🏷️ Basic Information

Make:

Kawasaki

Model:

KLV1000

Year:

2004-2006

Engine Code Variant:

V-twin, 90-degree, Liquid-cooled, DOHC, 4-valve per cylinder

👋 Introduction

Market Position:

The Kawasaki KLV1000, a dual-sport motorcycle, was positioned as a capable adventure touring machine, often leveraging its shared platform with the Suzuki DL1000 V-Strom, offering a blend of on-road comfort and off-road versatility.

Competitors:

Competed with other large-displacement adventure tourers like the BMW R1150GS/R1200GS, Honda VFR1200X Crosstourer (later models), and Yamaha XT1200Z Super Ténéré.

Key Features:

Robust V-twin engine, comfortable ergonomics for long-distance riding, upright riding position, wind protection, and the capability for light off-road excursions.

Manual Usability:

Designed for both professional mechanics and DIY enthusiasts, with simple explanations and step-by-step guidance.

📋 Manual Details

Primary Coverage:

Workshop Service Repair

Applicable Models:

Kawasaki KLV1000

Applicable Years:

2004, 2005, 2006

Page Count:

525

Manual Type:

Comprehensive Workshop Service Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Complete overhaul, diagnostics, adjustments, component replacement

Fuel System:

Fuel injection system, fuel pump, injectors, throttle body, troubleshooting

Ignition System:

Ignition coils, spark plugs, ECU, timing

Transmission:

Gearbox, clutch, shifting mechanism, diagnostics, overhaul

Drivetrain:

Final drive, chain and sprockets (if applicable), bearings

Suspension:

Front forks (telescopic, cartridge type), rear shock absorber, linkage, adjustments, rebuild

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, discs, bleeding, troubleshooting

Electrical System:

Wiring diagrams, starter motor, alternator, battery, lighting, fuses, relays, diagnostics

Cooling System:

Radiator, cooling fan, water pump, hoses, coolant specifications

Frame And Bodywork:

Chassis, fairings, seat, fuel tank, mounting points, disassembly/assembly

Exhaust System:

Exhaust pipes, mufflers, gaskets, catalytic converter (if equipped)

Wheels And Tires:

Wheel removal/installation, tire specifications, pressure recommendations

Steering:

Handlebar, steering stem bearings, front fork alignment

Maintenance:

Routine checks, lubrication, filter replacements, fluid changes, adjustments

Troubleshooting:

Diagnostic procedures for common and complex issues, fault codes

Repair:

Detailed step-by-step repair procedures for all major components

Disassembly Assembly:

Complete instructions for taking apart and putting back together vehicle components

Adjustment:

Precise instructions for setting various vehicle parameters (e.g., idle speed, clutch, suspension)

Installation:

Procedures for installing new or replacement parts

Special Tools:

Identification and usage of specialized tools required for specific procedures

Depth:

Comprehensive, from basic maintenance to complete engine rebuilds and electrical diagnostics

Diagrams Illustrations:

Includes detailed pictorial diagrams, exploded views, drawings, and photos to guide through service procedures.

Torque Specifications:

Provides essential torque values for fasteners during assembly and installation, crucial for safety and component longevity.

Wear Limits:

Specifies wear limits for various components, enabling technicians to determine when parts require replacement.

Diagnostic Procedures:

Includes information on diagnosis and testing of various systems to identify root causes of problems.

📊 Manual Specifications

File Format:

PDF

Compatibility:

Windows, Mac, Linux OS

Software Requirement:

Adobe Reader

Print Quality:

Printable (high resolution, allows for clear reproduction of text and diagrams)

Binding Type:

Digital (N/A for PDF, but implies easy navigation and searching)

Paper Type:

Digital (N/A for PDF, but the content is designed for easy reading and comprehension on screen or print)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, 90° V-twin

Displacement:

996 cc

Bore X Stroke:

98.0 x 66.0 mm

Valve Train:

DOHC, 8 valves (4 per cylinder)

Compression Ratio:

11.3:1

Horsepower:

Approx. 98 HP @ 8,000 RPM (estimated, varies by region and tune)

Torque:

Approx. 75 lb-ft @ 6,500 RPM (estimated, varies by region and tune)

Fuel Delivery:

Digital Fuel Injection with dual 42mm throttle bodies

Fuel Type:

Unleaded gasoline (minimum 91 RON)

Oil Capacity W Filter:

Approx. 3.2 Liters (check manual for exact specification)

Recommended Oil:

Kawasaki recommends specific SAE viscosity grade oils (e.g., 10W-40) meeting API SG or higher specifications. Refer to manual for precise fluid specifications.

🔧 Transmission

Type:

6-speed constant mesh

Clutch:

Wet, multi-plate, cable-actuated

Final Drive:

Sealed O-ring type chain

📐 Dimensions

Length:

Approx. 2,220 mm (87.4 in)

Width:

Approx. 830 mm (32.7 in)

Height:

Approx. 1,340 mm (52.8 in)

Wheelbase:

Approx. 1,520 mm (59.8 in)

Dry Weight:

Approx. 214 kg (472 lbs)

Wet Weight:

Approx. 230 kg (507 lbs) (with all fluids)

Fuel Capacity:

Approx. 22 Liters (5.8 US gal)

🛡️ Safety Features

Safety Features:

Dual front disc brakes with 4-piston calipers, single rear disc brake, robust chassis design, integrated lighting system. Specific crash ratings are not typically provided for motorcycles in the same way as cars, but the design prioritizes rider safety through reliable stopping power and stable handling.

💡 Technology Features

Infotainment System:

Basic instrumentation including speedometer, tachometer, odometer, trip meters, and warning lights. Not equipped with advanced infotainment systems found on modern touring bikes.

Driver Assistance:

No electronic rider aids like traction control or ABS typically found on these early models. Focus is on mechanical and rider-controlled systems.

Connectivity:

None beyond basic electrical system connections.

🔧 Maintenance

Oil Change:

Typically every 6,000 km or 12 months, whichever comes first. Refer to the manual for precise intervals and conditions.

Spark Plug Check:

Recommended inspection at approximately 12,000 km, replacement as needed.

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment every 1,000 km or after riding in adverse conditions.

Valve Clearance:

Inspection recommended at 24,000 km. Refer to manual for precise checks.

Tire Pressure Recommendations:

Refer to the manual for specific front and rear tire pressure recommendations for optimal performance and safety.

Air Filter Replacement:

Recommended at specific intervals or when visually dirty. Check manual for exact service schedule.

Brake Fluid:

DOT 4 recommended. Refer to manual for specific type and replacement intervals.

Coolant:

Permanent type, antifreeze solution (50% ethylene glycol based). Refer to manual for specific type and capacity.

Clutch Fluid:

If hydraulic clutch, typically DOT 4. Refer to manual for specifications.

Common Issues:

Potential issues can include standard motorcycle wear and tear such as clutch wear, chain and sprocket wear, suspension seal leaks. Specific to this model, sometimes minor electrical gremlins or fuel system adjustments might be encountered, all of which this manual will detail how to diagnose and repair.

📚 Vehicle History

Brand Heritage:

Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for its performance-oriented and reliable machines across various segments, from sportbikes to cruisers and off-road motorcycles.

Model Evolution:

The KLV1000 (also known as the Versys 1000 in some markets under different branding/development) was developed as a premium adventure touring motorcycle. Its design philosophy aimed to combine touring comfort with sporty handling, often benefiting from shared technology and engineering with partner brands (in this case, Suzuki's V-Strom platform).

Production Years:

2004, 2005, 2006