BMW C600 Sport/C650 GT Belt and Roller Service

Just a few tips; the official BMW documentation appears at the end of this document.

Belt & Variator Holder

Source: BMW Motorad
Holder: 83 30 2 297 988
Belt: 24 82 7 729 767

Dr. Pulley Sliders and Guides

Source: www.drpulley.info
Sliders: SR3020R/8-28
Guides: SP3020-AH

Other Tools

Top-to bottom (left side):

3/8” ratchet, 1/2" ratchet, 1/2" breaker bar, 1/2" torque wrench, BMW variator holder, 14" zip tie.

Top to bottom (right side):

Large flathead screwdriver, T30 screwdriver, T25 socket, T30 socket, 1/2"-3/8" converters, 33mm socket

Other Stuff

Brake parts cleaner and green Scotch-Brite pad

BMW C600/C650 Belt and Roller Change Page 2

A Few Tips

Some of these tips are specific to the C650 GT but many are also applicable to the C600 Sport.

1. Removing the body plastics is a pretty straightforward process. Exercise care when removing the
fuel door as it is easily broken. I’ve found it easier to bend the entire door (along its long axis)
than to try to pry off the two tabs holding it to the center cover.

2. All of the plastics come off in the order listed in the maintenance manual.
BMW C600/C650 Belt and Roller Change Page 3

3. Removing the CVT cover is also simple until you get to the one bolt buried under a structural
member. BMW was kind enough to provide a hole in which T30 screwdriver can be placed to
loosen the bolt. You won’t be able to remove it completely but the cover can be removed with it
in place. The following two pictures show the bolt and passthrough.

4. Once the cover is off, use a large screwdriver and hammer to bend the safety tabs on the clutch
and variator nuts down. Place the holder over the variator and clutch nut and loosen the variator
nut with a 33mm socket and breaker bar.

For the clutch nut (the one closest to the back wheel) use a 17mm socket and turn the shaft nut
clockwise to loosen the clutch nut.

5. Once all the pieces are off I cleaned the clutch bell and variator parts with the brake cleaner and
Scotch-Brite pad until there was no trace of gunk. It’s important keep the clutch and variator
faces clean; a final wipe down before replacing the CVT cover is a good idea.
BMW C600/C650 Belt and Roller Change Page 4

6. One other bit of trickiness was seating the new belt in the clutch. I placed the clutch on the
garage floor with the smaller end up. Kneeling on it, I took the large flathead screwdriver
(wrapped in a shop towel) and placed it into the clutch making sure it went to the center. I then
slowly pulled up and twisted (at the same time) it to open the clutch and seat the belt*. I used the
zip tie to keep it seated while I put it back on the bike. It’s important that whatever you use not
damage the clutch face. (Before deciding on this method I put a ding in mine but cleaned it up
with some 600-grit sandpaper and steel wool).

*Make sure the belt is on correctly. The BMW belt has white arrows indicating the direction;
these should face toward the front of the bike when viewed from above.

7. I ended up swapping the BMW rollers for Dr. Pulley sliders having heard good results from other
C600/C650 owners and also good experience on my other scooter. It’s important the sliders be
positioned correctly; Dr. Pulley includes a picture of the correct installation with the parts. It’s
also important to replace the guides. The Dr. Pulley guides seem to fit tighter then the BMW ones
and are reportedly quieter.

8. Reassembly is the reverse procedure. Be sure to adhere to the torque specifications for the clutch
and variator nuts (100Nm or 74 Ft/Lb). Also remember to bend the clutch and variator nut safety
tabs back up.

9. Have fun out there!

BMW-Motorrad - 0133 - C 650 GT, K19

24 82 501 Replacing CVT belt with rollers (for maintenance)

Preparatory work
Removing filler cap
Removing centre cover
Removing right side panel
Removing centre right footplate insert and footrest plate
Installing rear right footplate insert and footrest plate
Removing rear footplate
Removing rear right footplate carrier

Core activity
(-) Removing CVT sound-absorbing hood

Release the cable (arrows).

Remove screws (1) and remove sound-absorbing hood (2).

(-) Removing CVT cover

Remove screws (1) and remove cover (2).

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BMW-Motorrad - 0133 - C 650 GT, K19

(-) Slackening threaded fasteners of CVT adjuster unit and CVT

output

Bend up tabs of lock washer (1)

Engage holder (No. 24 0 511).
Slacken nut (2).
Turn shaft (3) to slacken nut (4).
Remove holder (No. 24 0 511).

