shoe of the wiring harness (3). It is
very important to check that the cables are correctly connected to the
ammeter and the battery.
Disconnect cable jumper (1) and read current level on scale (7).
Check

Perform two measurements:

with ignition OFF
with ignition switch/steering lock locked

Technical data
permissible standby with/without max 2 mA
current value anti-theft
alarm system

Result:

Ammeter shows a measured current of 0.0 A.

Measure:
Check the fuse in the ammeter; replace if necessary and repeat the
measurement.
Result:
No current or measured value is not shown correctly on the scale.
Measure:
Connect cable jumper (1).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
This is to avoid a reset of the electronic control units when the ammeter is
set to the next lowest measuring range.
Set ammeter to the next lower measuring range (5).
Disconnect cable jumper (1) and read current level again.
Result:
Measured current is greater than permissible value.
Measure:
Enter the current in the measured-data record and use the measured-data
record to identify the cause of the fault.
The measured-data record is available in the Service Information No.
59/2005.

Follow-up work
Checking, if necessary correcting date
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

61 21 011 Renewing battery

+ 61 21 522

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat

Core activity
(-) Removing battery

ATTENTION
Battery not disconnected in accordance with correct procedure
Risk of short-circuit
Always proceed in compliance with the specified disconnection sequence.

Remove bolt (1).

Disconnect battery earth lead (2).

Open positive terminal cover (1) to lock (arrow).

Remove bolt (2).
Disconnect positive battery cable (3).

Loosen diagnostic connector (1) from holder (2).

Remove screws (3).
Remove the battery holder (4).
Remove the battery (5).

(-) Replacing battery

Remount positive terminal cover (1) to new battery (2).

Dispose of all battery in a manner compliant with national regulations.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

(-) Charging (AGM) battery

Set the BMW Motorrad battery charger to the correct charging

characteristic.
Workshop equipment
BMW Motorrad battery charger (version for Europe without GB)
BMW Motorrad battery charger (GB/AUS/NZL version)
BMW Motorrad battery charger (Japan version)
BMW Motorrad battery charger (USA/CAN version)
Charge the battery with the BMW Motorrad battery charger, taking care to
comply with the operating instructions.
Note the charge date on the battery (with separate label/tag).

(-) Installing battery

Position battery (5).

Install battery holder (4) with screws (3).

Tightening torques
Battery holder to rear-wheel cover
M5 x 12 5 Nm

Secure diagnostic connector (1) in holder (2)

ATTENTION
Battery not connected in accordance with correct procedure
Risk of short-circuit
Always proceed in compliance with specified installation sequence.

Position positive battery cable (1) and install bolt (2).

Tightening torques
Wiring harness to battery
M6 x 13.5 5 Nm

Close positive terminal cover (3).

Position battery earth lead (1), smooth side (arrow) up and install screw(2).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Tightening torques
Wiring harness to battery
M6 x 13.5 5 Nm

Make sure there is sufficient distance (arrow) between the locking lever (1)
and the battery earth lead (2); if applicable, twist the battery earth lead (2) a
little.

If applicable, secure the wiring harness (1) (arrow) to the retaining bridge
(3) with a cable strap.

Follow-up work
Checking, if necessary correcting date
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

61 21 502 Replace battery (check for battery)

Core activity
(-) Removing battery

Loosen diagnostic connector (1) from holder (2).

Remove screws (3).
Remove the battery holder (4).
Remove the battery (5).

(-) Replacing battery

Remount positive terminal cover (1) to new battery (2).

Dispose of all battery in a manner compliant with national regulations.

(-) Installing battery

Position battery (5).

Install battery holder (4) with screws (3).

Tightening torques
Battery holder to rear-wheel cover
M5 x 12 5 Nm

Secure diagnostic connector (1) in holder (2)

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

61 31 001 Replacing multi-controller

+ 61 31 950
Equipment trim-level variant:

06AB - ConnectivityOE

0272 - Preparation for navigation systemOE

0636 - Centre standOE

0519 - Heated gripsOE

ATTENTION
Opening of switch unit
Damage to the conductors coated with protective sealing lacquer
Do not separate the top and bottom parts of the switch unit.

Preparatory work
Remove the left handlebar weight
removing left grip unit

Core activity
(-) Removing left multifunction switch

Unclip the retaining tabs (arrows).

Remove cover (1).

Disconnect connector (1) for the multifunction switch.

Disconnect connector (2) for the heated grip.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Push up retainer (1).

Remove handlebar grip (2).

(-) Removing multi-controller

Remove screws (1).

Release plug (2) for heated grip.
Remove Multi-Controller (3) from grip (4).

(-) Installing multi-controller

Position Multi-Controller (1) on handle (2) making sure that recesses (3) and
stops (4) engage.
Work connector (5) for grip heating through Multi-Controller (1).
Position connector (5) for grip heating and install screws (6) observing
routing of grip heating cable (arrow).

Tightening torques
Multi-controller to grip
Screw for plastic, 2.5 x 23 0.4 Nm

(-) Installing left multifunction switch

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Install handlebar grip (1) , and at the same time insert connector (2) for the
heated grip.
Retaining lug (3) engages.

Lubricate the rubber pad (arrow).

Installation tool
Silicone spray 83 19 2 208 609

Connect connector (2) for the heated grip.

Connect connector (1) for the multifunction switch.

Install the cover (1).

The retaining tabs (arrows) engage.

Follow-up work
Securing left grip unit
Installing left handlebar weight
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

61 31 006 Replacing brake light switch for rear brake

+ 61 31 547

Core activity
(-) Removing microswitch for rear brake

Remove grooved drive stud (1).

Remove microswitch (2).

(-) Installing microswitch for rear brake

Position microswitch (2).

Install new grooved drive stud (1).

Follow-up work
Installing footbrake lever
Install front right footrest plate
Secure the right footrest plate
Installing front right footrest

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Securing footbrake cylinder
Installing right heel deflector
Installing front left footrest plate
Securing selector rod
Removing engine lifter
Remove wedges below rear wheel
Removing motorcycle from rear-wheel stand
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

61 31 009 Replacing rear ride-height sensor

+ 61 31 959
Equipment trim-level variant:

0191 - Dynamic ESAOE

Core activity
(-) Removing height sensor, rear

Release jointed rod (1) from ball stud (2).

Remove screws (1).

Release the ride height sensor (2) from holder (3).

Disconnect connector (1) for the ride height sensor.

Remove ride height sensor (2).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
(-) Replacing rear ride-height sensor

Remove nut (1) and ball stud (2).

Clean the threads.
Secure nut (1) and ball stud (2) to ride height sensor (3).

Tightening torques
Ball end (actuator rod) to ride-height sensor
Nut, M6
Ball end, M6 x 14 8 Nm
Reuse and secure using Loctite
2701, Thread-locking compound
(micro-encapsulated)

(-) Installing height sensor, rear

Hold ride height sensor (2) in position.

Connect connector (1) for the ride height sensor.

Position ride height sensor (2) in holder (3).

Install screws (1).

Tightening torques
Ride-height sensor to bracket
M5 x 12 4 Nm
Oval-head screw for thermoplastic 2 Nm
plastic

Secure jointed rod (1) on ball stud (2) while counter-holding ball stud (2).

Follow-up work
Installing carbon canister

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Securing bracket for activated charcoal filter
Installing left side cap
Connect the BMW Motorrad diagnostic system to the vehicle
Calibrating ride-height sensor
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

61 31 047 Replace operating facility for intelligent emergency call

+ 61 31 647
Equipment trim-level variant:

06AC - Intelligent emergency callOE

Core activity
(-) Removing the operating facility for intelligent emergency call

Remove the cable strap (arrows).

Release the cable (1) and (2) for the intelligent emergency call.
Disconnect the connector (3) for the intelligent emergency call and release.
Feed the cable (2) for the intelligent emergency call through the frame (4)
towards the right.

Remove cable strap (arrow).

Feed the cable (1) through.
Remove the tensioning strap (2).

Remove bolt (1).

Remove the operating facility for the intelligent emergency call (2).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

(-) Installing the operating facility for intelligent emergency call

Fit the operating facility for the intelligent emergency call (1).
Install bolt (2).

Tightening torques
Switch for intelligent emergency call to clamp
M5 x 22 3 Nm
Thread-locking compound
(mechanical)

Route the cable (1) and feed through towards left.

Install tensioning straps (2).
Secure the cable strap (arrow).

Feed the cable (2) for the intelligent emergency call through the frame (4)
towards the left.
Secure and connect the connector (3) for the intelligent emergency call.
Fit the cable (1) and (2) for the intelligent emergency call.
Secure the cable strap (arrows) and route the excess cable length into loops
if applicable.

Follow-up work
Installing fuel tank
Installing right fairing side panel with badge carrier
Installing right radiator cowl
052021 BMW Motorrad, UX-VA-4 2/3
BMW-Motorrad - F 850 GS
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

61 31 048 Replace impact sensor for intelligent emergency call

+ 61 31 648

Core activity
(-) Remove impact sensor for intelligent emergency call

Disconnect connector (1) for impact sensor.

Remove the bolt (2) while counter-holding the nut (3) .
Release the impact sensor (4).

(-) Installing impact sensor for intelligent emergency call

Fit the impact sensor (4).

Install the bolt (2), while counter-holding the nut (3).

Tightening torques

Connect connector (1) for impact sensor.

Follow-up work
Securing right side cap with brake fluid expansion tank
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

61 31 063 Renewing complete multi-function switch on left handlebar

+ 61 31 904

ATTENTION
Opening of switch unit
Damage to the conductors coated with protective sealing lacquer
Do not separate the top and bottom parts of the switch unit.

Core activity
(-) Removing left multifunction switch

Unclip the retaining tabs (arrows).

Remove cover (1).

Disconnect connector (1) for the multifunction switch.

Remove 2-pin connector (2) with the blanking plug.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Push up retainer (1).

Remove handlebar grip (2).

(-) Installing left multifunction switch

Install (2) handlebar grip.

Retaining lug (1) engages.

Lubricate the rubber pad (arrow).

Installation tool
Silicone spray 83 19 2 208 609

Connect 2-pin connector (2) with the blanking plug.

Connect connector (1) for the multifunction switch.

Install the cover (1).

The retaining tabs (arrows) engage.

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Follow-up work
Securing left grip unit
Installing left handlebar weight
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

61 31 073 Renewing complete multi-function switch on right handlebar

+ 61 31 905

Press the releases (arrows) at front and back and disconnect connector (1)
for the throttle twistgrip.

Remove bolt (1).

Pull cover (2) down slightly.

Push cover (1) forward and up to remove, noting retaining catches (2).

Disconnect 2-pin connector (1) with blanking cap.

Disconnect connector (2) for the multifunction switch.
Remove bolt (3).
Remove multifunction switch (4).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

(-) Installing right multifunction switch

Hold the multifunction switch (4) in position.

ATTENTION
Screws overtightened past the specified value
Component damage
Tighten the screws only to their specified tightening torque.

Install bolt (3).

Tightening torques
Multifunction switch to throttle grip
Screw for plastic, PT2.5 x 15 0.4 Nm

Connect connector (2) for the multifunction switch.

Connect 2-pin connector (1) with the blanking cap.
Position cover (1) and push backwards and down, paying attention to
retaining catches(2).

Push cover (2) until the multifunction switch is closed.

ATTENTION
Screws overtightened past the specified value
Component damage
Tighten the screws only to their specified tightening torque.

Install bolt (1).

Tightening torques
Lid to right multifunction switch
Screw for plastic, PT2.5 x 15 0.4 Nm

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Connect connector (1) for throttle grip.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

61 31 295 Removing/installing or replacing clutch switch

+ 61 31 911

Preparatory work
Removing the cover for clutch switch

Core activity
(-) Removing clutch switch

Operate clutch lever (1) and fix it with a rubber band.

Disconnect connector (2).
Remove bolt (3).
Remove clutch switch (4).

(-) Install the clutch switch

Clean the threads.

Position clutch switch (4).
Install bolt (3).

Tightening torques
Microswitch to clutch lever fitting
M2 x 22, Replace screw 0.3 Nm
Micro-encapsulated, Thread-locking
compound (micro-encapsulated)

Connect connector (2).

Remove the rubber band from clutch lever (1).

Follow-up work
Installing the cover for clutch switch
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

61 31 302 Replacing switch for side stand

+ 61 31 913

Core activity
(-) Removing side-stand switch

Remove screws (1).

Remove cover (2).

Remove screw (1) and side-stand switch (2).

Disconnect connector (3) for side-stand switch.

(-) Installing side-stand switch

Clean the threads.

Connect connector (1) for side-stand switch.
Position side-stand switch (2), checking locator (arrow) and switch lug (3).
Install bolt (4).

Tightening torques
Side-stand switch to side-stand screw
M6 x 16, Replace screw 6 Nm
Thread-locking compound (micro-
encapsulated)

Secure cover (2) with screws (1).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

61 33 011 Replacing horn

+ 61 33 502

Core activity
(-) Removing horn

Disconnect connector (1).

Remove bolt (2).
Remove horn (3).

(-) Install the horn

Position horn (3).

Install bolt (2).

Tightening torques
Horn to bracket
M8 x 16 19 Nm

Connect connector (1).

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

61 35 002 Replacing angular rate sensor

+ 61 35 652

Preparatory work
Removing seat
Removing battery

Core activity
(-) Removing angular rate sensor

Remove the nuts (1) and bracket (2) for the angular rate sensor.
Release the angular rate sensor (3).
Disconnect the connector (4) and remove the angular rate sensor (3).

