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KAWASAKI KLV1000 Service Repair Manual 2004-2008

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🏷️ Basic Information Identification Make: Kawasaki Model: KLV1000 Model Nickname: V-Strom 1000 (based on Suzuki DL1000 V-Strom) Production Years Covered: 2004, 2005, 2006, 2007, 2008 Codes Engine Code Series: H041...
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KAWASAKI KLV1000 Service Repair Manual 2004-2008KAWASAKI KLV1000 Service Repair Manual 2004-2008KAWASAKI KLV1000 Service Repair Manual 2004-2008KAWASAKI KLV1000 Service Repair Manual 2004-2008
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLV1000
Model Nickname:
V-Strom 1000 (based on Suzuki DL1000 V-Strom)
Production Years Covered:
2004, 2005, 2006, 2007, 2008
Codes
Engine Code Series:
H041
Chassis Code Series:
A1, A2, A3, A4, A5 (corresponding to model year variants)
👋 Introduction
Market Position
Segment:
Adventure Touring Motorcycle
Target Audience:
Motorcyclists seeking versatility for long-distance touring and light off-road capability.
Competitive Analysis
Key Competitors:
BMW R1150GS/R1200GS, Honda VFR800X Crossrunner, Triumph Tiger 955i/1050.
Klv1000 Advantage:
Offered a potent V-twin engine and robust chassis, often at a more accessible price point than some European competitors. The Kawasaki badging aimed to leverage their sports motorcycle heritage.
Key Features
Engine Configuration:
90-degree V-twin, liquid-cooled, DOHC.
Chassis Design:
Aluminum twin-spar frame for rigidity and light weight.
Suspension Setup:
Long-travel telescopic front forks and adjustable rear monoshock for comfort and off-road capability.
📋 Manual Details
Coverage Areas
Primary Regions Covered:
Global
Specific Market Notes:
While branded Kawasaki, the KLV1000 is a rebadged Suzuki DL1000 V-Strom, meaning many mechanical and electrical specifications will align with its Suzuki counterpart.
Page Count
Estimated Page Count:
400-500 pages (typical for comprehensive service manuals)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine disassembly, assembly, lubrication, cooling, fuel injection, ignition, emission control, starting, charging.
Transmission Drivetrain Systems:
Clutch, gearbox, final drive (chain and sprockets), lubrication.
Chassis Frame Suspension Steering:
Frame inspection, front fork overhaul, rear shock absorber, swingarm, steering head bearings, wheel bearings.
Braking Systems:
Front and rear brake systems, hydraulic lines, master cylinders, calipers, pads, discs, ABS (if equipped).
Electrical Systems:
Wiring diagrams, lighting, ignition system, charging system, starter motor, instrumentation, sensors, ECU troubleshooting.
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, throttle body.
Exhaust System:
Exhaust pipes, mufflers, catalytic converter (if applicable).
Body Panels Trim:
Fairings, seat, fuel tank cover, side covers, fenders, lights.
Procedures Included
Maintenance Procedures:
Routine servicing, oil and filter changes, air filter replacement, spark plug replacement, chain adjustment and lubrication, brake fluid flush.
Repair Procedures:
Engine top-end rebuilds, gearbox overhauls, suspension component replacement, electrical fault diagnosis, clutch replacement, brake caliper rebuilds.
Troubleshooting Guides:
Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable).
Special Tools And Jigs:
Identification of required special tools for specific procedures.
Technical Depth
Depth Of Information:
Comprehensive, covering routine maintenance to full engine and chassis overhauls.
Diagnostic Capabilities:
Detailed diagnostic procedures, including electrical system troubleshooting and component testing.
Rebuild Specifications:
Detailed specifications for engine and transmission component clearances, torque values, and assembly procedures.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Searchability:
Fully searchable text content for quick information retrieval.
Print Quality
Print Readability:
High-resolution scans ensuring clear text and diagrams.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, 90° V-twin, DOHC, 8 valves
Displacement:
996 cc
Bore X Stroke:
98.0 mm x 66.0 mm
Compression Ratio:
11.3:1
Performance
Peak Horsepower:
98 hp @ 7,600 rpm (approximate, may vary by market)
Peak Torque:
76 lb-ft @ 6,400 rpm (approximate, may vary by market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Throttle Body Size:
42 mm
Fuel Type:
Unleaded gasoline, 91 octane or higher
Lubrication
Oil Capacity With Filter Change:
3.8 Liters (4.0 US qt)
Recommended Oil Viscosity:
10W-40 (API SG or higher, JASO MA)
Ignition
Ignition System:
Digital CDI with electronic ignition timing
Spark Plugs:
NGK CR9EK (or equivalent)
🔧 Transmission
Standard
Transmission Type:
Constant mesh 6-speed
Clutch Type:
Wet, multi-plate, cable-actuated
Final Drive:
Sealed O-ring type chain, 17T front, 41T rear sprockets (typical)
Features
Gear Ratios:
Refer to manual for specific gear ratios; designed for strong mid-range torque and touring comfort.
