KAWASAKI KLV1000 Motorcycle Service Repair Manual 2004-2008

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🏷️ Basic Information Identification Make: Kawasaki Model: KLV1000 Model Nickname: V-Strom 1000 (rebadged) Year Start: 2004 Year End: 2008 Codes Chassis Code: E1/E2/E3/E4/E5 (example, specific to model generation) Engine Code:...

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Type: Motorcycle

Vendor:

Sku: 603395

Tags: 2004 2005 2006 2007 2008 Kawasaki KLV Models KLV1000 Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLV1000

Model Nickname:

V-Strom 1000 (rebadged)

Year Start:

Year End:

Codes

Chassis Code:

E1/E2/E3/E4/E5 (example, specific to model generation)

Engine Code:

V501 (example, specific to model generation)

👋 Introduction

Market Position

Category:

Adventure Touring Motorcycle

Target Audience:

Touring riders, commuters, riders seeking versatility for on-road and light off-road use.

Competitive Analysis

Key Competitors:

Suzuki V-Strom DL1000, BMW R1150GS/R1200GS, Honda Varadero 1000, Yamaha TDM900.

Klv1000 Advantage:

Offers a robust, torquey V-twin engine in a comfortable adventure touring package, often at a competitive price point.

Key Features

Engine Configuration:

V-twin, liquid-cooled, 4-stroke.

Suspension Type:

Long-travel adjustable front and rear suspension.

Ergonomics:

Upright riding position, comfortable for long distances.

Braking System:

Dual front discs and single rear disc with hydraulic actuation.

📋 Manual Details

Coverage Areas

Markets Covered:

Global (varies by specific manual edition)

Region Specific Notes:

May include variations for emissions, lighting, and regulatory compliance based on region.

Page Count

Approximate Page Count:

Manual Type

Type:

Service Repair Manual

Scope:

Comprehensive professional workshop manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of the engine.

Engine Electrical:

Ignition system, charging system, starting system, ECU, sensors, wiring diagrams.

Fuel System:

Fuel injection system (throttle bodies, injectors, fuel pump, pressure regulator), fuel tank, fuel lines.

Transmission:

Clutch operation, gearbox (gear selection, shifting mechanism), final drive (chain, sprockets).

Chassis And Suspension:

Frame, front fork (telescopic, adjustable), rear shock absorber (adjustable, linkage system), swingarm.

Brakes:

Front and rear disc brakes, hydraulic system, master cylinders, calipers, brake pads, brake fluid specifications.

Wheels And Tires:

Wheel bearing inspection, tire replacement, wheel specifications, tire pressure recommendations.

Electrical System:

Lighting (headlight, taillight, indicators), instrumentation, horn, battery, fuses, relays, starter motor.

Bodywork And Fairings:

Removal and installation of fairings, seat, fuel tank, fenders, luggage rack.

Cooling System:

Radiator, cooling fan, coolant specifications, water pump, thermostat.

Exhaust System:

Exhaust pipes, muffler, catalytic converter (if applicable), gasket replacement.

Diagnostics And Troubleshooting:

Systematic fault finding procedures for common and uncommon issues.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain adjustment, brake checks, fluid level checks.

Major Overhauls:

Engine rebuilds, transmission servicing, suspension overhaul.

Component Replacement:

Detailed instructions for replacing all major and minor components.

Electrical Troubleshooting:

Wiring diagram interpretation, diagnostic connector usage, sensor testing.

Suspension Adjustment:

Preload, compression, and rebound damping adjustments.

Fuel System Cleaning And Adjustment:

Throttle body synchronization, injector cleaning procedures.

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine and chassis rebuilds.

Diagnostic Tools:

References specific diagnostic procedures and potential use of specialized tools (e.g., diagnostic scan tools, specialized wrenches).

Torque Specifications:

Detailed torque values for all critical fasteners.