(-) Installing angular rate sensor

Make sure shouldered bushings (1) are installed.

Connect the connector (4) for the angular rate sensor (3).
Fit the angular rate sensor (3) and bracket (2) for the angular rate sensor.
Install nuts (1).

Tightening torques

Follow-up work
Installing battery
Connect the BMW Motorrad diagnostic system to the vehicle
Performing vehicle test with BMW Motorrad diagnostic system and
resetting the adaptation values
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Disconnecting BMW Motorrad diagnostic system from vehicle
Checking, if necessary correcting date
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

61 35 003 Replacing control unit for electronic suspension adjustment

+ 61 35 655

Core activity
(-) Removing control unit for electronic suspension adjustment

Release the control unit for the electronic chassis and suspension setting (1)
from the fixtures (arrows) and pull out.
Unlock and disconnect the connector (2) and remove the control unit for the
electronic chassis and suspension setting (1).

(-) Install the control unit for electronic suspension adjustment

Fit the control unit for the electronic chassis adjustment (1), connect and
lock the connector (2).
Install the control unit for the electronic chassis and suspension setting (1)
and secure in the fixtures (arrows).

Follow-up work
Installing rear carrier
Installing luggage carrier

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
=> Testing software (Description in item: 61 00 502, Billed as
a separate item)

=> Programming control units of vehicle (along with testing

software) (Description in item: 61 00 510, Billed as a
separate item)
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

61 35 026 Replacing control unit basic module (without testing software/programming)

+ 61 35 653

Preparatory work
Removing seat
Removing luggage carrier
Removing rear carrier

Core activity
(-) Removing control unit basic module

Disconnect plug (1) for basic module.

Press the lock (arrow) downward and remove the control unit (2).

(-) Installing control unit basic module

Install the control unit (2); make sure it is locked (arrow).

Connect connector (1) for the control unit .

Follow-up work
Installing rear carrier
Installing luggage carrier

=> Testing software (Description in item: 61 00 502, Billed as

a separate item)

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
=> Programming control units of vehicle (along with testing
software) (Description in item: 61 00 510, Billed as a
separate item)
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

61 35 028 Replace control unit for intelligent emergency call (without checking/programming
software)
+ 61 35 528

Core activity
(-) Removing the control unit for intelligent emergency call

Remove bolt (1).

Remove the bracket (2) and release the control unit (3) for the intelligent
emergency call.
Disconnect the connector (4) and remove the control unit (3) for the
intelligent emergency call.

(-) Installing the control unit for intelligent emergency call

Fit the control unit (1) for the intelligent emergency call and connect the
connector (2).
Position control unit (1) for intelligent emergency call, noting the installation
position.
Aerial (arrow) faces up.
Hold the bracket (3) in position.
Install bolt (4).

Follow-up work
Installing battery holder
Connect battery with vehicle

=> Testing software (Description in item: 61 00 502, Billed as

a separate item)

=> Programming control units of vehicle (along with testing

software) (Description in item: 61 00 510, Billed as a
separate item)
Logging on to control unit for intelligent emergency call

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Checking, if necessary correcting date
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

61 35 503 Setting service-due date with BMW Motorrad diagnostic system (for maintenance)

Core activity
(-) Setting the service date with BMW Motorrad diagnosis system

Start diagnosis system and perform the vehicle test.

Select Activities from the menu, call up the Service schedules and set the
service date.

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

61 35 504 Setting service countdown distance with BMW Motorrad diagnostic system (for
maintenance)

Core activity
(-) Setting the service for remaining distance with BMW Motorrad
diagnosis system

Start diagnosis system and perform the vehicle test.

Select Activities from the menu, call up the Service schedules and set the
countdown distance.

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

61 35 505 Setting service-due date and service countdown distance with BMW Motorrad
diagnostic system (for maintenance)

Core activity
(-) Setting the service date and service for remaining distance with
BMW Motorrad diagnosis system

Start diagnosis system and perform the vehicle test.

Select Activities from the menu, call up the Service schedules and set the
service date and the countdown distance.

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

61 36 001 Replacing starter relay

+ 61 36 560

Core activity
(-) Removing starter relay

Release lid..
Disconnect connector (1).
Remove nuts (2) and release cables (3) and (4).
Remove expanding rivet (5).
Such as with pliers (No. 13 1 511).
Release starter motor relay (6), unhook the tab (arrow) and remove it.

(-) Installing starter relay

Install starter motor relay (6) and hook in the tab (arrow).
Install expanding rivet (5).
Install cables (3) and (4) and nuts (2).

Tightening torques
Wiring harness to starter relay
M6, Replace nut 6 Nm
Thread-locking compound
(mechanical)

Connect connector (1).

Secure lid.

Follow-up work
Installing left side cap
Connect battery with vehicle
Checking, if necessary correcting date
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

61 36 040 Replacing main relay

+ 61 36 540

Core activity
(-) Remove main relay

Turn holder (1) for the carbon canister.

Press the lock (arrow) and remove main relay (2).

(-) Install main relay

Install main relay (2) and make sure that the lock (arrow) engages audibly.
Turn back holder (1) for the carbon canister in position.

Follow-up work
Installing carbon canister
Securing bracket for activated charcoal filter
Installing left side cap
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

62 11 199 Replacing instrument cluster (without (testing software/programming)

+ 62 11 510

NOTICE
Before removal, test the control unit with the BMW Motorrad diagnostic
system and make a backup copy of the data.

Core activity
(-) Removing instrument panel

Remove retaining clips (1).

Pull instrument cluster (2) out of rubber grommets (3).
Disconnect connector (4) from instrument cluster (2) and remove instrument
cluster (2).

(-) Installing instrument panel

NOTICE
When control units (for example engine management system, ABS,
instrument cluster) are replaced on a motorcycle with CAN bus, the BMW
Motorrad diagnostic system has to be used to register each new component.

Connect connector (4) to instrument cluster (2) and hold instrument cluster
(2) in position.
Seat instrument cluster (2) in rubber grommets (3).
Install retaining clips (1).

Follow-up work

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
=> Testing software (Description in item: 61 00 502, Billed as
a separate item)

=> Programming control units of vehicle (along with testing

software) (Description in item: 61 00 510, Billed as a
separate item)
Securing right slipstream deflector
Securing left slipstream deflector
Installing centre slipstream deflector
Install the windscreen
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

63 12 000 Adjust headlight

+ 63 12 500

Core activity
(-) Checking headlight beam throw

Requirement
Motorcycle standing on a smooth, level surface.
Rider's weight applied to the motorcycle.

Set the spring preload to the basic setting.

Start the engine and check that the headlight setting.
Check
Distances:
(a): distance between headlight and vertical surface
(b): height of centre of headlight
(c): distance to light/dark cut-off

Technical data
Distance between 5m
headlight and vertical
surface
For headlight
adjustment
Distance from Suspension 5 cm
light/dark limit to set to basic
upper edge of low- setting and
beam headlight light- vehicle
emitting surface loaded with
85 kg

Result:
Headlight beam angle not correct.
Measure:
Correcting headlight beam angle
Start the engine.
Rider's weight applied to the motorcycle.
Adjust headlight beam throw by turning adjusting screw (1).

Technical data
Distance from Suspension 5 cm
light/dark limit to set to basic
upper edge of low- setting and
beam headlight light- vehicle
emitting surface loaded with
85 kg

Follow-up work
Final check of work performed
052021 BMW Motorrad, UX-VA-4 1/1
BMW-Motorrad - F 850 GS

63 12 091 Replacing headlight

+ 63 12 637

CAUTION
Hot control unit
Risk of burning
The control unit gets hot during operation; allow the control unit to cool down
before starting work.

Core activity
(-) Removing headlight

Release hooks (arrows) and remove holder locks (1).

Remove retaining clips (1) and washers (2).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Release headlight (1).

Disconnect connector (2) for the headlight.
ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Remove headlight (1), pressing the left fairing side panel (3) and the right
fairing side panel (4) slightly outwards while doing so.

(-) Replacing headlight

Remount rubber grommets (1) on new part.

(-) Installing headlight

Make sure rubber grommets (1) are correctly seated.

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
052021 BMW Motorrad, UX-VA-4 2/3
BMW-Motorrad - F 850 GS
Take care not to scratch components; cover or mask as necessary.

Hold headlight (1)in position, pressing the left fairing side panel (3) and the
right fairing side panel (4) slightly outwards while doing so.
Connect connector (2) for the headlight.
Hold headlight (1) in position.

Install washers (2) and retaining clips (1).

Install holder locks (1), hooks (arrows) must engage.

Follow-up work
Installing top front-wheel cover
Installing front spray guard
Checking headlight beam throw
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

63 12 505 Replacing control unit for LED bulb (headlight removed)

Core activity
(-) Remove the control unit

Remove screws (1).

Remove control unit (2) with seal (3).

(-) Installing control unit

Install control unit (2) with seal (3).

Pay attention to mounting orientation!
Install screws (1).

=> Testing software (Description in item: 61 00 502, Billed as a

separate item)
=> Programming control units of vehicle (along with testing software)
(Description in item: 61 00 510, Billed as a separate item)

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

63 13 002 Replacing front left flashing turn indicator

+ 63 13 521

Core activity
(-) Removing front left flashing turn indicator

Remove bolt (1) and nut (2).

Unhook and remove the turn indicator (3).

(-) Installing front left flashing turn indicator

Feed in, hook in and position the turn indicator (3).

Install bolt (1) and nut (2).

Tightening torques
Front turn indicator to slipstream deflector
M6 x 20 3 Nm

Follow-up work
Installing left slipstream deflector
Install the windscreen
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

63 21 380 Removing and installing or replacing complete rear light

+ 63 21 502

Core activity
(-) Removing rear-light unit

Remove retaining clips (1) and washers (2).

Release rear light (3), detaching rubber grommet (4).
Disconnect connector (5) for rear light.
Remove rear light (3).

(-) Replacing rear light

Convert retaining clip (1), washer (2) and rubber grommet (3) to new part
(4).

(-) Installing rear-light unit

Hold rear light (3) in position.

Connect connector (5) for rear light.
Position rear light (3), attaching rubber grommet (4).
Install washers (2) and retaining clips (1).

Follow-up work
Securing number-plate carrier
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

63 23 012 Replacing left rear turn indicator

+ 63 23 501

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat

Core activity
(-) Removing rear left flashing turn indicator

Disengage connector (1) from bracket (arrow) and disconnect connector (2)
for left turn indicator.

Disengaging number-plate carrier

Remove screws (1) and screws (2).
Release locators (arrows) of number plate carrier (3) from rear-wheel cover
(4) and release number plate carrier (3).

Remove bolt (1).

Unhook and remove left turn indicator (2).

(-) Installing rear left turn indicator

Hook in left turn indicator (2) and secure it with bolt (1).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

Tightening torques
Flashing turn indicator to number-plate carrier
M6 x 20 3 Nm

Connect connector (2) for left turn indicator, secure connector (1) in bracket
(arrow).

Securing number-plate carrier

Follow-up work
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

65 75 020 Replace batteries for control unit of anti-theft alarm system

+ 65 75 520
Equipment trim-level variant:

0603 - Anti-theft alarm (DWA)OE

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat

Core activity
(-) Removing anti-theft alarm control unit

Remove bolt (1).

Release anti-theft alarm (2).
Disconnect connector (3) for anti-theft alarm.
Remove anti-theft alarm (2).

(-) Removing batteries for anti-theft alarm control unit

Remove screws (1).

Remove the cap (2).
Remove batteries (3).

(-) Installing batteries for anti-theft alarm control unit

Install batteries (1) making sure that polarity is correct.

Technical data
Battery type CR 123 A

Check the seal (2) for damage; replace if necessary.

Hold lid (3) in position.
Install screws (4).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
(-) Installing anti-theft alarm control unit

Hold anti-theft alarm (2) in position.

Connect connector (3) for the anti-theft alarm.
Position anti-theft alarm (2), noting the guides (arrows).
Install bolt (1).

Follow-up work
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

65 75 510 Replacing control unit of anti-theft alarm (without testing software/ programming)
Equipment trim-level variant:

0603 - Anti-theft alarm (DWA)OE

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Removing seat

Core activity
(-) Removing anti-theft alarm control unit

Remove bolt (1).

Release anti-theft alarm (2).
Disconnect connector (3) for anti-theft alarm.
Remove anti-theft alarm (2).

(-) Installing anti-theft alarm control unit

Hold anti-theft alarm (2) in position.

Connect connector (3) for the anti-theft alarm.
Position anti-theft alarm (2), noting the guides (arrows).
Install bolt (1).

Follow-up work
=> Testing software (Description in item: 61 00 502, Billed as
a separate item)

=> Programming control units of vehicle (along with testing

software) (Description in item: 61 00 510, Billed as a
separate item)
Installing seat

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

65 81 050 Replacing ambient-temperature sensor

+ 65 81 550

Core activity
(-) Installing ambient-temperature sensor

Cut open cable strap (Arrow) and release outside temperature sensor (1).
Disconnect connector (2).

(-) Installing ambient-temperature sensor

Connect connector (2).

Secure outside temperature sensor (1) with cable strap (Arrow).

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

66 12 001 Replacing control unit for Keyless Ride

+ 66 12 501
Equipment trim-level variant:

0193 - Keyless RideOE

Core activity
(-) Removing control unit for Keyless Ride

Punch-mark shear screws (1) in the centre (arrows).

