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Kawasaki KLV1000-A1 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLV1000-A1 Year: 2004 Codes Chassis Code: A1 👋 Introduction Market Position Vehicle Segment: Adventure Touring Motorcycle Target Audience: Touring riders, off-road enthusiasts, everyday...
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Type: Motorcycle
Vendor:
Sku: 603389
Kawasaki KLV1000-A1 2004 Service Repair ManualKawasaki KLV1000-A1 2004 Service Repair ManualKawasaki KLV1000-A1 2004 Service Repair ManualKawasaki KLV1000-A1 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLV1000-A1
Year:
2004
Codes
Chassis Code:
A1
👋 Introduction
Market Position
Vehicle Segment:
Adventure Touring Motorcycle
Target Audience:
Touring riders, off-road enthusiasts, everyday commuters
Competitive Analysis
Key Competitors:
Suzuki V-Strom DL1000, Honda VFR800X Crossrunner, Yamaha TDM900
Key Features
Engine Type:
V-twin, liquid-cooled
Chassis Design:
Sturdy frame, comfortable ergonomics for long-distance riding
Suspension:
Long-travel suspension for varied terrain
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics
Page Count
Estimated Pages:
400-500
Manual Type
Type:
Factory Service Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, tuning, fuel injection, ignition, cooling, lubrication
Transmission:
Clutch, gearbox internals, shift mechanism, lubrication
Chassis And Suspension:
Front fork, rear shock absorber, swingarm, steering head bearings, wheels, tires
Brakes:
Front and rear hydraulic disc brakes, master cylinders, calipers, fluid replacement, bleeding
Electrical System:
Battery, charging system, ignition system, lighting, starter motor, instrumentation, wiring diagrams
Fuel System:
Fuel tank, fuel pump, injectors, fuel pressure regulation
Exhaust System:
Catalytic converter, mufflers, pipes
Bodywork:
Fairings, seat, fuel tank cover, fenders
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points
Troubleshooting:
Diagnostic flowcharts for common issues, error code interpretation
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly
Tune Up:
Ignition timing, idle speed adjustment, throttle body synchronization
Diagnostic Testing:
Testing of electrical components, sensors, and actuators
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
Detail Level:
Includes torque specifications, clearances, and specialized tool requirements
📊 Manual Specifications
File Format
Searchability:
Searchable PDF text
Printability:
Printable pages
Print Quality
Image Resolution:
High-resolution diagrams and illustrations
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, four-stroke, DOHC, 8-valve
Displacement:
996 cc
Bore X Stroke:
98.0 x 66.0 mm
Compression Ratio:
11.3:1
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 95 hp @ 8,000 rpm (manufacturer claimed)
Torque:
Approx. 74 lb-ft @ 6,500 rpm (manufacturer claimed)
Fuel System
Fuel Delivery:
Fuel Injection, DFI (Digital Fuel Injection)
Fuel Type:
Unleaded gasoline, 91 octane (or higher)
Lubrication
Oil Capacity:
Approximately 3.2 liters with filter change
Recommended Oil:
API SG, SF or higher, SAE 10W-40 motorcycle oil
Ignition
Ignition System:
Digital CDI
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Clutch Type:
Wet, multi-plate, cable operated
Features
Gear Ratios:
Detailed ratios provided in manual
Final Drive:
O-ring sealed chain
Fluid Requirements
Transmission Oil Type:
SAE 80W API GL-4 or GL-5 gear oil
Transmission Oil Capacity:
Approximately 2.0 liters
📐 Dimensions
Exterior
Length:
2,165 mm (85.2 in)
Width:
830 mm (32.7 in)
Height:
1,365 mm (53.7 in)
Wheelbase:
1,535 mm (60.4 in)
Ground Clearance:
170 mm (6.7 in)
Seat Height:
855 mm (33.7 in)
Weights
Dry Weight:
Approx. 204 kg (450 lbs)
Curb Weight:
Approx. 221 kg (487 lbs)
Fuel Tank Capacity:
22 liters (5.8 US gal)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle specific safety ratings not typically provided in this format)
Active Features
Braking System:
Dual 310mm front discs, single 260mm rear disc
ABS:
Not standard on the A1 model (optional availability varies by market)
Passive Features
Lighting:
Halogen headlight, LED taillight
Mirrors:
Wide-view mirrors
💡 Technology Features
Infotainment
Instrument Panel:
Analog tachometer, digital speedometer, fuel gauge, clock, gear position indicator, warning lights
Driver Assistance
Traction Control:
Not equipped
Connectivity
Power Outlet:
Optional accessory, not standard
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months
Air Filter Replacement:
Every 12,000 km (7,500 miles) or 12 months
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Valve Clearance Check:
Every 24,000 km (15,000 miles)
Chain Lubrication Inspection:
Every 1,000 km (600 miles) or after riding in rain
Fluid Specifications
Brake Fluid Type:
DOT 4
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, rear shock absorber bushings
Potential Faults:
Stalling at low RPM (can be fuel injection or vacuum related), occasional electrical connector issues.
Tooling
Special Tools Mentioned:
Includes specific Suzuki or Kawasaki tools for fuel injection synchronization, timing, and special bearing presses.
📚 Vehicle History
Brand Heritage
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company
Model Evolution
Development Basis:
Based on the Suzuki DL1000 V-Strom platform through a licensing agreement.
Unique Kawasaki Elements:
Distinct Kawasaki styling, tuning, and potentially minor component differences.
Production
Production Period:
Approximately 2004-2007 (model years may vary)
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
While the KLV1000 itself did not win specific awards as a Kawasaki model, its Suzuki V-Strom donor platform received numerous accolades for touring capability and value.
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