Easing Maintenance

There are a few items which cause some frustration when working on the 650GS.

The small modifications below will simplify maintenance and eliminate a couple of frustrations

As we find solutions for items which are difficult to work with we will add more here

Left Foot Peg Mount

The upper mounting bolt for the left hand foot peg mount is difficult to access due to the bracket shape.

Cut off the upper front edge of the bracket as per the picture to enable the mounting bolt
to be accessed far more easily.

Exhaust Shield

Removing the stainless steel guard on the exhaust system requires removing the main rear sub frame bolt and the top foot peg mounting bolt.

Cutting the cover to open the ends of the bolt holes as per the picture enables the guard to slide on and off by only loosening the bolts without removing them


Regulator Bracket

Removing the regulator bracket requires removing the front engine bolts.

Cutting the bracket to open the ends of the bolt holes as per the picture enables

the bracket to slide on and off by only loosening the bolts without removing them

Airbox

Dont over tighten inlet fixing screws.

They are self tapping screws threading into plastic.

If you strip the inner mount the outer can be drilled out to extend the screws into the plastic a further 10-15mm.

Tail/Brake Lamp Assembly

The mounting of the Tail Lamp assembly means it has to be removed when working around the rear of the bike, connection of the wiring is also difficult.

The modification on Tail Lamp Brace page allows it to remain in place, simplifies maintenance plus the wiring access hole makes connection far simpler, it also overcomes broken upper mounts.


Rigid Oil Return Line

The rigid oil return line on the F Series makes removal of the left engine covers difficult. The G Series have a relocated oil return line against the side of the cylinder. The G Series line may fit the F Series.
There are a number of solutions to the rigid oil line ranging from complete replacement to fitting a small flexible section in the upper rear section. The pdf opposite contains details on flexible oil lines.        Flexible Oil Line pdf

General Notes
Bolts
Regularly check fairing, front mud guard and pannier bolts. We find they tend to work loose when the machine is used off road or on rough roads.