First pre-drill shear screws (1) with a small drill and then drill them out with
a larger drill.

Technical data
Ignition (Pilot) hole min 10 mm
switch/steering lock - diameter 2 mm
drilling depth for
drilling out tamper- Hole 10 mm
proof shear screws diameter 5 mm

Heat the area around the thread of shear screws (1) without overheating the
control module for Keyless Ride (2).

Technical data
Release/mating 80 °C
temperature

Remove shear screws (1) with a suitable screw extractor.

Remove the control module for Keyless Ride (2).

(-) Installing control unit for Keyless Ride

Position the control module for the Keyless Ride (1) on the fork bridge (2).
Install shear screws (3) and tighten until the tool engagement (arrow) tears
off head (4).

Tightening torques
Control module for Keyless Ride to fork bridge
M8 x 18, Replace screw Tighten bolt until tool
Thread-locking compound (micro- handle shears off.
encapsulated)

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Follow-up work
Installing top fork bridge
Securing handlebars
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle
Programming the vehicle control, control unit with BMW Motorrad
diagnosis system
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

66 12 002 Replacing the antenna for Keyless Ride

+ 66 12 502
Equipment trim-level variant:

0193 - Keyless RideOE

Core activity
(-) Removing LF aerial

Remove cable strap (arrow).

Disconnect and release the plug connection (1) for the audio frequency
aerial .
Remove audio frequency aerial (2).

(-) Installing LF aerial

Install the audio frequency aerial (3).

Secure cable strap (2).
Secure and connect the plug connection (1) for the audio frequency aerial.

Follow-up work
Installing battery
Installing seat
Checking, if necessary correcting date
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

Workshop installation instructions

Repair Guide

BMW Motorrad
BMW-Motorrad - F 850 GS

77 02 002 Installing automatic chain-lubrication system

+ 77 02 503

Preparatory work
Removing seat
Removing front spray guard
Removing top front-wheel cover
Removing the fuel tank cover
Removing left radiator cowl
Removing the fairing side panel with the left badge holder
Removing right radiator cowl
Removing the fairing side panel with the right badge holder
Removing fuel tank

Core activity
(-) Pulling off hose from tank vent valve

Pull off hose (1) from tank vent valve (2) in the direction of the arrow.

(-) Installing vacuum adapter

Cut through hose (1) at the edge of the protective hose (arrow).

Measure the surface (arrow) on T-connecting element (1).

Mark the excess length (arrow) on hose (2) and cut it off.
Slide hose (2) fully onto T-connecting element (1) from both sides.
Connect vacuum connection (3) on T-connecting element (1).
Insert vacuum hose (4) in vacuum connection (3).

052021 BMW Motorrad, UX-VA-4 1/6

BMW-Motorrad - F 850 GS

(-) Installing hose to throttle valve assembly vent and tank vent
valve

Slide hose (1) onto tank vent valve (2) in the direction of the arrow.

Route vacuum hose (1) in cable channel (2).

(-) Affixing BMW Motorrad sticker

ATTENTION
Use of unsuitable cleaning and care products
Damage to surfaces
Use a mild solution of soap in water and a soft sponge for cleaning.
Do not use other solvents or fuel.

NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.

Clean the surface for gluing.

Pull off the protective film from label (1).

052021 BMW Motorrad, UX-VA-4 2/6

BMW-Motorrad - F 850 GS
Stick the label according to the mounting orientation of oil reservoir (2).

(-) Fixing oil reservoir

Installing breather hose

Connect vent hose (1) in oil reservoir (2).

Fix oil reservoir (1) in oil reservoir holder (2) only lightly to carbon canister
holder (5) with cable straps (3) and (4).

(-) Connecting vacuum hose

Let vacuum hose (1) rest against oil-tank port (2) from above and mark it.
Cut vacuum hose to marked length.
Insert vacuum hose (1) in oil-tank port (2).
Route vent hose (3) next to vacuum hose (1).

052021 BMW Motorrad, UX-VA-4 3/6

BMW-Motorrad - F 850 GS
(-) Removing chain guard

Remove screws (1) from chain guard (3).

Remove expanding rivet (2) in direction (arrow).

(-) Routing supply hose

ATTENTION
Use of unsuitable cleaning and care products
Damage to surfaces
Use a mild solution of soap in water and a soft sponge for cleaning.
Do not use other solvents or fuel.

Clean the surface on rear wheel swinging arm (1).

NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.

Secure supply hose (6) to the chain lubrication system bracket with cable
strap (5).
Insert supply hose (6) through holder (4).
Secure supply hose (6) to rear wheel swinging arm (1) with cable straps (3)
and (2).

(-) Installing bracket for supply tube nozzle

Install supply nozzle (1) with hose clamp (2) and cable strap (3) on holder
(4).

Install holder (2) with screw (1) under chain guard (3).

Tightening torques
Chain guard to swinging arm
M6 x 16, Replace screw 3 Nm

052021 BMW Motorrad, UX-VA-4 4/6

BMW-Motorrad - F 850 GS
Thread-locking compound (micro-
encapsulated)

(-) Installing chain guard

Install screws (1) on chain guard (3).

Install expanding rivet (2).

(-) Connecting conveying hose

Let supply hose (1) rest against oil reservoir (2) and cut it to the correct
length.
Connect supply hose (1) to oil reservoir (2).

(-) Secure the oil tank

Secure oil reservoir (1) in oil reservoir holder (2) to carbon canister holder
(5) with cable straps (3) and (4).

(-) Affixing sticker to handlebars

052021 BMW Motorrad, UX-VA-4 5/6
BMW-Motorrad - F 850 GS

ATTENTION
Use of unsuitable cleaning and care products
Damage to surfaces
Use a mild solution of soap in water and a soft sponge for cleaning.
Do not use other solvents or fuel.

NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.

Clean the surface for gluing.

Pull off the protective film from label (1).
Affix the sticker at a clearly visible location on the handlebars; the optimum
position depends on the equipment complement of the motorcycle.

Follow-up work
Installing fuel tank
Installing left fairing side panel with badge carrier
Installing left radiator cowl
Installing right fairing side panel with badge carrier
Installing right radiator cowl
Installing the fuel tank cover
Installing top front-wheel cover
Installing front spray guard
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 6/6

BMW-Motorrad - F 850 GS

77 11 010 Installing sports silencer

+ 77 11 510

Remove screws (1).

Remove silencer cover (2).

(-) Removing silencer

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

Slacken nut (1) on the clamp (2).

Slide clamp (2) upwards.

Remove bolt (1) with shaped washer (2).

Remove silencer (3).
Remove bolts (4) with holder (5).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
(-) Assemble sports silencer

Lubricate the sports silencer on the inner diameter before connecting the
connecting pipe.

Lubricant
Copper paste 81 22 9 400 794

Connect connecting pipe (1) in sports silencer (3).

Tighten the clamp (2).

Tightening torques
Silencer to front silencer
M8 19 Nm

Install shouldered bushing (1) in sports silencer (2).

Slacken retaining clip (3) for installation.

(-) Installing sports silencer

ATTENTION
Use of unsuitable cleaning agents
Damage to the surface
Clean the outer skin of the sports silencer only with a care spray
recommended by an authorised BMW Motorrad dealer and a soft, dry cloth.

NOTICE
The lifespan of the insulating material in the silencer depends on engine
performance and style of riding.
Consult an authorised BMW Motorrad dealer if the silencer becomes louder
or if its external appearance changes.
Note, however, that slight discolouration of the silencer is normal. This
discolouration is caused by the high temperature of the exhaust gas.

Lubricate the sports silencer on the inner diameter before connecting it.

Lubricant
Copper paste 81 22 9 400 794

Install holder (4) with bolts (5).

Tightening torques
Sports silencer to rear frame

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
M8 x 40 19 Nm

Connect sports silencer (1) to exhaust manifold.

Hold washer (3) in position and install bolt (2) until hand-tight.
Tighten retaining clip (6)

Tightening torques
Silencer to front silencer
M8 19 Nm

Tighten the screw (2).

Tightening torques
Sports silencer to rear frame
M8 x 40 19 Nm

(-) Install the silencer cover

Install silencer cover (2).

Install screws (1).

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

77 13 051 Installing retrofit kit for power-output restriction to 35 kW

+ 77 13 504

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)
Removing seat

Core activity
(-) Connect the BMW Motorrad diagnostic system to the vehicle

Connect the BMW Motorrad battery charger.

NOTICE
When carrying out diagnosis and programming, use a battery charger with 30
A approved by BMW Motorrad that ensures an on-board system voltage of
13 V.

Loosen diagnostic connector (1) from holder (2).

Connect diagnostic connector (1) with connecting cable (3) for diagnosis
system.
NOTICE
See the information about the BMW Motorrad diagnostic system for all further
instructions.

(-) Converting power reduction with the BMW Motorrad diagnosis

system

In the Vehicle management menu item, call up the Vehicle modification

menu item.
Select the Conversions menu item.

Follow the instructions of the BMW Motorrad diagnosis system.

(-) Disconnecting BMW Motorrad diagnostic system from vehicle

Close all diagnostic programs and switch off the ignition.

Follow-up work
052021 BMW Motorrad, UX-VA-4 1/2
BMW-Motorrad - F 850 GS
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 14 000 Installing aluminium engine guard

+ 77 14 551

Remove screws (1) and plastic engine guard (2).

(-) Installing aluminium engine guard

Install rubber grommets (1) and shouldered bushings (2).

Position aluminium engine guard (2).

Install screws (1).

Tightening torques
Engine guard to bracket
M6 x 25 9 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

77 14 100 Installing crash bars

+ 77 14 500

Preparatory work
Removing the cover for wiring harness

Core activity
(-) Installing left crash bar

Position engine protection bar (1), install screws (2) and screw (3) but do not
tighten.
Tighten the screws (2).

Tightening torques
Engine protection bar on side stand bearing support and engine
M8 x 25 19 Nm
Thread-locking compound (micro-
encapsulated)

Tighten the screw (3).

Tightening torques
Engine protection bar on engine block
M8 x 35 19 Nm
Thread-locking compound (micro-
encapsulated)

(-) Install the right crash bar

Position right engine protection bar (1), sliding it onto left engine protection
bar (2), and install screws (3), (4) and (5) hand-tight.
Tighten the screw (3).

Tightening torques
Engine protection bar on side stand bearing support and engine
M8 x 25 19 Nm
Thread-locking compound (micro-
encapsulated)

Tighten screw (4).

Tightening torques
Engine protection bar on engine block
M8 x 35 19 Nm
Thread-locking compound (micro-
encapsulated)

Tighten screw (5).

Tightening torques
Crash bar to crankcase
M10 x 30 56 Nm

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Thread-locking compound (micro-
encapsulated)

(-) Connecting engine protection bar

Install bolt (1).

Tightening torques
Crash bar, left, to engine protection bar, right
M5 x 14 6 Nm
Thread-locking compound (micro-
encapsulated)

Follow-up work
Installing the cover for wiring harness
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 15 002 Install adjustable gearshift lever

+ 77 15 502

Core activity
(-) Releasing lower gearshift rod

Remove retaining clip (1).

Release gearshift rod (2) from gearshift lever (3), checking sealing washer
(4).

(-) Removing gearshift lever

Remove shouldered bushing (1), counter-holding screw (2).

Remove gearshift lever (3) and thrust washer (4).
Save shouldered bushing (1) and thrust washer (4), components will be
reused.

(-) Installing adjustable gearshift lever

Clean components as needed.

Position shouldered bushing (1), gearshift lever (2) and thrust washer (3),
counter-holding screw (4).
Tighten shouldered bushing (1), counter-holding screw (2).

Tightening torques
Gearshift lever to footrest plate
M8 x 25 19 Nm

(-) Securing lower gearshift rod

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Secure gearshift rod (1) on gearshift lever (2), checking sealing washer (3).
Install retaining clip (4).

(-) Adjusting foot piece

To adjust foot piece (1) in front bore hole, slacken bolt (2).
Turn foot piece (1) to the desired position.
NOTICE
A peg that has been set too high or too low can lead to problems when shifting
gear. Check the position of the peg if you experience shifting problems.

Tighten the screw (2).

Tightening torques
Foot piece on gearshift lever
M6 x 25 8 Nm

To transfer foot piece (1) to rear bore hole (arrow), remove bolt (2).
Install foot piece (1) in rear bore hole (arrow) and insert bolt (2) but do not
tighten.
Turn foot piece (1) to the desired position.
NOTICE
A peg that has been set too high or too low can lead to problems when shifting
gear. Check the position of the peg if you experience shifting problems.

Tighten the screw (2).

Tightening torques
Foot piece on gearshift lever
M6 x 25 8 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 22 012 Installing brake lever

+ 77 22 618

Remove the nut (1).

Remove bolt (2).
Remove lever (3).

(-) Installing High Performance handbrake lever

Lubricate tyre tread (arrow) of brake lever (2).

Lubricant
Klüberplex BEM 34-132 31 42 7 713 934

Lubricate screw (1), leaving out the thread.

Lubricant
Klüberplex BEM 34-132 31 42 7 713 934

Insert lever (2).

Install bolt (1) and nut (3).