Transmission Fluid:
Use engine oil (refer to engine oil specifications).
📐 Dimensions
Exterior
Overall Length:
2270 mm (89.4 in)
Overall Width:
830 mm (32.7 in)
Overall Height:
1365 mm (53.7 in)
Wheelbase:
1535 mm (60.4 in)
Ground Clearance:
175 mm (6.9 in)
Seat Height:
840 mm (33.1 in)
Weights
Dry Weight:
207 kg (456 lbs)
Curb Weight:
232 kg (511 lbs) (fully fueled, with all standard equipment)
Fuel Tank Capacity:
22 Liters (5.8 US gal)
Luggage Capacity:
N/A (designed for accessory luggage systems)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle safety is typically assessed through independent rider testing and component integrity).
Active Features
Braking System:
Dual 310 mm discs with 4-piston calipers (front), Single 260 mm disc with 2-piston caliper (rear). Optional ABS available on some models.
Tire Sizes:
Front: 110/80R19, Rear: 150/70R17 (typical)
Headlight Type:
Dual Halogen (55/60W)
Passive Features
Frame Construction:
Rigid aluminum twin-spar frame for stability.
Windscreen:
Adjustable windscreen for rider comfort and protection from elements.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, clock, and warning lights.
Audio System:
N/A (Not equipped with an integrated audio system from the factory).
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on certain model years/trims.
Connectivity
Diagnostic Ports:
Standard motorcycle diagnostic connectors for ECU access (covered in the electrical section).
Lighting Technology:
Halogen headlights, LED taillight (typical).
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 6,000 miles or 6 months, whichever comes first.
Air Filter Inspection:
Every 6,000 miles; replace as needed.
Spark Plug Replacement:
Every 12,000 miles or 12 months.
Valve Clearance Check:
Every 12,000 miles or 12 months (critical for this V-twin).
Chain Lubrication And Adjustment:
Every 600 miles or after washing/rain.
Fluid Specifications
Coolant Type:
Pre-mixed ethylene glycol based coolant with corrosion inhibitors (refer to manual for exact type and mix ratio).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Fork Oil Type And Level:
Refer to manual for specific viscosity (e.g., Showa SS-01 or equivalent) and level.
Known Issues
Cam Chain Tensioner:
Early models of the DL1000 (and thus KLV1000) could suffer from weak cam chain tensioners leading to rattle. Aftermarket upgrades are available.
Stator Issues:
Some owners have reported stator failures, affecting charging system performance. Proper diagnosis is key.
Misfires Under Load:
Can sometimes be attributed to fuel quality, clogged injectors, or ignition system issues, all of which are covered in the manual.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycle Division:
Kawasaki Heavy Industries Motorcycle & Engine Company has a long history of performance motorcycles, known for its Z, Ninja, and Vulcan series.
Model Evolution
Klv1000 Origin:
The KLV1000 is a collaborative effort, being a rebadged version of Suzuki's highly successful DL1000 V-Strom. This partnership allowed Kawasaki to enter the adventure touring segment quickly with a proven platform.
Suzuki Dl1000 Vstrom:
The DL1000 V-Strom was introduced in 2002 and was lauded for its comfortable ergonomics, strong V-twin engine, and all-around capability.
Production
Manufacturing Location:
Typically produced in Japan (aligns with Suzuki's production for the V-Strom).
Model Lifespan As Klv1000:
A relatively short but significant period, filling a niche in Kawasaki's lineup.
🏆 Awards & Recognition
Recognitions
Klv1000 Specific Awards:
No specific awards for the KLV1000 branding itself, but it inherits the positive reception and accolades of the Suzuki DL1000 V-Strom.
Ratings
Motorcycle Journalist Reviews:
The DL1000 V-Strom platform received consistently positive reviews for its powerful V-twin engine, comfortable riding position, and value proposition in the adventure touring segment.
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