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2004 KAWASAKI KLV1000 Motorrad Service-Reparaturhandbuch

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🏷️ Basic Information Identification Make: Kawasaki Model: KLV1000 Year: 2004 Product Type: Service Repair Manual 👋 Introduction Market Position Segment: Adventure Touring / Sport Touring Motorcycle Target Audience: Riders seeking...
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2004 KAWASAKI KLV1000 Motorrad Service-Reparaturhandbuch2004 KAWASAKI KLV1000 Motorrad Service-Reparaturhandbuch2004 KAWASAKI KLV1000 Motorrad Service-Reparaturhandbuch2004 KAWASAKI KLV1000 Motorrad Service-Reparaturhandbuch
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLV1000
Year:
2004
Product Type:
Service Repair Manual
👋 Introduction
Market Position
Segment:
Adventure Touring / Sport Touring Motorcycle
Target Audience:
Riders seeking a versatile motorcycle for long-distance touring, commuting, and light off-road excursions.
Competitive Analysis
Key Competitors:
Suzuki V-Strom DL1000, Honda VFR Interceptor, Yamaha TDM900, BMW R1150GS/R1200GS (earlier models).
Key Features
Engine Layout:
Derived from the popular Suzuki SV1000 V-twin engine, renowned for its torquey power delivery and character.
Chassis Design:
Sturdy twin-spar aluminum frame offering stability and handling characteristics suitable for various road conditions.
Ergonomics:
Upright riding position, comfortable seat, and adjustable windscreen for long-distance comfort.
📋 Manual Details
Coverage Areas
Engine Mechanical:
Complete
Engine Management:
Complete
Transmission:
Complete
Chassis Components:
Complete
Electrical System:
Complete
Fuel System:
Complete
Cooling System:
Complete
Exhaust System:
Complete
Suspension:
Complete
Brakes:
Complete
Wheels Tires:
Complete
Frame Bodywork:
Complete
Troubleshooting:
Comprehensive
Page Count
Pages:
Approximately 600+
Manual Type
Type:
Service Repair Manual
Manual Source:
Factory authorized service manual.
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
V-twin, 996cc, liquid-cooled, 4-stroke, DOHC, fuel injection, ignition system, lubrication, cooling system, exhaust system.
Powertrain:
6-speed transmission, clutch operation, final drive (chain).
Chassis Suspension:
Front telescopic forks (adjustable preload, rebound, compression), rear monoshock (adjustable preload, rebound, compression), steering head bearings.
Braking System:
Front dual hydraulic disc brakes with dual-piston calipers, rear hydraulic disc brake with single-piston caliper, hydraulic lines and master cylinders.
Electrical Components:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, indicators), instrumentation, sensors, wiring diagrams.
Fuel And Emission Control:
Fuel tank, fuel pump, fuel injectors, throttle body, ECU mapping, evaporative emission control system.
Procedures Included
Routine Maintenance:
Oil change, oil filter replacement, air filter cleaning/replacement, spark plug replacement, chain lubrication/adjustment, brake pad inspection/replacement, coolant check/replacement, valve clearance inspection/adjustment.
Major Repairs:
Engine disassembly/reassembly, transmission overhaul, clutch replacement, fork seal replacement, shock absorber servicing, brake caliper overhaul, wheel bearing replacement.
Diagnostics:
Troubleshooting common issues, diagnostic trouble codes (DTCs) interpretation, fuel injection system diagnostics, electrical fault finding.
Specifications:
Torque values for all fasteners, engine clearances, fluid capacities, electrical component resistance values, diagnostic parameter readings.
Assembly Disassembly:
Detailed step-by-step instructions for removing and installing major components, including engine, transmission, suspension, and body panels.
Electrical Troubleshooting:
Includes flowcharts and diagnostic procedures for common electrical faults, testing of sensors, ignition system, charging system, and lighting.
Technical Depth
Depth:
Comprehensive, covering routine maintenance to full engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications for professional and advanced home mechanics.
Diagnostic Tools:
Specifies use of common hand tools, torque wrenches, multimeter, feeler gauges, and specialized Kawasaki/Suzuki diagnostic equipment or equivalent third-party tools.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text for quick information retrieval.
Resolution:
High-resolution for clear diagrams and text.