Tightening torques
Hand lever to handbrake fitting
M6 x 35, Screw 1 Nm
M6, Nut Tightening
sequence: Tighten
the nut, counter-
holding the bolt
6 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

77 22 013 Installing clutch lever

+ 77 22 619

Core activity
(-) Removing clutch lever

(-) Remount intermediate lever on HP clutch lever

Remove bush (1).

Remove intermediate lever (2) and spring (3) from clutch lever (4).

Clean and lubricate bush (1).

Lubricant
Unirex N3 83 19 2 160 349

Clean marked area (arrow) on intermediate lever (2) and lubricate.

Lubricant
Unirex N3 83 19 2 160 349

Position intermediate lever (2) with spring (3) on HP clutch lever (4) ensuring
the correct fit of the spring (3).
Install bush (1).

(-) HP Installing clutch lever

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
HP Lubricate clutch lever (5) and bolt (4).

Lubricant
Unirex N3 83 19 2 160 349

Attach clutch cable (6) and position HP clutch lever (5).

Make sure that clutch cable (6) is routed in the recess of clutch lever fitting
(arrow), adjusting screw (1)and lock nut (2) is routed.
Install bolt (4) and new nut (3).

Tightening torques
Hand lever lever to clutch lever fitting
M6 x 30, Screw 6 Nm
M6, Nut Tightening
Thread-locking compound sequence: Tighten
(mechanical) the nut, counter-
holding the bolt
8 Nm

Turn back lock nut (2) and adjusting screw (1) again.

Follow-up work
Installing the cover for clutch switch
Checking/adjusting clutch play
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 22 029 Install the elevated handlebars

+ 77 22 529

Preparatory work
Remove the left handlebar weight
Releasing handlebar fitting for clutch
removing left grip unit
Removing the right handlebar weight
Disengaging brake fitting for front wheel
Removing right multifunction switch
Removing the throttle twistgrip

Core activity
(-) Removing handlebars

Remove screws (1).

Remove clamping block (2).
Release handlebars (3).

Remove handlebars (1) from grip unit (2).

(-) Installing handlebars high

Lubricate the rubber pad (arrow).

Installation tool
Silicone spray 83 19 2 208 609

Slide grip unit (1) onto handlebars high (2), checking the rubber element
(arrow).

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Position handlebars high (1) with clamping block (2).
Align handlebars high (1) with the marks (arrows).
WARNING
Incorrect tightening sequence of the handlebar clamps.
Handlebars work loose when vehicle is ridden.
Tighten the handlebar clamps to the specified torque and in the specified
sequence.

Install screws (3).

Tightening torques
Handlebar clamping block to fork bridge
M8 x 35 Tightening
sequence: in the
forward direction of
travel, tighten until
seated
19 Nm

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 22 185 Installing heated handlebar grips

+ 77 22 795

Preparatory work
Removing the right handlebar weight
Remove the left handlebar weight

Core activity
(-) Removing right multifunction switch

Press the releases (arrows) at front and back and disconnect connector (1)
for the throttle grip.

Remove bolt (1).

Pull cover (2) down slightly.

Push cover (1) forward and up to remove, noting retaining catches (2).

Release connector (1) with blind cap, then remove it.

Disconnect connector (2) for the multifunction switch.
Remove bolt (3).
Remove multifunction switch (4).

052021 BMW Motorrad, UX-VA-4 1/7

BMW-Motorrad - F 850 GS

(-) Removing the throttle twistgrip

Remove bolt (1).

Remove throttle grip (2).

(-) Installing throttle twistgrip

Install throttle grip (2).

Install bolt (1).

Tightening torques
Throttle twistgrip to handlebar
M3.5 x 30 2 Nm

(-) Installing right multifunction switch

ATTENTION
Screws overtightened past the specified value
Component damage
Tighten the screws only to their specified tightening torque.

Hold the new multifunction switch (4) in position.

Install bolt (3).

Tightening torques
Multifunction switch to throttle grip
Screw for plastic, PT2.5 x 15 0.4 Nm

052021 BMW Motorrad, UX-VA-4 2/7

BMW-Motorrad - F 850 GS
Connect connector (2) for the multifunction switch.
Connect connector (1) for the heated grip and clip it into position.

Position cover (1) and push backwards and down, paying attention to
retaining catches(2).

Press cover (2) upwards until the multifunction switch is closed.

ATTENTION
Screws overtightened past the specified value
Component damage
Tighten the screws only to their specified tightening torque.

Install bolt (1).

Tightening torques
Cover to multifunction switch
Screw for plastic, 2.5 x 15 0.4 Nm

Connect connector (1) for throttle grip.

(-) removing left grip unit

Push collar of rubber grip (1) slightly aside and remove screw (2).

052021 BMW Motorrad, UX-VA-4 3/7

BMW-Motorrad - F 850 GS

Remove the straps (1).

Disconnect connector (2) from clutch switch (3).

Turn the handlebars all the way to the left.

Pull off grip unit(1), paying attention to the cable leg (2) while doing so.

(-) Removing left handlebar grip

Unclip the retaining tabs (arrows).

Remove cover (1).

Remove connectors (1) and (2).

052021 BMW Motorrad, UX-VA-4 4/7

BMW-Motorrad - F 850 GS

Push up retainer (1).

Remove handlebar grip (2).

(-) Installing left handlebar grip

Install handlebar grip (1) , and at the same time insert connector (2) for the
heated grip.
Retaining lug (3) engages.

Lubricate the rubber pad (arrow).

Installation tool
Silicone spray 83 19 2 208 609

Connect connector (2) for the heated grip.

Connect connector (1) for the multifunction switch.

Install the cover (1).

The retaining tabs (arrows) engage.

052021 BMW Motorrad, UX-VA-4 5/7

BMW-Motorrad - F 850 GS

(-) Securing left grip unit

Turn the handlebars all the way to the left.

Push on grip unit(1), paying attention to the cable leg (2) while doing so.

Push collar of rubber grip (1) slightly aside and install screw (2).

Tightening torques
Handlebar grip, left, to handlebar
M3.5 x 30 2 Nm

Connect connector (2) with clutch switch (3).

Secure straps (1).

Follow-up work
Installing right handlebar weight
Installing left handlebar weight
Removing seat
052021 BMW Motorrad, UX-VA-4 6/7
BMW-Motorrad - F 850 GS
Connect the BMW Motorrad diagnostic system to the vehicle
Performing software update with the BMW Motorrad diagnosis system
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 7/7

BMW-Motorrad - F 850 GS

77 23 006 Installing adjustable footbrake lever

+ 77 23 506

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing footbrake lever

Unclip bolt (1) from pushrod (2) and remove from pushrod (2) and footbrake
lever (3) .

Remove bolt (1), counter-holding it at two-flats (arrows) of shouldered

bushing (2) .
Release footbrake lever (3) from footrest plate (4) .

Detach footbrake lever (1) from return spring (2) and remove together with
shouldered bushing (3) and thrust washer (4) .

(-) Installing footbrake lever

Lubricate shouldered bushing (3).

Lubricant

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Staburags NBU 30 PTM 07 55 9 056 992

Hold footbrake lever (4) in position with shouldered bushing (3) and washer
(5).
Install bolt (1) with contact disc (2).

Tightening torques
Brake pedal to footrest plate
M8 x 20 19 Nm

Engage spring (1).

(-) Adjust blow-by clearance at piston rod

Insert feeler gauge (1) in the direction of travel between footrest plate (2)
and brake lever (3).

Technical data
Blow-by clearance of On the limit 1.9...2.1 mm
the footbrake lever position for
the footbrake
lever on the
footrest plate.

Hold fork of pushrod (2) in position at footbrake lever (3).

Install bolts (1) and clip onto pushrod (2).

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 25 011 Installing front footrests

+ 77 25 777

Core activity
(-) Removing front left footrest

Remove the circlip (1).

Remove bolts (2).
Remove the footrest (3) with spring (4) and sleeve (5).

(-) Install the front left footrest

Clean and lubricate components.

Lubricant
Staburags NBU 30 PTM 07 55 9 056 992

Install spring (2) in footrest (3).

Hold footrest (3) with spring in position (2), inserting spring (2) in bore hole
(arrow) on the footrest plate (4).
Install bolts (1).
Install the circlip (5).

(-) Removing front right footrest

Remove the circlip (1).

Remove bolts (2).
Remove the footrest (3) with spring (4) and sleeve (5).

(-) Installing front right footrest

Clean and lubricate components.

Lubricant
Staburags NBU 30 PTM 07 55 9 056 992

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Install spring (2) in footrest (3).
Hold footrest (3) in position with spring (2), inserting spring (2) in bore hole
(arrow) of the footrest plate (4).
Install bolts (1).
Install the circlip (5).

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 25 200 Installing centre stand

+ 77 25 700

Preparatory work
Placing motorcycle on rear-wheel stand
Installing engine lifter

Core activity
(-) Assembling centre stand

Install stop pad (1) and buffer (2) in centre stand (3).
Install bearing bushes (4) in retaining panel of centre stand left (5) and
retaining panel of centre stand right (6).

(-) Disengaging gearshift rod

Remove retaining clip (1).

Release gearshift rod (2) from ball head (3).

(-) Removing front left footrest plate

Remove bolt (1) from swinging arm axle and store, subsequently needed
for reassembly.

If necessary, turn away the gearshift lever.

Remove bolt (1).
Remove screws (2) and screws (3).

052021 BMW Motorrad, UX-VA-4 1/5

BMW-Motorrad - F 850 GS
Store bolts (1), (2) and (3), subsequently needed for reassembly.
Remove footrest plate (4) with mounted parts, feeding out the lug (arrow).

(-) Removing side stand

Disconnect connector (1) for side-stand switch.

Remove bolt (2) and take off bearing support (3) with side stand from engine
block (4).
Store bolt (2), subsequently needed for reassembly.

(-) Removing adapter

Remove bolt (1) and remove adapter (2).

Store bolt (1), subsequently needed for reassembly.

(-) Installing retaining panel left for centre stand

Position retaining panel left (1) for centre stand on engine block (2) noting
dowel pin (arrow).
Install bolt (3).

Tightening torques
Retaining panel for centre stand to engine
M10 x 35 38 Nm

(-) Installing side stand

052021 BMW Motorrad, UX-VA-4 2/5
BMW-Motorrad - F 850 GS

Position bearing support (1) with side stand on engine block (2) and install
bolt (3) hand-tight.
Connect connector (4) for side-stand switch.

(-) Installing front left footrest plate

Hold footrest plate (4) with mounted parts in position, while feeding in the lug
(arrow).
Install bolts (3), bolts (2) and bolt (1), do not tighten.

Clean the seat of screw (1) carefully.

Install the bolt (1) and tighten.

Tightening torques
Rear wheel swinging arm to frame
M20 x 1.5, Replace screw 200 Nm

Tighten the screws (2).

Tightening torques
Footrest plate with side-stand bearing support on crankcase
M10 x 50 38 Nm

Tighten the screw (1).

Tightening torques
Retaining panel for centre stand to left footrest plate
M10 x 35 38 Nm

Tighten the screws (3).

Tightening torques

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS
Left footrest plate to crankcase
M8 x 40 - 10.9 28 Nm

Tighten the screw (1).

Tightening torques
Bearing support for side stand to crankcase
M10 x 35 38 Nm

(-) Securing selector rod

Push gearshift rod (2) on ball head (3).

Install retaining clip (1).

(-) Installing centre stand

Clean bearing seats (arrows), , but do not lubricate.

Insert centre stand (1) in left retaining plate (2).
Hold right retaining plate (3) in position and install screws (4).

Tightening torques

(-) Installing tension springs for centre stand

If applicable, hook new tension springs (1) into spring plates (2).
Position basic unit (No. 46 5 741) and mount (No. 46 5 746) on spring plates
(2).
Pretension tension springs (1).

052021 BMW Motorrad, UX-VA-4 4/5

BMW-Motorrad - F 850 GS

As applicable, clean the retaining pins (arrows) and lubricate.

Lubricant
Unirex N3 83 19 2 160 349

Follow-up work
Removing engine lifter
Removing motorcycle from rear-wheel stand
Final check of work performed

052021 BMW Motorrad, UX-VA-4 5/5

BMW-Motorrad - F 850 GS

77 31 026 Fix label set

+ 77 31 526

ATTENTION
Ensure that driving or cleaning are carried out outside the drying period
Labels are damaged or loose
Allow labels to dry for 24 hours.
Do not drive this vehicle before this drying period.

ATTENTION
Damage caused by high water pressure of high pressure cleaners
Labels are damaged or loose
Do not clean labels with high pressure or steam jet cleaning equipment
Use high pressure or steam jet cleaning equipment carefully.

NOTICE
This is an exemplary description for labelling decor.
The alignment and placement on the vehicle is also shown in the figures.
The foils are to be positioned in such a way that there is an even distance to
component edges around it.
The rounded area of the foils should be aligned with the component rounded
area.

Core activity
(-) Work preparation

Prepare mild soap solution as application liquid and fill into spray bottle.

Technical data
Mixture ration for the Water 5 l 5 drops of dish soap
production of the
application fluid

Pad the edges of the doctor blade, e.g. by sticking on a piece of microfibre
cloth.
Clean bonding surfaces on the vehicle.

Core activity
(-) Assembling hand protector, left and right

Install flat nut (1).

Position holder (2) on anti-twist locks (arrows) of left hand protector (3).
Install bolt (4).

Tightening torques
Hand protector to hand protector holder
M5 x 14, 3 mm collar 2 Nm

Install flat nut (1).

