Target Audience:
BMW R 1200 C Montauk owners and independent repair shops specializing in BMW motorcycles.
Value Proposition:
Provides factory-level repair information without the high cost of official BMW service manuals or CD-ROMs.
Alternatives:
Official BMW factory service manuals (often in binder or CD-ROM format), Haynes or Clymer manuals (typically less comprehensive).
Accessibility:
Delivered via email, eliminating shipping time and costs.
Usability:
Compatible with all PC-based Windows operating systems and Mac, offering flexibility in usage.
Completeness Claim:
Stated to be a 'COMPLETE Workshop Service / Repair Manual' and 'complete in itself', replicating factory shop manual content.
Primary Focus:
Complete Workshop Service and Repair
Systems Covered List:
Lubrication & Maintenance, Suspension, Brakes, Cooling System, Electrical System, Engine, Fuel System, Exhaust System, Transmission, Heating and Air Conditioning, Emission Control Systems, Body, Wiring Diagrams
Estimated Pages:
Comprehensive (exact count not specified, but described as 'complete' and covering 'every part')
Type:
Workshop Service Manual / Repair Manual
Engine:
Detailed coverage of engine assembly, disassembly, internal components, timing, valve adjustments, oil system, and cooling.
Fuel System:
Includes fuel injection system diagnosis, fuel pump, injectors, throttle body, and fuel tank maintenance.
Transmission:
Coverage for gearbox overhaul, clutch operation, shift mechanisms, and lubrication.
Brakes:
Detailed procedures for front and rear brake systems, including caliper overhaul, disc replacement, hydraulic lines, and ABS (if equipped).
Suspension:
Front fork servicing, rear shock absorber maintenance and replacement, linkage points, and wheel bearing checks.
Electrical System:
Comprehensive wiring diagrams, starter system, charging system (alternator, rectifier/regulator), ignition system, lighting, and accessory circuits.
Body:
Fairing removal and installation, seat servicing, fenders, tank mounting, and general chassis component procedures.
Heating Air Conditioning:
Specific to the 'CL' model variant which often implies a touring package with climate control systems. Detailed diagnosis and repair of HVAC components.
Maintenance:
Routine service checks, fluid changes, filter replacements, spark plug servicing, and pre-ride inspections.
Troubleshooting:
Diagnostic guides for common problems, symptom analysis, and step-by-step fault finding procedures.
Repair:
Detailed instructions for component disassembly, overhaul, reassembly, and adjustment for all major systems.
Rebuilding:
Full engine and transmission rebuild procedures, including torque specifications and critical measurements.
Wiring Diagrams:
Detailed, high-resolution wiring schematics for all electrical circuits.
Depth Level:
Comprehensive workshop level, suitable for professional technicians and advanced DIY mechanics.
Diagnostic Capability:
Includes diagnostic procedures for electronic control units (ECU) and sensors, though specific diagnostic tool requirements may not be detailed.
Searchability:
Likely text-searchable within PDF if properly OCR'd, aiding in quick information retrieval.
Printable Pages:
Allows printing of all, any, or specific sections as needed.
Image Resolution:
High-quality images and diagrams ('lots of pictures and diagrams').
Binding Type:
Digital PDF (no physical binding)
Paper Type:
N/A (Digital)
Engine Type:
Air-cooled, four-stroke, boxer-twin engine
Displacement:
1170 cc (1.2 Liters)
Bore X Stroke:
101 mm x 73 mm
Valve Train:
OHV (Overhead Valve), 2 valves per cylinder, pushrod operated
Horsepower Output:
61 hp (45 kW) at 5,000 rpm (approximate for 2004 model)
Torque Output:
98 Nm (72 lb-ft) at 3,000 rpm (approximate for 2004 model)
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic
Fuel Type:
Unleaded gasoline, minimum 95 RON (89 AKI)
Cooling Method:
Air-cooled with oil cooling circuit
Oil Type:
Recommended: BMW Motorrad Advantec Ultimate SAE 20W-50 or equivalent API SG/SH/SJ/SL rated multi-grade oil.
Oil Capacity:
Approx. 4.0 liters (4.2 US qt) with filter change
Transmission Type:
5-speed manual gearbox
Clutch Type:
Single dry plate, hydraulic actuation
Gear Ratios:
Specific ratios detailed in the manual (e.g., 1st: 3.53, 2nd: 2.43, 3rd: 1.81, 4th: 1.45, 5th: 1.23)
Gearbox Oil:
Recommended: SAE 75W-90 API GL-5 (e.g., BMW's own lubricant or equivalent).
Length:
Approx. 2,210 mm (87.0 in)
Width:
Approx. 910 mm (35.8 in) at handlebars
Height:
Approx. 1,120 mm (44.1 in) at handlebars
Dry Weight:
Approx. 250 kg (551 lbs)
Gross Vehicle Weight Rating:
Approx. 470 kg (1036 lbs)
Fuel Tank Capacity:
17.2 liters (4.5 US gal)
ABS:
Optional Integral ABS (Anti-lock Braking System) available, coverage in manual for diagnosis and service.
Braking System:
Dual disc front brakes, single disc rear brake with Brembo calipers. Manual covers all aspects.
Lighting:
Halogen headlight, LED taillight. Electrical system coverage includes bulb replacement and troubleshooting.
Audio System:
The Montauk CL variant often included an integrated audio system. The manual will cover its operation, maintenance, and potential troubleshooting.
Cruise Control:
Some models may have featured cruise control. The manual would provide details on its function and diagnostics within the electrical system section.
ABS Integration:
If equipped with Integral ABS, the manual details its operation, sensor checks, and hydraulic unit servicing.
Diagnostic Port:
Manual would guide on the location and use of diagnostic ports for BMW's proprietary diagnostic systems or general OBD-II (if applicable to this era/model).
Oil Change Interval:
Typically every 10,000 km (6,000 miles) or annually, whichever comes first (refer to manual for exact factory spec).
Valve Adjustment Interval:
Recommended every 20,000 km (12,000 miles) or as per manual's schedule, crucial for boxer engines.
Spark Plug Replacement:
Typically around 20,000 km (12,000 miles), with manual detailing specific plug types and gaps.
Brake Fluid:
DOT 4 synthetic brake fluid. Manual specifies bleeding procedures and fluid replacement intervals.
Coolant:
Not applicable, as the engine is primarily air-cooled with an oil circuit. No coolant fluid to specify.
Common Wear Items:
Clutch wear, rear drive spline lubrication, fork seal leaks, and electrical connector corrosion are common areas requiring attention, all of which are covered in detail.
Preventative Maintenance:
Manual emphasizes regular lubrication of drive shaft splines and checking electrical connections for longevity.
Brand History:
BMW Motorrad, a division of BMW AG, has a long history of producing high-quality motorcycles, particularly known for its boxer-twin engines and touring capabilities.
R Series Evolution:
The R 1200 C series represented BMW's entry into the cruiser market, blending traditional BMW engineering with American cruiser styling elements. The Montauk was a top-tier touring variant.
Production Period:
The R 1200 C range was produced from 1997 to 2004, making the 2004 model one of the final iterations.
Manufacturing Location:
Berlin, Germany (BMW Motorrad plant)