The 2002 BMW F650CS has 7 recalls, with the most serious being a rear brake caliper that can separate from its mount, rupture the brake line, and cause either a complete loss of rear braking or a sudden rear wheel lockup.
The drivetrain carries several concerns. The front drive belt wheel is secured by a hex nut that may not have been tightened to the correct torque during assembly, and that nut can back off during riding, putting the belt drive at risk. The rear drive belt wheel can also crack and eventually fail, causing the drive belt to come off and leaving the rear wheel with no drive power. Prior repair attempts on the belt wheel did not fully resolve the issue, as replacement wheels installed under an earlier repair may also crack. On the fuel side, the plastic flange on the fuel pump can become brittle if it contacts acidic substances such as battery acid or certain cleaning products, and may eventually crack and allow fuel to leak from the tank.
At a glance
What can fail
The plastic fuel pump flange can become brittle and crack when exposed to acids or acidic chemicals like battery acid or certain cleaners, potentially allowing fuel to leak from the tank.
What the fix does
Dealers will install an acid-resistant cap over the fuel pump flange to protect it.
Summarized — see the official notice for exact wording, dates, and contacts.
We may earn a commission for purchases made through these links.
At a glance
What can fail
The rear brake caliper attaching screws may not be tightened enough, allowing the caliper to separate from its mount. This could rupture the brake line, causing loss of rear braking or rear wheel lock-up.
What the fix does
Dealers will inspect the rear caliper screws and tighten them to the correct torque specification.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The hex nut securing the front drive belt wheel to the gearbox output shaft was installed with insufficient torque during assembly. The nut can loosen during operation, causing the belt wheel to slip on the shaft and damage the internal and external splines, eventually eliminating drive to the rear wheel.
What the fix does
The dealer will install a new hex nut and redesigned front drive belt wheel, and inspect the main-shaft splines for damage, replacing them if needed.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The rear drive belt wheel can crack and fail, causing the drive belt to slip off. This cuts power to the rear wheel. Even wheels installed during a previous recall are affected.
What the fix does
The dealer will replace the drive belt wheel with a reinforced version that has added soldering in the high-stress area.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The rear drive belt wheel may crack and fail, causing the drive belt to slip off and losing power to the rear wheel.
What the fix does
Dealers will inspect rear drive belt wheels from specific production batches and replace any wheels matching those production numbers.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The hex nut securing the front drive belt wheel to the gearbox output shaft was tightened below specification during assembly. This nut can loosen during riding, causing the belt wheel to shift on the shaft and damage the internal and external splines. Over time, this spline damage can prevent the output shaft from driving the rear wheel belt.
What the fix does
Dealers will inspect the hex nut torque and tighten it to specification if needed.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The rear brake caliper mounting screws may not be tightened enough, allowing the caliper to separate from its mount. This could rupture the brake line, causing loss of rear braking, or lock up the rear wheel and destabilize the motorcycle.
What the fix does
Dealers will inspect the rear caliper screws and tighten them to the correct torque specification.
Summarized — see the official notice for exact wording, dates, and contacts.