Clearances And Tolerances:

Specifications for component clearances and wear tolerances.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text for quick information retrieval.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-twin, four-stroke, liquid-cooled, DOHC

Displacement:

996 cc

Bore X Stroke:

98.0 x 66.0 mm

Compression Ratio:

11.3:1

Power Output:

Approximately 98 hp (73 kW) at 8,000 rpm

Torque Output:

Approximately 75 lb-ft (102 Nm) at 6,500 rpm

Performance

Top Speed:

Approximately 130 mph (210 km/h)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

22 Liters (5.8 US gal)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch:

Wet multi-plate, cable operated

Final Drive:

O-ring sealed chain

Features

Gear Ratios:

Specific ratios detailed in manual (e.g., 1st: 2.56, 2nd: 1.83, 3rd: 1.40, 4th: 1.11, 5th: 0.92, 6th: 0.79)

Transmission Fluid:

Refer to manual for specific API GL-4 or GL-5 gear oil requirements, capacity approximately 1.6 Liters.

📐 Dimensions

Exterior

Overall Length:

2,205 mm (86.8 in)

Overall Width:

840 mm (33.1 in)

Overall Height:

1,370 mm (53.9 in)

Wheelbase:

1,535 mm (60.4 in)

Ground Clearance:

175 mm (6.9 in)

Seat Height:

850 mm (33.5 in)

Weights

Dry Weight:

207 kg (456 lbs)

Curb Weight:

Approximately 230 kg (507 lbs) with fluids and full tank

🛡️ Safety Features

Ratings

Crash Safety Ratings:

N/A (Motorcycle specific safety is typically managed through design features and rider skill, not standardized crash test ratings like cars).

Active Features

Braking System Type:

Hydraulic disc brakes front and rear

Optional ABS:

Available on some models/markets, check VIN or specific model details.

Passive Features

Lighting:

Halogen headlight, LED taillight, turn signals.

Frame Construction:

Aluminum twin-spar frame for rigidity and light weight.

💡 Technology Features

Infotainment

Instrumentation:

Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, clock, coolant temperature indicator, gear position indicator (on some models/years).

Driver Assistance

ABS Availability:

Optional Anti-lock Braking System (ABS) on select models, enhancing braking safety.

Connectivity

Charging Port:

May have a 12V accessory socket or auxiliary charging port for GPS or electronic devices (check specific model fitment).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

At every oil change.

Air Filter Cleaning Or Replacement:

Check every 6,000 km (3,700 miles), clean or replace as needed. Replace at 12,000 km (7,500 miles).

Spark Plug Inspection:

Inspect every 12,000 km (7,500 miles), replace as needed.

Chain Adjustment:

Check and adjust every 1,000 km (600 miles) or as needed.

Valve Clearance Check:

First check at 24,000 km (15,000 miles), then every 24,000 km (15,000 miles) thereafter.

Fluid Specifications

Engine Oil Type:

API SG, SH, SJ, SL or JASO MA, MA1, MA2 compliant 10W-40 or 10W-50 semi-synthetic or fully synthetic motorcycle oil.

Engine Oil Capacity:

3.4 Liters (3.6 US qt) without filter change; 3.8 Liters (4.0 US qt) with filter change.

Coolant Type:

Permanent type antifreeze coolant (ethylene glycol based) with a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, front fork seals, wheel bearings, brake pads.

Potential Concerns:

Stator failures (common in some Suzuki V-Strom generations), cam chain tensioner wear, throttle body synchronization requiring periodic adjustment.

Recommended Upgrades:

Some owners opt for aftermarket stator upgrades for improved reliability. Regular cleaning of the radiator fins is also beneficial.

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycles:

Kawasaki Heavy Industries has a long and storied history in motorcycle manufacturing, known for performance and innovation across various categories.

Model Evolution

Klv1000 Origin:

The KLV1000 is essentially a rebadged Suzuki DL1000 V-Strom, a result of a manufacturing agreement/collaboration between Kawasaki and Suzuki. It leverages Suzuki's proven V-twin engine and chassis design.

Production Period:

Produced from 2004 to 2008, this generation was later succeeded by the revised Suzuki V-Strom 1000 (which did not carry a Kawasaki KLV badge).

Production

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Motorcycle Press Reviews:

Generally received positive reviews for its comfortable ergonomics, powerful engine, and touring capabilities, though some noted a less refined chassis compared to European competitors.

Ratings

Customer Satisfaction:

Widely regarded as a reliable and capable adventure touring machine by its owners, particularly for its value proposition.

Certifications

Emissions Compliance:

Meets emissions standards applicable to its production years and respective markets.