Position holder (2) on anti-twist locks (arrows) of right hand protector (3).
Install bolt (4).

Tightening torques
Hand protector to hand protector holder
M5 x 14, 3 mm collar 2 Nm

(-) Installing left hand protector

Clean the threads.

Place hand protector (1) in position.

Install handlebar weight (1).

Install bush (2) with bolt (3).
Position hand protector (4).
Tighten screw (3) making sure that the hand protector (4) does not twist out
of position.

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Tightening torques
Hand protector with handlebar weight to handlebar
M10 x 50 38 Nm
Thread-locking compound (Loctite
243, Medium strength)

Installing left mirror

Install complete left/right adapter (2) with mirror (3) and washer (4).

Tightening torques
Adapter to clamping block
M10 x 14 - 4.8 25 Nm

Slide rubber cover (1) over screw connection.

(-) Installing left hand protector

Clean the threads.

Place hand protector (1) in position.

Install handlebar weight (1).

Install bush (2) with bolt (3).
Position hand protector (4).
Tighten screw (3) making sure that the hand protector (4) does not twist out
of position.

Tightening torques
Hand protector with handlebar weight to handlebar
M10 x 50 38 Nm
Thread-locking compound (Loctite
243, Medium strength)

Installing left mirror

Install complete left/right adapter (2) with mirror (3) and washer (4).
052021 BMW Motorrad, UX-VA-4 2/3
BMW-Motorrad - F 850 GS

Tightening torques
Adapter to clamping block
M10 x 14 - 4.8 25 Nm

Slide rubber cover (1) over screw connection.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

77 33 025 Installing high windscreen

+ 77 33 525

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing windscreen

Remove screws (1).

Remove windscreen (2).

(-) Installing high windscreen

Make sure that rubber grommets (1) and shouldered bushings (2) are
installed.

Position windscreen (2).

Install screws (1).

Tightening torques
Windscreen to windscreen holder
M5 x 20 4 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

77 33 026 Installing low windscreen

+ 77 33 526

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing windscreen

Remove screws (1).

Remove windscreen (2).

(-) Removing windscreen holder

Remove screws (1).

Remove windscreen holder (2) .

(-) Installing short windscreen holder

Position windscreen holder (2).

Install screws (1).

Tightening torques
Windscreen holder to front panel carrier
M6 x 20 5 Nm

(-) Installing low windscreen

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Make sure that rubber grommets (1) and shouldered bushings (2) are
installed.

Position windscreen (2).

Install screws (1).

Tightening torques
Windscreen to windscreen holder
M5 x 20 4 Nm

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 42 138 Installing case carrier for aluminium case

+ 77 42 507

Preparatory work
Removing seat

Core activity
(-) Removing rear right and left footrest bracket

Remove the bolts (1) and footrest bracket (2).

Remove rear left footrest bracket in the same way.

(-) Installing holder for case holder on the right and left with rear
footrest bracket

Clean the threads.

Secure holder for case holder (1) and rear footrest bracket (2) with bolts (3).

Tightening torques
Case holder bracket (aluminium) with rear footrest bracket to rear
frame
M8 x 30 - 10.9 28 Nm
Thread-locking compound (micro-
encapsulated)

Install holder for case holder on the left side in the same way.

(-) Removing screws for rear carrier

Remove screws (1) and (2).

(-) Installing case holder for aluminium case

Clean the threads.

Hold right case holder (4) in position.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Insert long bolt (2), medium bolt (3) and short bolt (1), do not tighten yet.

Clean the threads.

Hold left case holder (4) in position.
Insert long bolt (2), medium bolt (3) and short bolt (1), do not tighten yet.

Install cage nut (1) on cross-member (2).

Position cross-member (2).
Install bolts (3) and (4), do not tighten yet.
Tighten all screws.

Tightening torques
Case carrier to rear frame
top front, M8 x 50 19 Nm
Thread-locking compound (micro-
encapsulated)
top rear, M8 x 35 19 Nm
Thread-locking compound (micro-
encapsulated)
front, M8 x 20 19 Nm
Thread-locking compound (micro-
encapsulated)
Cross-member to case holder/number plate carrier
M8 x 20 19 Nm
Thread-locking compound (micro-
encapsulated)
M5 x 14 4 Nm

Follow-up work
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 42 151 Installing case carrier

+ 77 42 504

Core activity
(-) Removing rear right and left footrest bracket

Remove the bolts (1) and footrest bracket (2).

Remove rear left footrest bracket in the same way.

(-) Removing left and right rear footrests

Remove lock washer (1) and bolts (2).

Remove rear footrest (3).
Adopt the same procedure to remove the right rear footrest.

(-) Installing left and right rear footrests on the rear footrest/case
holder

Hold footrest (3) in position.

Install bolts (2) and lock washer (1).
Adopt the same procedure to install the right footrest.

(-) Installing left rear footrest/case carrier

Clean the threads.

Secure rear footrest/case carrier (1) with screws (2).

Tightening torques

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Rear footrest holder to rear frame
M8 x 30 - 10.9, Replace screw 28 Nm
Thread-locking compound (micro-
encapsulated)

(-) Installing right rear footrest/case carrier

Clean the threads.

Secure rear footrest/case carrier (1) with screws (2).

Tightening torques
Rear footrest holder to rear frame
M8 x 30 - 10.9, Replace screw 28 Nm
Thread-locking compound (micro-
encapsulated)

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 43 125 Install rubber seal for aluminium topcase

+ 77 43 625

Core activity
(-) Position adhesion surface area

Position adhesion surface area (arrow) at the height of the retaining clip.

(-) Press top left rubber seal

Press rubber seal uniformly in the top left corner.

(-) Press rubber seal on the bottom right

Press rubber seal uniformly in the lower right corner.

(-) Align rubber seal

Place rubber seal on the entire profile seal, but do not press in.

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS

(-) Press rubber seal in corners

Press rubber seal uniformly in the remaining top right as well as bottom left
corners.

(-) Press in rubber seal completely

Press rubber seal uniformly starting from the centre on the longitudinal and
transverse sides.
Spread rubber seal smoothly in the same way.
NOTICE
After the installation no unevenness should be visible or feelable on touch.

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 44 030 Encode lock barrel

+ 77 44 530

Core activity
(-) Encoding lock barrel

Retainers (1) are installed according to the cut-in depths (arrows) of vehicle
key (2).

Align lock barrel (1) with chamber (2) without pressure spring mount facing
up.
Chamber (3) is not occupied.
Install compression springs (4) in lock barrel (1).

Install retainers (1) in chambers (2).

Protect retainers (1) from falling out and turn lock barrel (3).

Install compression springs (1) in lock barrel (2).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

Install retainers (1) in chambers (2).

Install lock plate (3) in last chamber (4).

Insert ignition key (1) in lock barrel (2).

Retainers (3) are pulled in when ignition key (1) is inserted, lock plate (4)
remains protruded.

Check
Check if all retainers (1) were pulled in flush in lock barrel (2).

Result:

All retainers (1) are pulled in flush.

Measure:
Lock barrel completely encoded and can be installed in lock.
Result:

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
One or more retainers (1) are protruding over lock barrel (2).
Measure:
Pull out ignition key (1) and replace corresponding retainer with matching
encoding.

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

77 44 047 Installing luggage carrier for topcase

+ 77 44 502

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing luggage carrier

Remove screws (1).

Remove luggage carrier (2).

(-) Assembling luggage carrier

Position topcase carrier (2) on luggage carrier (1).

Install screws (3).

(-) Installing luggage carrier with topcase carrier

Clean the threads.

Preparatory work
Open the topcase
Removing lock strip

Core activity
(-) Remove the lid finisher

Remove screws (1).

Remove screws (2).

Remove lid finisher (3) from topcase (4), noting the retaining lug (arrows).

(-) Installing backrest pad, top, for topcase

Requirement
Rubbing strip resting on a clean, soft surface.

Drill holes at marks (1) into lid finisher (2).

Technical data
Drilling to size HSS drill bit, 5.5 mm
dia.

Position top backrest pad for topcase (3) on lid finisher (2), align it flush and
install with screws (4) hand-tight.

(-) Installing lid finisher with backrest pad, top, on topcase

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Install lid finisher (3) with top backrest pad on topcase (4), noting the
retaining lug (arrows).

Install screws (2).

Install screws (1).

(-) Installing lock strip

Install lock strip (2) with screws (1).

(-) Close the topcase

Close the topcase, see Rider's Manual.

(-) Installing bottom backrest pad for topcase

Place topcase (1) on its handle side.

Engage screws (2) at the lugs (arrows) in bottom backrest pad (3) and
screw them in slightly.
Position bottom backrest pad (3) at lugs (4) and tighten screws (2).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

77 44 056 Installing backrest pad for aluminium topcase

+ 77 44 556

Core activity
(-) Peeling backing film off small backrest pad

Pull off protective films (arrows) off small backrest pad (1).

(-) Installing small backrest pad

NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.

Seat small backrest pad (1) at bottom edge (2) first, then working upward
along the contour, press lightly into position. Make sure that the small
backrest pad is centred between the two hinges (3) .
Fix the small backrest pad in position by pressing it firmly against the
topcase.

(-) Peeling backing film off large backrest pad

Pull off protective film (arrow) off large backrest pad (1).

(-) Installing large backrest pad

NOTICE

052021 BMW Motorrad, UX-VA-4 1/2

BMW-Motorrad - F 850 GS
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.

Align large backrest pad (1) between the two hinge mounts (2) to the centre.
The rivet (arrow) is centred in the recess (arrow).
Fix the large backrest pad in position by pressing it firmly against the
topcase.

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 2/2

BMW-Motorrad - F 850 GS

77 44 152 Installing topcase carrier for aluminium topcase

+ 77 44 508

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)
Removing seat

Core activity
(-) Removing luggage carrier

Remove screws (1).

Remove luggage carrier (2).

(-) Installing luggage carrier with topcase carrier

Clean the threads.

Hold luggage carrier in position with topcase carrier (1).
Install screws (2).

Tightening torques
Luggage carrier to rear frame
M8 x 40 19 Nm
Thread-locking compound (micro-
encapsulated)

Install screws (3).

Tightening torques
Luggage carrier to rear frame
M8 x 30 19 Nm
Thread-locking compound (micro-
encapsulated)

Follow-up work
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

77 45 006 Installing attachment for tank rucksack

+ 77 45 561

Preparatory work
Removing seat

Core activity
(-) Installing tank bag attachment elements

Positions attachment elements at rear (1) and install screws (2).

Place retaining strap (1) around frame (2) and close hook and loop fastener
(3).

Follow-up work
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

77 49 002 Fit adapter plate on case holder

+ 77 49 507
Equipment trim-level variant:

Case holder for aluminium caseOA

Core activity
(-) Fit adapter plate, left

Insert screws (1) with washers (2) in guiding grooves (3) in the adapter
plate.
Position adapter plate (4) on case holder (5).
Position clamping blocks (6) on case holder (5) from the rear and install
screws (1) in clamping blocks (6) until uniformly hand-tight.
Insert screws (1) with long washer (7) in guiding groove (3) in the adapter
plate.
Position long clamping block (8) on case holder (5) from the rear and install
screws (1) in long clamping block (8) until hand-tight.

(-) Tighten adapter plate, left

NOTICE
Before tightening the adapter plate, check if the required height has been
achieved.
Fasten the adapter plate as low as possible due to the centre of gravity of the
vehicle, vehicle height and driving conditions can however require a different
position.

Align adapter plate (1) centrally to case holder (2).

Tighten all screws (3) uniformly.

Tightening torques
Tighten adapter plate
M6 x 40 8 Nm

(-) Stick adhesive tape in holder for adapter plate

NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.

Rest the adhesive tape on the holder for adapter plate (1) and mark the
contour of the holder.
Cut the adhesive tape into 3 strips.
Pull off the protective film and stick adhesive tapes (2), (3) and (4).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

(-) Attaching bracket for right adapter plate to case carrier

Attach holder (1) for the adapter plate to case holder (2) centrally between
the tabs (arrows).

(-) Fit adapter plate, right

Position adapter plate (1) on holder (2) for the adapter plate.
Insert screws (3) with washers (4) in guiding grooves (5) in adapter plate (1).
Position clamping blocks (6) on holder (2) for the adapter plate from the rear
and install screws (1) in clamping blocks (6) until uniformly hand-tight.

Insert screws (3) with washer (4) in guiding groove (5) on adapter plate (1).
Position clamping block (6) on case holder (7) from the rear and install
screws (3) in clamping blocks (6) until uniformly hand-tight.
Insert screws (3) with long washer (8) in guiding groove (5) in adapter plate
(1).
Position long clamping block (9) on case holder (7) from the rear and install
the screws (3) in the long clamping block (8) uniformly until hand-tight. Make
sure that clamping block (8) is installed through the tab (arrow).

(-) Tighten adapter plate, right

NOTICE

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS
Before tightening the adapter plate, check if the required height has been
achieved.
Fasten the adapter plate as low as possible due to the centre of gravity of the
vehicle, vehicle height and driving conditions can however require a different
position.

Align holder (1) for the adapter plate centrally to the tabs (arrows).
Tighten all the screws (2) uniformly.

Tightening torques
Tighten adapter plate
M6 x 40 8 Nm

(-) Fix reflectors on the left and right adapter plate (only for US
versions)

Install reflector (1) with bolt (2), washer (3) and nut (4) in the middle guiding
groove (arrow).
Tighten reflector (1) in the lowest position.
Secure reflector on the left side in the same way.

