2002 BMW F 650 GS Dakar Complete Engine Assembly | 9-Dec-2009

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

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

Many thanks to the amazing people of the Chain Gang (the F650.com forums), especially to Flash for his remarkable maintenance DVDs, and to Haakon for his sagely wisdom and guidance. 🙂

The video was shot using a Canon PowerShot A460, and comprises of the following sections:

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

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