Print Quality
Print Readiness:
Optimized for printing individual sections or the entire manual.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 8-valve, V-twin
Displacement:
996 cc (60.7 cu in)
Bore X Stroke:
98.0 mm x 66.0 mm
Compression Ratio:
11.3:1
Valve Actuation:
Double Overhead Camshafts (DOHC), chain driven
Performance
Horsepower Claimed:
Approx. 98 HP @ 8,000 RPM (varies slightly by market)
Torque Claimed:
Approx. 77 lb-ft @ 6,500 RPM (varies slightly by market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle bodies
Fuel Type:
Unleaded gasoline, 91 octane (AKI) or higher
Lubrication
Oil Type:
SAE 10W-40, API SG or higher, JASO MA compliant motorcycle oil
Oil Capacity:
3.4 L (3.6 US qt) with filter change
Cooling System
Coolant Type:
Permanent-type coolant (50% ethylene glycol and 50% distilled water)
Coolant Capacity:
1.8 L (1.9 US qt)
🔧 Transmission
Standard
Transmission Type:
Constant-mesh, 6-speed
Clutch Type:
Wet, multi-plate, manual
Final Drive:
Sealed O-ring type chain, 525 pitch
📐 Dimensions
Exterior
Length:
2,240 mm (88.2 in)
Width:
840 mm (33.1 in)
Height:
1,375 mm (54.1 in)
Wheelbase:
1,530 mm (60.2 in)
Ground Clearance:
165 mm (6.5 in)
Weights
Dry Weight:
205 kg (452 lbs)
Curb Weight:
Approx. 230 kg (507 lbs) with all fluids and a full tank
Capacities
Fuel Tank Capacity:
22 L (5.8 US gal)
🛡️ Safety Features
Ratings
Safety Features:
ABS was optional or standard on certain trims/markets, Dual disc front brakes for strong stopping power.
Active Features
Braking:
Standard dual front hydraulic disc brakes, single rear hydraulic disc brake. Optional Anti-lock Braking System (ABS).
Passive Features
Lighting:
Halogen headlamp, LED taillight, turn signals for visibility.
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, digital speedometer, fuel gauge, odometer, trip meters, clock, various warning lights (engine, oil, neutral, turn signals, high beam).
Driver Assistance
ABS Availability:
Optional Anti-lock Braking System (ABS) available on some models/markets.
Connectivity
Diagnostic Ports:
Includes diagnostic connectors for electronic troubleshooting (requires specific diagnostic tools).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Interval:
Every 12,000 km (7,500 miles) or 12 months.
Air Filter Interval:
Inspect every 6,000 km (3,700 miles), clean or replace as needed.
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Valve Clearance Check:
Every 18,000 km (11,200 miles) or 24 months.
Coolant Replacement:
Every 24,000 km (15,000 miles) or 24 months.
Fluid Specifications
Brake Fluid:
DOT 4
Clutch Fluid:
DOT 4 (if hydraulic)
Fork Oil Type:
SAE 10W (refer to manual for exact type and level)
Known Issues
Common Problems:
Potential for regulator/rectifier failure (common in many bikes of this era), occasional issues with throttle body syncing, cam chain noise if maintenance is neglected. Some owners report a slightly snatchy throttle response at low RPMs which can be smoothed with ECU tuning or throttle body modifications. Exhaust headers can sometimes develop rust or discoloration.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki Heavy Industries is a well-established Japanese manufacturer known for its high-performance motorcycles across various segments, including sportbikes, cruisers, and off-road machines.
Model Evolution
Klv Lineage:
The KLV1000 was Kawasaki's offering in the burgeoning adventure-touring segment. It shared its engine and much of its mechanical DNA with the Suzuki DL1000 V-Strom, a result of a collaboration/parts sharing agreement between Kawasaki and Suzuki during this period. This allowed Kawasaki to quickly enter the segment with a proven powertrain.
Production
Production Years:
2004 - 2007
Manufacturing Location:
Japan (Likely utilizing Suzuki's manufacturing facilities due to powertrain sharing).
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While not typically winning major awards, the KLV1000 was generally well-received for its comfortable ergonomics, torquey engine, and practical features for adventure touring, especially considering its shared platform with the popular Suzuki V-Strom.
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