Full Fork Service on a BMW F650GS Dakar | Step-by-Step Guide

In this video, we’ll walk you through the step-by-step process of changing the fork seals on a 2005 BMW F650GS Dakar. Whether you’re a seasoned mechanic or you’ve never touched a wrench, our detailed guide will help get the job done right. This guide covers everything from removing the forks to replacing the seals and reassembling your motorcycle. The tools and supplies I used can be found below. Don’t forget to like, and subscribe for more motorcycle maintenance tutorials!
Note: This process is specifically for the Dakar version of the F650GS. The process is slightly different on the standard GS.
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Tool List:
Shop manual
Ratio-rite
Drain pan
41mm seal driver
Torque wrench (6Nm - 41Nm range for this job)
Ratchet
Sockets
10mm
13mm
24mm
M6 Hex
M8 Hex
T45
Nice to haves:
Tapered plastic body panel removal tool
90 degree pick
Impact wrench
Air compressor & air chuck
Lift & pancake jack
41mm Motion Pro Seal Bullet (You can use a plastic bag instead)
Parts & Supplies List:
High quality seal kit (SKF or OEM) (SKF P#: KITG-41S)
Bushings (I recommend OEM)
High quality fork oil (2l)(7.5W)
Crush washer damper rod bolt (x2)(BMW P#31 42 2 312 710)(12.7mm OD x 8mm ID)
Scotch Brite pad (red)
Medium strength thread locker
Shop Towels
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Amazon Affiliate Link List
Tools:
Ratio Rite measuring cup - amzn.to/4bnKTcj
Drain pan - amzn.to/3V40tnt
Motion Pro Fork Seal Bullet (41mm) - amzn.to/3V7jBkN
Motion Pro 41mm Ringer Fork Seal Driver - amzn.to/4bndrlY
GEARWRENCH tools - amzn.to/3yprgSr
GEARWRENCH ⅜ Drive Torque Wrench - amzn.to/3QQp9NV
GEARWRENCH 90 Tooth ⅜ Drive Ratchet - amzn.to/44LLQbK
GEARWRENCH ⅜ Drive 10mm Socket - amzn.to/3wNhB7F
GEARWRENCH ⅜ Drive 13mm Socket - amzn.to/3Kbu6gk
GEARWRENCH ⅜ Drive 24mm Socket - amzn.to/4bkyo1a
GEARWRENCH ⅜ Drive Hex & Torx Bit Master Set - amzn.to/4dHfUtd
GEARWRENCH ⅜ Drive Hex Bit 6mm Socket - amzn.to/3UOfDvO
GEARWRENCH ⅜ Drive Hex Bit 8mm Socket - amzn.to/4aooVED
GEARWRENCH ⅜ Drive Hex Bit T45 Socket - amzn.to/3wuGZPL
GEARWRENCH Pick Set - amzn.to/4bFUgDH
GEARWRENCH 90 Degree Pick - amzn.to/44Ldhm2
GEARWRENCH Screwdriver Set - amzn.to/4boHQAD
Titan Tools 6-Piece Multi-Wedge Pry Tool Set - amzn.to/4aG9bND
Milwaukee ⅜ Impact Wrench - amzn.to/3QLBbs0
Air Nozzle - amzn.to/3wvArjP
Pancake Jack - amzn.to/44JBqtf
Parts & Shop Supplies:
SKF Seal Kit - amzn.to/3K9Iw0J
Bel-Ray High Performance Fork Oil - amzn.to/3K6N87G
Scotch Brite Pads - amzn.to/3wNkEwD
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Torque List, Specifications, & Capacities
Torque specs:
Front Axle - 45Nm
Axle pinch bolt - 23Nm
ABS sensor - 9Nm (plus medium strength thread locker)
Brake caliper bolts - 41Nm (plus medium strength thread locker)
Stabilizer bracket bolts - 21Nm
Fork bridge bolts (Triple clamp bolts) - 21Nm
Damper rod bolt - 25Nm (with new crush washer)
Fork cap - Not listed in BMW manual
Capacities:
Fork Oil - 560cc of 7.5w synthetic fork oil (Dakar)
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Time Stamps
00:00 Start
00:16 Tools
00:37 Identifying a fork leak
1:37 Lift the bike
2:04 Motorcycle disassembly
6:32 Fork disassembly & inspection
18:32 Fork reassembly
19:38 USE GOOD SEALS!
29:03 Filling the forks with oil
31:21 Reinstalling the forks
32:34 Reinstalling the front wheel & brakes
34:36 Outro

[@Matt-py4sc]

Super well documented, thanks for this! Saving for the day I need to do the job.

[@MotoDuoMedia]

Glad to help!