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

77 51 001 Installing LED auxiliary headlights

+ 77 51 502
Equipment trim-level variant:

LED additional headlightOA

NOTICE
The LED auxiliary headlights have an overheat cutout. The headlights
automatically reduce their brightness if a certain temperature is reached;
under extreme circumstances the headlights can even switch themselves off.
The headlights return to full brightness once they have cooled down
sufficiently.

Preparatory work
Removing seat

Core activity
(-) Holder for cable tie to bracket for auxiliary headlight

Install holder (1) for cable strap and holder for plug connector (2) on holder
(3).

(-) Installing bracket for additional LED headlight

Slide up holder (1) for additional LED headlight from the bottom in the
direction of the arrow.

Remove bolts (1) (see magnifying glass).

Attach holder (2) to front panel carrier (3).
Install screws (1).

Tightening torques
Bracket for additional LED headlight to front panel carrier
M6 x 25 8 Nm
Micro-encapsulated, Thread-locking
compound (micro-encapsulated)

052021 BMW Motorrad, UX-VA-4 1/6

BMW-Motorrad - F 850 GS

(-) Installing LED auxiliary headlight

Position LED additional headlight (1) on holder (2).

Install nuts (3) and bolts (4).

Tightening torques
Additional LED headlight to bracket
M6 x 40 6 Nm

(-) Installing switch for LED auxiliary headlights

Removing left mirror
Release the rubber cover (4).
Remove the left/right adapter (1) and the lock nut (3) with mirror (2).

Removing clamping block

Remove screws (1).
Remove clamping block (2) of manual controls (3).

052021 BMW Motorrad, UX-VA-4 2/6

BMW-Motorrad - F 850 GS

Installing clamping block for manual controls for clutch control

Attach clamping block (1) to manual controls (2).
Install screws (3) loosely.
Position manual controls (2) on marks (arrow).
Tighten the screws (3).

Tightening torques
Handbrake fitting to handlebars
M6 x 20 Tightening
sequence: tighten
top until fully closed
8 Nm

Hold switch for additional LED headlight (1) in position at clamping block (2).
Install bolt (3).

Tightening torques
Additional switch to clamping block
M5 x 12 2 Nm

Installing left mirror

Install left/right adapter (1).

Tightening torques
Adapter to clamping block
M10 x 14 - 4.8 25 Nm

Install the mirror (2) and align.

Tighten the lock nut (3).

Tightening torques
Mirror (locknut) to clamping piece
M10 x 1.25 Left-hand thread,
22 Nm

Slide rubber cover (4) over screw connection.

(-) Routing and securing connecting line for switch for LED
auxiliary headlight

WARNING
Steering angle constrained by routing of cables or Bowden cables not in
compliance with correct procedure.
Impairment of road safety.
Check the freedom of movement of the handlebars.

052021 BMW Motorrad, UX-VA-4 3/6

BMW-Motorrad - F 850 GS
Open rubber retaining band (1).
Route access line (2) downwards parallel to the wiring harness (3).
Insert access line (2) in rubber retaining band (1) and close.

Remove the original cable straps (arrows) and re-secure access line (1) to
main frame (2) with cable straps (arrows) and previously loosened lines, if
necessary, at the same position.

Slide plug connector (1) to holder (2) for connector in the direction of the
arrow.

(-) Removing protective cap from connecting plug

Remove protective cap (1) of plug connector (2).

(-) Connecting switch for LED auxiliary headlight and LED

auxiliary headlight

Connect plug for optional accessories connector of main wiring harness (1)
to the plug for access line of additional LED headlight (2).

052021 BMW Motorrad, UX-VA-4 4/6

BMW-Motorrad - F 850 GS

Connect plug for access line for the additional LED headlight switch (1) to
plug for the additional LED headlight (2).

(-) Connecting and routing connecting line for LED auxiliary

headlight

Guide branch of access line (1) to the additional LED headlight on the right
(2) and connect plug (3).
Secure access line (1) with cable strap (arrows) to holder(4).

Secure access line (1) with cable strap (arrows) to holder(2).

Guide branch of access line (1) to the additional LED headlight on the left
(2) and connect plug (3).
Secure access line (1) with cable strap (arrows) to holder (4).

052021 BMW Motorrad, UX-VA-4 5/6

BMW-Motorrad - F 850 GS

Secure access line (1) with cable strap (arrows) to holder (2).

Remove the original cable straps (arrows) and re-secure access line (1) to
front panel carrier (2) with cable straps (arrows) and previously loosened
lines, if necessary, at the same position.

Follow-up work
Connect the BMW Motorrad diagnostic system to the vehicle
Performing software update with the BMW Motorrad diagnosis system
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Checking alignment of LED auxiliary headlights
Final check of work performed

052021 BMW Motorrad, UX-VA-4 6/6

BMW-Motorrad - F 850 GS

77 51 004 Installing headlight guard

+ 77 51 653

Core activity
(-) Removing headlight

Release hooks (arrows) and remove holder locks (1).

Remove retaining clips (1) and washers (2).

Release headlight (1).

Disconnect connector (2) for the headlight.
ATTENTION

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Remove headlight (1), pressing the left fairing side panel (3) and the right
fairing side panel (4) slightly outwards while doing so.

(-) Replacing LED headlight frame

Remove screws (1).

Remove frame (2).

(-) Installing frame for LED headlight guard

Connect frame (2) on LED headlight (3).

Install screws (1).

(-) Installing LED headlight

Make sure rubber grommets (1) are correctly seated.

ATTENTION

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Install washers (2) and retaining clips (1).

Install holder locks (1), hooks (arrows) must engage.

(-) Installing headlight shield

NOTICE
Use the headlight guard only when off-roading. Riding on public roads with the
headlight guard fitted to the motorcycle is prohibited.

Install LED headlight guard plate (3) on LED headlight frame (1) with screws
(2).

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS
(-) Installing top front-wheel cover

Secure top front-wheel cover (1) in retaining lugs (arrows) of left fairing side
panel (2) and right fairing side panel (3), noting the locators (4).

(-) Installing front spray guard

Position spray guard (2) , thereby securing it in retaining lugs (arrows) of

front-wheel cover above(3).
Install long screws (1).

Follow-up work
Checking headlight beam throw
Final check of work performed

052021 BMW Motorrad, UX-VA-4 4/4

BMW-Motorrad - F 850 GS

77 51 151 Installing LED flashing turn indicators

+ 77 51 651

Preparatory work
Removing seat

Core activity
(-) Releasing left slipstream deflector

Remove expanding rivet (1) and screws (2).

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Release slipstream deflector(3) and place it on side panel (4).

Remove slipstream deflector cover (5).

(-) Removing front left flashing turn indicator

Remove cable strap (arrow).

Disconnect plug (1) for turn indicator.

Remove bolt (1) and nut (2).

Rotate turn indicator (3) to release and remove the lock.

(-) Installing front left LED flashing turn indicator

Guide in and set turn indicator (1) and lock it by turning it.
Install bolt (2) and nut (3).

Tightening torques

052021 BMW Motorrad, UX-VA-4 1/6

BMW-Motorrad - F 850 GS
Front turn indicator to slipstream deflector
M6 x 20 3 Nm

Connect the connector (1) for the turn indicator.

Secure the cable strap (arrow).

(-) Securing left slipstream deflector

Insert slipstream deflector cover (1) in slipstream deflector (2).

Hold slipstream deflector (2) in position.
Install expanding rivet (3) and screws (4).

(-) Releasing right slipstream deflector

Remove expanding rivet (1) and screws (2).

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Release slipstream deflector(3) and place it on side panel (4).

Remove slipstream deflector cover (5).

(-) Removing front right flashing turn indicator

Remove cable strap (arrow).

052021 BMW Motorrad, UX-VA-4 2/6

BMW-Motorrad - F 850 GS
Disconnect plug (1) for turn indicator.

Remove bolt (1) and nut (2).

Rotate turn indicator (3) to release and remove the lock.

(-) Installing front right LED flashing turn indicator

Guide in and set turn indicator (1) and lock it by turning it.
Install bolt (2) and nut (3).

Tightening torques
Front turn indicator to slipstream deflector
M6 x 20 3 Nm

Connect the connector (1) for the turn indicator.

Secure the cable strap (arrow).

(-) Securing right slipstream deflector

Insert slipstream deflector cover (1) in slipstream deflector (2).

Hold slipstream deflector (2) in position.

052021 BMW Motorrad, UX-VA-4 3/6

BMW-Motorrad - F 850 GS
Install expanding rivet (3) and screws (4).

(-) Removing number-plate carrier

Pull bulb socket (1) out of the bulb support.

Loosen cable (2) from holder (3).

Remove cable strap (arrow) and set plug (1) aside.

Release and disconnect plug (2) for right turn indicator.
Release and disconnect plug (3) for left turn indicator.

Remove screws (1) and (2).

Fold out and remove number plate carrier (3) .

(-) Removing rear right and left turn indicators

Expose cable (2) with plug (1).

Remove nuts (3) and bolts (4).

052021 BMW Motorrad, UX-VA-4 4/6

BMW-Motorrad - F 850 GS
Turn turn indicator (5) upwards and remove.

(-) Installing rear right and left LED flashing turn indicators

Feed the cable (1) with plug into position.

Hold turn indicator (2) in position and turn it backwards.
Insert nuts (4).
Install screws (3).

Tightening torques
Flashing turn indicator to number-plate carrier
M6 x 20 3 Nm

(-) Installing number-plate carrier with LED turn indicators

Work plug (1) and (2) for the LED flashing turn indicator through the
openings (arrows).

Attach number plate carrier (1) in the openings (arrows) and fold up.

Install screws (1), and (2).

052021 BMW Motorrad, UX-VA-4 5/6

BMW-Motorrad - F 850 GS

Tightening torques
Number-plate carrier to rear frame
M6 x 16 3 Nm

Connect plugs (2) and (3) for LED flashing turn indicators and secure them.
Secure the plug (1) with the cable strap (arrow).

052021 BMW Motorrad, UX-VA-4 6/6

BMW-Motorrad - F 850 GS

77 52 008 Installing preparation for navigation system

+ 77 52 730

Core activity
(-) Exposing connector for connecting Mount Cradle

Remove protective cap (2) from connector (1).

(-) Installing preparation for navigation system

Insert key (1) in lock barrel (2).

Lubricate the lock barrel (2).

Lubricant
MI-Setral-43 N 83 23 2 152 082

Insert lock barrel (2) with key (1) and turn until locking pawl (arrow) is
locked.

Removing screws in left handlebar clamping block

NOTICE
In order to retain the basic setting of the handlebars unchanged, always
slacken only one side of the handlebar clamping block.

Remove screws (1) in left handlebar clamping block.

Installing securing screws in left handlebar clamping block

Clean and lubricate the securing screws.

052021 BMW Motorrad, UX-VA-4 1/8

BMW-Motorrad - F 850 GS

Lubricant
MP 3 paste 07 55 9 062 476

Screw in bolts (21) and (3) slightly.

Tighten front mounting bolt (2) first.
Tighten rear mounting bolt (3).

Tightening torques
Securing screw to handlebar clamping block
M8 x 30 - 10.9 Tightening
Lubricate screw, Lubricant (MP 3 sequence: in the
paste) forward direction of
travel, tighten until
seated
25 Nm

Removing screws for right handlebar clamping block

NOTICE
In order to retain the basic setting of the handlebars unchanged, always
slacken only one side of the handlebar clamping block.

Remove screws (1) in the right handlebar clamping block.

Installing securing screws in right handlebar clamping block

Clean and lubricate the securing screws.

Lubricant
MP 3 paste 07 55 9 062 476

Slightly screw in screws (2) and (3).

Tighten front mounting bolt (2) first.
Tighten rear mounting bolt (3).

Securing holder on securing screws

Insert spacing bushings (1) into rubber grommets (2).

Install holder (3) with screws (4) and washers (5) on mounting bolts (6).

Tightening torques
Bracket to screws for handlebar clamp
M5 x 20, Replace screw 5 Nm
Thread-locking compound
(mechanical)

Route cable (1) down and secure it with the cable straps (2) and loops (3).

Connect bush (1) , 3-pin, to plug (2) for navigation system.

(-) Remove the left handlebar weight

052021 BMW Motorrad, UX-VA-4 3/8

BMW-Motorrad - F 850 GS
Remove bolt (1) and remove handlebar weight (2).

(-) removing left grip unit

Push collar of rubber grip (1) slightly aside and remove screw (2).

Remove the straps (1).

Disconnect connector (2) from clutch switch (3).

Turn the handlebars all the way to the left.

Pull off grip unit(1), paying attention to the cable leg (2) while doing so.

(-) Removing left handlebar grip

Unclip the retaining tabs (arrows).

Remove cover (1).

052021 BMW Motorrad, UX-VA-4 4/8

BMW-Motorrad - F 850 GS

Remove connectors (1) and (2).

Push up retainer (1).

Remove handlebar grip (2).

(-) Removing blanking plug from multifunction switch

Remove dummy connector (1) of multifunction switch (2).

(-) Installing left handlebar grip with Multi-Controller

ATTENTION
Opening of switch unit
Damage to the conductors coated with protective sealing lacquer
052021 BMW Motorrad, UX-VA-4 5/8
BMW-Motorrad - F 850 GS
Do not separate the top and bottom parts of the switch unit.

Do not attempt to open the switch unit.

