Vehicle Segment:
Adventure Touring (ADV) Motorcycle.
Target Audience:
Riders seeking a versatile machine for long-distance touring, commuting, and light off-road exploration.
Key Competitors:
Suzuki V-Strom DL1000, Honda Varadero XL1000V, BMW R1150GS/R1200GS (early models).
Platform Sharing:
The KLV1000 shares its core V-twin engine and chassis components with the Suzuki DL1000 V-Strom, highlighting a significant manufacturing collaboration.
General Coverage:
Comprehensive mechanical and electrical systems for the 2004 Kawasaki KLV1000.
Page Count:
Extensive, likely several hundred pages (specific count not provided in product info, typical for workshop manuals).
Manual Type:
Workshop Service Repair Manual
Language:
English (typical for global models, confirm if possible)
Format:
Likely Digital (PDF) - searchable, printable, with diagrams.
Engine Systems:
Engine overhaul, top-end, bottom-end, cooling system, lubrication system, fuel injection system, ignition system, exhaust system.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and reassembly, final drive (chain and sprockets).
Chassis Frame:
Frame inspection, steering head bearing service, suspension (front forks, rear shock absorber), swingarm.
Braking System:
Brake caliper overhaul, master cylinder service, brake line replacement, hydraulic system bleeding, pad replacement.
Electrical System:
Wiring diagrams, lighting system, starting system, charging system (alternator, battery), instrument cluster, sensor diagnostics.
Fuel System:
Fuel tank service, fuel pump operation, fuel injectors, fuel pressure testing.
Bodywork Fittings:
Fairing removal and installation, seat service, fuel tank cover, side panels.
Maintenance Procedures:
Routine maintenance checks, oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment and lubrication.
Troubleshooting Guide:
Diagnostic charts for common issues, symptom-based problem solving.
Disassembly Reassembly:
Step-by-step instructions for major component removal and installation.
Torque Specifications:
Detailed torque values for all critical fasteners and bolts.
Diagnostic Capabilities:
Advanced diagnostic procedures, including sensor testing and electronic control unit (ECU) interactions.
Repair Complexity:
Suitable for both home mechanics and professional technicians, covering everything from basic adjustments to full engine rebuilds.
Special Tools:
Identification and usage of specialized tools required for certain procedures.
Engine Type:
90-degree V-twin, four-stroke, liquid-cooled, DOHC, 8 valves.
Bore X Stroke:
98 mm x 66 mm
Horsepower:
Approx. 98 HP @ 8,000 RPM (rated at crankshaft)
Torque:
Approx. 100 Nm (74 lb-ft) @ 6,500 RPM (rated at crankshaft)
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle valves.
Ignition System:
Digital ignition with two spark plugs per cylinder.
Oil Type:
API SG, SF, or SG/CD, SAE 10W-40 or 10W-50 (check manual for precise recommendations).
Oil Capacity:
Approx. 3.4 Liters (3.6 US qt) with filter change.
Transmission Type:
6-speed constant mesh sequential.
Optional Transmission:
N/A (Single standard transmission)
Clutch Type:
Wet, multi-plate.
Final Drive:
O-ring sealed chain drive.
Transmission Fluid:
SAE 80W GL-4 Gear Oil (for gearbox, check manual for exact specification).
Length:
Approx. 2,200 mm (86.6 in)
Width:
Approx. 865 mm (34.1 in)
Height:
Approx. 1,380 mm (54.3 in)
Wheelbase:
Approx. 1,535 mm (60.4 in)
Dry Weight:
Approx. 207 kg (456 lbs)
Wet Weight:
Approx. 230 kg (507 lbs) (fully fueled and ready to ride)
Fuel Tank Capacity:
22 Liters (5.8 US gal)
Safety Ratings:
N/A (Motorcycle safety is typically assessed through independent reviews and rider experience rather than formal crash ratings like cars).
Braking System Type:
Dual hydraulic disc front, single hydraulic disc rear.
ABS Availability:
ABS was an optional feature on some models, not standard across all KLV1000s.
Lighting:
Halogen headlights, LED taillight, amber turn signals.
Infotainment Features:
Basic instrumentation: Speedometer, tachometer, fuel gauge, coolant temperature gauge, trip meters, clock. No advanced infotainment systems were standard.
Driver Assistance Features:
ABS (optional), standard ABS was not a focus for this generation of adventure bikes.
Connectivity Options:
N/A (No Bluetooth or smartphone integration).
Oil Filter Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Inspection:
Every 12,000 km (7,500 miles).
Spark Plug Replacement:
Every 24,000 km (15,000 miles).
Valve Clearance Check:
Every 24,000 km (15,000 miles).
Coolant Type:
Ethylene glycol-based coolant, 50% solution with distilled water. (Refer to manual for specific type like Kawasaki's KLC).
Common Wear Items:
Cam chain tensioner (potential for rattle), clutch plates, wheel bearings, stator (early models).
Fuel System Considerations:
Fuel pump diaphragm can be a point of failure over time; injector cleaning may be required.
Electrical Reliability:
While generally robust, regulator/rectifier issues can sometimes occur in older bikes.
Kawasaki History:
Kawasaki Heavy Industries is a Japanese conglomerate with a long-standing history in motorcycle manufacturing, known for performance and reliability.
Klv1000 Origin:
The KLV1000 (also known as the Kawasaki KLR1000 in some markets) was introduced as Kawasaki's entry into the burgeoning adventure-touring segment. It leveraged the popular engine and platform from the Suzuki DL1000 V-Strom, a result of a significant alliance between Kawasaki and Suzuki.
Production Years:
2004 - 2006 (brief production run before being replaced).
Manufacturing Location:
Likely Japan, utilizing components from the Suzuki collaboration.