(-) Removing CVT adjuster unit

Remove the following components:

Nut (1)
Lock washer (2)
Spacer (3)

Remove CVT adjuster unit (1) and sleeve (2).

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BMW-Motorrad - 0133 - C 650 GT, K19

(-) Removing CVT output with drive belt and clutch bell

Remove nut (1), while counter-holding at shaft (2) if necessary.

Remove lock washer (3).

Remove CVT output (1) with drive belt (2).

Remove clutch bell (1).

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BMW-Motorrad - 0133 - C 650 GT, K19

(-) Checking clutch

Check
Check clutch (1) and clutch bell (2) for wear.

Technical data
Minimum height, Projection min 2.5 mm
clutch lining past lining
backer

Result:
Clutch linings are worn or damaged, clutch bell shows scoring on friction
face.
Measure:
=> 21 21 511, Replacing clutch packet (CVT output removed) (Billed as a
separate item)

(-) Replacing CVT belt

When installing belt (1), make sure that the direction of rotation (arrow) is
correct: arrows point in direction of rotation.

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BMW-Motorrad - 0133 - C 650 GT, K19

(-) Replacing CVT roller weights and sliders

Remove guide plate (1) , sliders (2) and roller weights (3).
Replace sliders (2) and roller weights (3).
Lubricate sliders (2) and their tracks (arrows) in variator plate (4).

Lubricant
Unirex N3 83 19 2 160 349

Install roller weights (3), sliders (2) and guide plate (1), noting the installed
position of roller weights (3).

Make sure that the installed position of roller weights (1) is correct
(arrows):
The side with the thin plastic edge faces toward the low side wall in
variator plate (2).

(-) Installing CVT output with drive belt and clutch bell
Installing drive belt in CVT output

When installing drive belt (1), make sure that the direction of rotation
(arrow) is correct: arrows point in direction of rotation.

Use a tyre lever to hold down thrust washer (1), taking care not to damage
the friction faces (arrows).

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BMW-Motorrad - 0133 - C 650 GT, K19

Pull drive belt (1) as tight to the pulley as possible and secure the loose
end with a cable tie (arrow).
Drive belt (1) is secured to permit subsequent assembly of the CVT
adjuster unit.

Install clutch bell (1).

Install CVT output (1) with drive belt (2).

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BMW-Motorrad - 0133 - C 650 GT, K19

Position lock washer (3) on shaft (2).

Install nut (1) and tighten until hand-tight.

(-) Installing CVT adjuster unit

Clean CVT spacing sleeve (1).

Lubricate the cavity (arrow).

Lubricant
Unirex N3 83 19 2 160 349

Install CVT spacing sleeve (2) and removing escaping grease.

Note
The friction faces of the CVT belt, CVT belt and coupling must be clean and
free of grease.

Install CVT adjuster unit (1).

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BMW-Motorrad - 0133 - C 650 GT, K19

Make sure that engagement of the splines (arrow) between guide plate (1)
and CVT shaft (2) is correct.

Install spacer (3) and lock washer (2).

Install nut (1) and tighten until hand-tight.

Make sure that installation is correct: with nut (1) installed, the groove
(arrow) in CVT shaft (2) must be visible.

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BMW-Motorrad - 0133 - C 650 GT, K19

(-) Securing threaded fastener of CVT adjuster unit and clutch

Engage holder (No. 24 0 511).

Tighten nut (2).

Tightening torques
CVT (front) to CVT input shaft
M22 x 1.5, secure with lock washer 100 Nm

Turn shaft (3) to tighten nut (4).

Tightening torques
CVT output to CVT output shaft
M22 x 1.5, secure with lock washer 100 Nm

Remove holder (No. 24 0 511).

Bend up the tabs of locking washer (1).
Remove the cable tie (arrow) from drive belt (1).

(-) Installing CVT cover

Install cover (2) and secure with screws (1).

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Tightening torques
CVT cover to crankcase
M6 x 45 10 Nm

(-) Installing CVT sound-absorbing hood

Secure CVT sound-absorbing hood (2) with screws (1).

Tightening torques
Sound-absorbing hood to CVT cover
M6 x 18 10 Nm

Secure the cable (arrows).

Finishing work
Installing rear right footplate carrier
Installing right footplate
Installing rear right footplate insert and footrest plate
Installing centre right footplate insert and footrest plate
Installing right side panel

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BMW-Motorrad - 0133 - C 650 GT, K19

Installing centre cover

Closing seat
Installing filler cap
Final check of work performed

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