Install handlebar grip (1), and at the same time insert blanking plug (2).
Retaining lug (3) engages.

Lubricate the rubber pad (arrow).

Installation tool
Silicone spray 83 19 2 208 609

Connect 2-pin connector (2) with the blanking plug.

Connect connector (1) for the multifunction switch.

Install the cover (1).

The retaining tabs (arrows) engage.

(-) Securing left grip unit

Turn the handlebars all the way to left.

Push on grip unit(1), paying attention to the cable (2) while doing so.

052021 BMW Motorrad, UX-VA-4 6/8

BMW-Motorrad - F 850 GS

Slightly pull back rubber grip (1).

Install bolt (2).

Tightening torques
Handlebar grip, left, to handlebar
M3.5 x 30 2 Nm

Connect connector (2) for clutch switch (3).

Install tensioning straps (1).

(-) Installing left handlebar weight

Position handlebar weight (2) and install bolt (1).

Tightening torques
Handlebar weight to handlebars
M10 x 50 38 Nm

Follow-up work
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle
Performing software update with the BMW Motorrad diagnosis system
052021 BMW Motorrad, UX-VA-4 7/8
BMW-Motorrad - F 850 GS
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 8/8

BMW-Motorrad - F 850 GS

77 52 012 Installing Smartphone Cradle

+ 77 52 512

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)

Core activity
(-) Removing screws in left handlebar clamping block

NOTICE
In order to retain the basic setting of the handlebars unchanged, always
slacken only one side of the handlebar clamping block.

Remove screws (1) in left handlebar clamping block.

(-) Installing securing screws in left handlebar clamping block

Clean and lubricate the securing screws.

Lubricant
MP 3 paste 07 55 9 062 476

Screw in bolts (21) and (3) slightly.

Tighten front mounting bolt (2) first.
Tighten rear mounting bolt (3).

(-) Removing screws for right handlebar clamping block

NOTICE
In order to retain the basic setting of the handlebars unchanged, always
slacken only one side of the handlebar clamping block.

052021 BMW Motorrad, UX-VA-4 1/5

BMW-Motorrad - F 850 GS
Remove screws (1) in the right handlebar clamping block.

(-) Installing securing screws in right handlebar clamping block

Clean and lubricate the securing screws.

Lubricant
MP 3 paste 07 55 9 062 476

Slightly screw in screws (2) and (3).

Tighten front mounting bolt (2) first.
Tighten rear mounting bolt (3).

(-) Securing holder on securing screws

Insert spacing bushings (1) into rubber grommets (2).

Install holder (3) with screws (4) and washers (5) on mounting bolts (6).

Tightening torques
Bracket to screws for handlebar clamp
M5 x 20, Replace screw 5 Nm
Thread-locking compound
(mechanical)

052021 BMW Motorrad, UX-VA-4 2/5

BMW-Motorrad - F 850 GS

(-) Smartphone Cradle Installation

Remove screws (1) and clamping block (2) with transverse axis (3) from
holder (4).

Remove nuts (1) and bolts (2).

Disconnect clamping block upper section (3) and -lower section (4) and
remove transverse axis (5) and keep them safely aside (will be reused).

Position new clamping block lower section (1) and new clamping block
upper section (2) centred at cross-member (3).
Position Smartphone Cradle (4) on the new clamping block upper
section (2).
Install Smartphone Cradle (4) with screws (5).

Tightening torques
Smartphone Cradle to bracket
M4 x 30 1.3 Nm

Insert mounting elements (1) with mounted Smartphone Cradle (2) into the
holder (3).
Position Smartphone Cradle (2) and install it with screws (4).

052021 BMW Motorrad, UX-VA-4 3/5

BMW-Motorrad - F 850 GS

Tightening torques
Cross-member to upper section of bracket
M5 x 12 5 Nm

(-) Exposing optional accessories plug

Pull optional accessories connector (1) and pull off protective cap (2).

(-) Routing connecting cable

WARNING
Steering angle constrained by routing of cables or Bowden cables not in
compliance with correct procedure.
Impairment of road safety.
Check the freedom of movement of the handlebars.

Guide down access line (1) along brake line and secure with cable strap
(arrows) and rubber strap (2).

(-) Making connection to Smart Phone Cradle

Secure access line (1) with cable strap (arrow) to front panel carrier.
Push plug for Smartphone Cradle (3) onto the plug mounting and connect
using optional accessories connector (4).
Place protective cap (5) on plug (6) for additional power supply.

052021 BMW Motorrad, UX-VA-4 4/5

BMW-Motorrad - F 850 GS

Follow-up work
Final check of work performed

052021 BMW Motorrad, UX-VA-4 5/5

BMW-Motorrad - F 850 GS

77 52 202 Install holder for navigation system

+ 77 52 702
Construction status:

August 2020

Equipment trim-level variant:

0553 - Windscreen, highOE

Core activity
(-) Install holder for navigation system

Requirement
Windscreen adjuster is in upper position

Remove screws (1) and lay them safely aside, will be reused.

Fit holder for navigation system (1) on windscreen adjuster (2).

Install screws (3).

Tightening torques
Holder for navigation system with windscreen adjuster to front panel
carrier
M6 x 40 5 Nm

(-) Installing lock barrel in holder for navigation device

Insert key (1) in lock barrel (2).

Lubricate the lock barrel (2).

Lubricant

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
MI-Setral-43 N 83 23 2 152 082

Insert lock barrel (2) with key (1) and turn clockwise until locking pawl
(arrow) locks.

(-) Exposing connector for connecting Mount Cradle

Remove protective cap (2) from connector (1).

(-) Routing and connecting wiring harness for navigation system

Connect holder for cable strap (1) on bridge of windscreen adjuster (2).
Route wiring harness (3) along holder for navigation system (4) and work
toward the bottom.
Close the cable strap (arrows).

Connect connector (1) of original wiring harness (2) with connector (3) of
wiring harness for navigation system (4).
Connect plug connection at predefined position (5) to front panel carrier (6).

Connect holder for cable strap (1) on bridge of front panel carrier (2).
Form excess length of wiring harness for navigation system (3) into loops
and secure with cable straps (arrow) on holder for cable strap (1).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Follow-up work
Installing centre slipstream deflector
Install the windscreen
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

77 53 004 Installing LED headlight

+ 77 53 909

Core activity
(-) Removing headlight

Release hooks (arrows) and remove holder locks (1).

Keep components, will be reused.

Remove retaining clips (1) and washers (2).

Keep components, will be reused.

Remove retaining clips (1) and washers (2).

Keep components, will be reused.

Release headlight (1).

Disconnect connector (2) for the headlight.
ATTENTION
Use of hard or sharp-edged objects in proximity to component

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS
Component damage
Take care not to scratch components; cover or mask as necessary.

Remove headlight (1), pressing the left fairing side panel (3) and the right
fairing side panel (4) slightly outwards while doing so.

(-) Preparing headlight for installation

Remount rubber grommets (1) on new part.

(-) Installing LED headlight

Make sure rubber grommets (1) are correctly seated.

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Install washers (2) and retaining clips (1).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Install washers (2) and retaining clips (1).

Install holder locks (1), hooks (arrows) must engage.

Follow-up work
Installing top front-wheel cover
Installing front spray guard
Remove the left handlebar weight
removing left grip unit
Removing left multifunction switch
Installing left multifunction switch for LED headlight
Securing left grip unit
Installing left handlebar weight
Checking headlight beam throw
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

77 53 005 Installing RDC

+ 77 53 910

Core activity
(-) Removing left brake caliper

Press brake caliper(1) against the brake disc (2) to force the pistons back.

Remove screws (1).

Release brake caliper (2) and push aside while taking note of the sensor
cable (3).

(-) Remove the right brake caliper

Press brake caliper(1) against the brake disc (2) to force the pistons back.

Remove screws (1).

Loosen brake caliper (2) and hang it to one side.

052021 BMW Motorrad, UX-VA-4 1/14

BMW-Motorrad - F 850 GS

(-) Removing front wheel

Release clamping screws (1) on left and right.

Remove front wheel (3).

(-) Removing front tyre

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Remove the tyre with commercially available tools.

(-) Remove rubber valve

Use a suitable tool to remove rubber valve .

(-) Installing RDC sensor

Clean the seat for RDC sensor.

Insert valve (1), RDC sensor (2) and nut (3).

052021 BMW Motorrad, UX-VA-4 2/14

BMW-Motorrad - F 850 GS
If necessary, note the distance from the rim flange (arrows) and tighten nut
(3).

Tightening torques

Attach sign (1) for sensor position at the height of the valve (2).
NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.

(-) Checking battery forRDC sensor

Check
Check the battery for RDC sensor (1) with the RDC test tool (No. 61 1 673).
Alternatively, the BMW Test Tool, order number 88 30 2 456 858 can be
used.

Result:
Battery is too weak.
Measure:
Renew RDC sensor (1).

(-) Installing front tyre

When fitting the tyre, note the tyre pressure monitoring sensor (RDC
sensor).

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

052021 BMW Motorrad, UX-VA-4 3/14

BMW-Motorrad - F 850 GS
Use commercially available tools/fitting equipment and work to the
manufacturer's specifications to fit tyres, and make sure that the direction-of-
rotation arrows on tyre and rim point in the same direction.

Check

Inflate the tyre to test pressure and check the valve for leaks.

Technical data
Wheel valve test 4 bar
pressure

Result:
Valve leaking
Measure:
Replace the valve insert.
Result:
Valve leak-tight
Measure:
Correct the tyre pressure.

Technical data
Tyre pressure, front One-up, tyre 2.2 bar
cold
Two-up 2.5 bar
and/or with
luggage, tyre
cold

Check the tyre and make sure the line is at a uniform distance from the rim
flange all the way round.

(-) Static balancing of front wheel

Technical data
Permissible front- max 5 g
wheel imbalance
Balance weight for max 80 g
front wheel
Weights have to be
affixed with one half
on the left and one
half on the right, in

052021 BMW Motorrad, UX-VA-4 4/14

BMW-Motorrad - F 850 GS
other words centred
on the rim

Repeat the balancing procedure as a check.

(-) Install the front wheel

Clean and lubricate spacer bush (1), If necessary.

Install spacer bush (1).

Lubricant
Unirex N3 83 19 2 160 349

Clean and lubricate quick-release axle (2).

Lubricant
Unirex N3 83 19 2 160 349

ATTENTION
Front wheel installed wrong way round
Risk of accident
Note direction-of-rotation arrows on tyre or rim.

ATTENTION
Installation of front wheel not in compliance with correct procedure
Damage to wheel speed sensor
Note the wheel-speed sensor when rolling in the front wheel.

Position front wheel (3).

Install quick-release axle (2).
Install bolt (1) and tighten, counter-hold the quick-release axle on the right
side with the hexagon head (No. 36 3 691) while doing so.

Tightening torques
Axle screw in front quick-release axle
M20 x 1.5 50 Nm

Compress the telescopic forks several times to avoid twisting, lower front-
wheel stand, if required.
Tighten clamping bolts (1) on left and right.

Tightening torques
Clamp of quick-release axle
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence

052021 BMW Motorrad, UX-VA-4 5/14

BMW-Motorrad - F 850 GS
19 Nm

(-) Securing right brake caliper

Position brake caliper (2).

Install screws (1).

Tightening torques
Brake caliper to telescopic fork
M10 x 45 38 Nm

(-) Securing left brake caliper

Position brake caliper (1) and holder (2) while noting the sensor cable (3).
Install screws (4).

Tightening torques
Brake caliper to telescopic fork
M10 x 45 38 Nm

(-) Removing front-wheel stand

ATTENTION
Vehicle toppling to side
Risk of damage to parts if vehicle topples
Make sure that the vehicle is secured so that it cannot topple sideways.

Raise grip of basic stand (No. 36 3 971) and remove complete with mounts
(No. 36 3 972).

(-) Remove the rear wheel

052021 BMW Motorrad, UX-VA-4 6/14
BMW-Motorrad - F 850 GS

ATTENTION
Brake actuation with brake pads or brake calipers removed
Brake pistons pushed out
Do not operate brake.
Install brake pads and brake caliper or insert the piston resetting device.

Push brake caliper (1) against brake disc (2) to push back the piston.

Remove nut (1) with washer (2).

Remove quick-release axle (1).

ATTENTION
Removal of rear wheel not in accordance with correct procedure
Damage to wheel speed sensor
Note the wheel-speed sensor when rolling out the rear wheel.

Remove rear wheel (2), while paying attention to the brake caliper (3) and
push aside if required.

Remove the left spacer bush (1).

Remove chain sprocket support (2) and judder damper (3).
Remove right spacer bush (4).

052021 BMW Motorrad, UX-VA-4 7/14

BMW-Motorrad - F 850 GS

(-) Removing rear tyre

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Remove the tyre with commercially available tools.

(-) Remove rubber valve

Use a suitable tool to remove rubber valve .

(-) Installing RDC sensor

Clean the seat for RDC sensor.

Insert valve (1), RDC sensor (2) and nut (3).
If necessary, note the distance from the rim flange (arrows) and tighten nut
(3).

Tightening torques

Attach sign (1) for sensor position at the height of the valve (2).
NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.

(-) Checking battery forRDC sensor

Check

052021 BMW Motorrad, UX-VA-4 8/14

BMW-Motorrad - F 850 GS
Check the battery for RDC sensor (1) with the RDC test tool (No. 61 1 673).
Alternatively, the BMW Test Tool, order number 88 30 2 456 858 can be
used.

Result:
Battery is too weak.
Measure:
Renew RDC sensor (1).

(-) Installing rear tyre

When fitting the tyre, note the tyre pressure monitoring sensor (RDC
sensor).

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Use commercially available tools and work to the manufacturer's

specifications to fit the tyres, and make sure that the direction-of-rotation
arrows on tyre and rim point in the same direction.

Check

Inflate the tyre to test pressure and check the valve for leaks.

Technical data
Wheel valve test 4 bar
pressure

Result:
Valve leaking
Measure:
Replace the valve insert.
Result:
Valve leak-tight
Measure:
Correct the tyre pressure.

Technical data
Tyre pressure, rear One-up, tyre 2.5 bar
cold
Two-up 2.9 bar
and/or with

052021 BMW Motorrad, UX-VA-4 9/14

BMW-Motorrad - F 850 GS
luggage, tyre
cold

Check the tyre and make sure the line is at a uniform distance from the rim
flange all the way round.

(-) Static balancing of rear wheel

Align the balancing jig (No. 36 3 601) with knurled screw (1) and bubble
level (2).
Check the carrier axle for runout and damage.
Install adapter axle (No. 36 5 571) with conical adapter (No. 36 5 572) in the
rear-wheel bearing and tension.
Position adapter axle (No. 36 5 571) with the rear wheel on balancer (No. 36
3 601).
Allow the rear wheel to settle to a stop.
Clean the attachment points for the adhesive weights.
Affix the adhesive weights uniformly spaced on both sides of the rim
opposite the wheel's heaviest point.

Repeat the balancing procedure as a check.

(-) Install the rear wheel

As applicable, clean the areas indicated (arrows) and lubricate.

Lubricant
Optimoly TA 18 21 9 062 599

Position brake caliper (1) in guide (2).

Lubricating the spacer bushes and radial shaft seal of chain sprocket
support
Remove all dirt and old lubricant from the components.
Lubricate the components at the areas indicated (arrows).

Lubricant
Unirex N3 83 19 2 160 349

052021 BMW Motorrad, UX-VA-4 10/14

BMW-Motorrad - F 850 GS

Check judder damper (3) for damage, deformation or wear and replace, if
required..
Lubricate and install judder damper (3).

Installation tool
Silicone spray 83 19 2 208 609

Install right spacer bush (4).

Install chain sprocket support (2).
Install left spacer bush (1).

Clean and lubricate quick-release axle (1).

Lubricant
Unirex N3 83 19 2 160 349

ATTENTION
Installation of rear wheel not in accordance with correct procedure
Damage to wheel speed sensor
Note the wheel-speed sensor when rolling in the rear wheel.

Install rear wheel (2) noting that brake caliper (3) is seated in the guide
(Arrow).
Install quick-release axle (1).

Push rear wheel (1) forward and loop the chain (2) over the chain sprocket
(3).
Install nut (4) with washer (5), but do not tighten yet.

(-) Bedding in brake pads

WARNING

052021 BMW Motorrad, UX-VA-4 11/14

BMW-Motorrad - F 850 GS
Brake pads not lying against the brake disc
Risk of accident due to delayed braking effect.
Before driving, check that the brakes respond without delay.

After completing work, operate the brake several times until the brake pads
are bedded.

(-) Removing luggage carrier

Remove screws (1).

Remove luggage carrier (2).

(-) Removing rear carrier

Remove screws (1) with long shouldered bushings (2).

Remove screws (3) with short shouldered bushings (4).
Remove rear carrier (5).

(-) Exposing plug for RDC

Remove cable strap (arrow).

Release connector (1) and protective cap (2).
Remove the protective cap (2).

(-) Install RDC control unit

Connect connector (3).

Clasp and position the RDC control unit (2) in fixture (arrow).
Install expanding rivet (1).

052021 BMW Motorrad, UX-VA-4 12/14

BMW-Motorrad - F 850 GS

(-) Installing rear carrier

Pay attention to the correct mounting location and mounting orientation of

the buffer case hanging system (1), (2), (3) and (4) in rear carrier (5).
Arrow (6) on underside of the buffer points in the forward direction of travel.

Clean the threads.

(-) Installing luggage carrier

Clean the threads.

Position luggage carrier (2).
Install screws (1).

Disconnect connector (2) for the heated grip.

Push up retainer (1).

Remove handlebar grip (2).

(-) Installing left multifunction grip for speed control

Install handlebar grip (1) , and at the same time insert connector (2) for the
heated grip.
Retaining lug (3) engages.

052021 BMW Motorrad, UX-VA-4 2/8

BMW-Motorrad - F 850 GS

Lubricate the rubber pad (arrow).

Installation tool
Silicone spray 83 19 2 208 609

Connect connector (2) for the heated grip.

Connect connector (1) for the multifunction switch.

Install the cover (1).

The retaining tabs (arrows) engage.

(-) Securing left grip unit

Turn the handlebars all the way to the left.

Push on grip unit(1), paying attention to the cable leg (2) while doing so.

Push collar of rubber grip (1) slightly aside and install screw (2).

Tightening torques
Handlebar grip, left, to handlebar

052021 BMW Motorrad, UX-VA-4 3/8

BMW-Motorrad - F 850 GS
M3.5 x 30 2 Nm

Connect connector (2) with clutch switch (3).

Secure straps (1).

(-) Installing left handlebar weight

Position handlebar weight (2) and install bolt (1).

Tightening torques
Handlebar weight to handlebars
M10 x 50 38 Nm

(-) Removing the right handlebar weight

Remove bolt (1) and remove handlebar weight (2).

(-) Removing right multifunction switch

052021 BMW Motorrad, UX-VA-4 4/8

BMW-Motorrad - F 850 GS
Press the releases (arrows) at front and back and disconnect connector (1)
for the throttle twistgrip.

Remove bolt (1).

Pull cover (2) down slightly.

Push cover (1) forward and up to remove, noting retaining catches (2).

Disconnect 2-pin connector (1) with blanking cap.

Disconnect connector (2) for the multifunction switch.
Remove bolt (3).
Remove multifunction switch (4).

(-) Removing throttle grip

Remove bolt (1).

Remove throttle grip (2).

052021 BMW Motorrad, UX-VA-4 5/8

BMW-Motorrad - F 850 GS

(-) Installing throttle grip for speed control

Install new throttle grip (2).

Install bolt (1).

Tightening torques
Throttle twistgrip to handlebar
M3.5 x 30 2 Nm

(-) Installing right multifunction switch

Hold the multifunction switch (4) in position.

ATTENTION
Screws overtightened past the specified value
Component damage
Tighten the screws only to their specified tightening torque.

Install bolt (3).

Tightening torques
Multifunction switch to throttle grip
Screw for plastic, PT2.5 x 15 0.4 Nm

Connect connector (2) for the multifunction switch.

Connect 2-pin connector (1) with the blanking cap.
Position cover (1) and push backwards and down, paying attention to
retaining catches(2).

052021 BMW Motorrad, UX-VA-4 6/8

BMW-Motorrad - F 850 GS

Push cover (2) until the multifunction switch is closed.

ATTENTION
Screws overtightened past the specified value
Component damage
Tighten the screws only to their specified tightening torque.

Install bolt (1).

Tightening torques
Lid to right multifunction switch
Screw for plastic, PT2.5 x 15 0.4 Nm

Connect connector (1) for throttle grip.

(-) Installing right handlebar weight

Position handlebar weight (2) and install bolt (1).

Tightening torques
Handlebar weight to handlebars
M10 x 50 38 Nm

Follow-up work
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle
052021 BMW Motorrad, UX-VA-4 7/8
BMW-Motorrad - F 850 GS
Performing software update with the BMW Motorrad diagnosis system
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 8/8

BMW-Motorrad - F 850 GS

77 53 010 Install ABS Pro, DTC and Pro riding mod.

+ 77 53 510

Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46 52 510,
Billed as a separate item)
Ordering enabling code for software update with BMW Motorrad
diagnosis system
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle

Core activity
(-) Performing software update with the BMW Motorrad diagnosis
system

Requirement
Engine is off.
Battery is fully charged and battery charger is connected.

NOTICE
Do not attempt to perform work of any other kind on the motorcycle while
programming/coding is in progress.

Switch off all electrical consumers.

Start the diagnosis system.
Identify the vehicle.

Select the retrofit.

Create a measures plan and perform the retrofit.

(-) Disconnecting BMW Motorrad diagnostic system from vehicle

Close all diagnostic programs and switch off the ignition.

Follow-up work
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 1/1

BMW-Motorrad - F 850 GS

77 53 070 Installing Pro shift assistant

+ 77 53 920

Preparatory work
Ordering enabling code for software update with
BMW Motorrad diagnosis system

Core activity
(-) Removing the cover for wiring harness

Release the cable (1) from the holder (arrow).

Remove screw (2), release cover (3) of detent pins (4) and remove.

(-) Releasing upper gearshift rod

Remove retaining clip (1). Raise the retaining clip, it will be used
again.
Release gearshift rod (2) from ball head (3).

(-) Releasing lower gearshift rod

Remove retaining clip (1). Raise the retaining clip, it will be used
again.
Release gearshift rod from ball head (2).

052021 BMW Motorrad, UX-VA-4 1/3

BMW-Motorrad - F 850 GS

(-) Securing gearshift rod with shift assistant Pro

Press the lower link rod of shift assistant Pro (1) on ball head (2).
Install retaining clip (3) in lower link rod (1).
Press upper link rod of shift assistant Pro (4) on ball head (5).
Install retaining clip (3) in upper link rod (4).

(-) Exposing connector for Pro shift assistant

Release the cable strap (arrow) and expose connector (1) for the
shift assistant.
Unlock connector (1) for the shift assistant.
Remove protective cap (2) from connector (1).

Insert connector (1) on shift assistant (2).

(-) Installing the cover for wiring harness

Lightly lubricate detent pins (1).

Installation tool
Silicone spray 83 19 2 208 609

Hold cover (2) in such a way that cable (3) for side-stand switch
runs above the spacer (4).

052021 BMW Motorrad, UX-VA-4 2/3

BMW-Motorrad - F 850 GS

Cable (3) is not trapped.

Clip cover (2) into detent pin (1) and install screw (5).
Secure the cable (6) in the holder (arrow).

Follow-up work
Removing seat
Connect the BMW Motorrad diagnostic system to the vehicle
Performing software update with the BMW Motorrad diagnosis
system
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing seat
Final check of work performed

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

77 53 100 Installing anti-theft alarm

+ 77 53 501

Core activity
(-) Exposing connector

Pull back plug (1) to install the anti-theft alarm.

(-) Installing anti-theft alarm

052021 BMW Motorrad, UX-VA-4 3/3

BMW-Motorrad - F 850 GS

77 53 170 Install USB-charging interface

+ 77 53 670

Core activity
(-) Removing right slipstream deflector

Remove cable strap (arrow).

Disconnect plug connection (1) for right turn indicator.

Remove expanding rivet (1) and screws (2).

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Release the slipstream deflector (3) and take off with slipstream deflector
cover (4).

(-) Installing adapter cable for USB charging socket

Connect connector (1) for socket of original wiring harness (2) to connector
(3) of adapter cable for USB charging socket (4).
Connect plug connection at predefined position (5) to front panel carrier (6).
Route adapter cable for USB charging socket (4) along original wiring
harness (2) downward and secure with cable straps (arrows).

Remove cable strap (arrows) on bottom of front panel carrier (1).

052021 BMW Motorrad, UX-VA-4 1/4

BMW-Motorrad - F 850 GS

Route adapter cable for USB charging socket (1) along wiring harnesses (2)
and (3).
Secure wiring harnesses (1), (2) and (3) with cable strap (arrows).

Route adapter cable for USB charging socket (1) along wiring harness (2) to
the top and secure with cable strap (arrows).

(-) Replacing slipstream deflector, right

Remove bolt (1) and nut (2).

Rotate turn indicator (3) counter-clockwise to detach lock.
Remove turn indicator (3) from slipstream deflector (4) and work cable (5)
clear.

Installing USB charging socket in new slipstream deflector

Insert USB charging socket (1) in new slipstream deflector (2). Make sure
lug (arrow) of USB charging socket (1) engages in recess of either (3) or (4)
of slipstream deflector (2).
Install the nut (5).

052021 BMW Motorrad, UX-VA-4 2/4

BMW-Motorrad - F 850 GS

Tightening torques
Socket or USB charging socket to trim panel
M18 x 1 3 Nm

Transfer flat nut (6) to new slipstream deflector (2).

Insert cable (1) into new slipstream deflector (2) and fit turn signal (3).
Rotate turn indicator (3) clockwise to fasten lock.
Install bolt (4) and nut (5).

Tightening torques
Front turn indicator to slipstream deflector
M6 x 20 3 Nm

(-) Installing new right slipstream deflector

Connect connector (1) at USB charging socket (2).

ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.

Insert slipstream deflector cover (1) in slipstream deflector (2).

Position slipstream deflector (2).
Install expanding rivet (3) and screws (4).

Connect plug connection (1) for right turn indicator.

Form excess length of cable into loops and secure together with plug
connection (1) with cable strap (arrow).

052021 BMW Motorrad, UX-VA-4 3/4

BMW-Motorrad - F 850 GS

Follow-up work
Installing left slipstream deflector
Installing the fork partition
Install the windscreen
Final check of work performed

052021 4/4

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