🏷️ Basic Information

Make:

Kawasaki

Model:

KLV1000

Model Designation:

Suzuki DL1000 V-Strom based adventure tourer

Years Covered:

2003, 2004, 2005

Chassis Codes:

Based on Suzuki DL1000 V-Strom platform, specific Kawasaki KLV1000 chassis codes may apply but are not explicitly detailed in provided information. Generally, these would align with DL1000 identification.

Engine Codes:

Based on Suzuki DL1000 V-Twin engine. Specific Kawasaki variants or designations not detailed.

👋 Introduction

Market Position:

The Kawasaki KLV1000, a rebadged Suzuki DL1000 V-Strom, was positioned as a versatile adventure touring motorcycle, capable of both long-distance highway cruising and light off-road exploration.

Competitive Analysis:

Competed in the large-displacement adventure touring segment against models like the BMW R1150GS, Honda Varadero XL1000V, and Triumph Tiger.

Key Features:

Torquey V-twin engine, comfortable ergonomics for long rides, adjustable windscreen, robust chassis, dual-purpose capability.

📋 Manual Details

Coverage Areas:

Comprehensive repair and maintenance for Kawasaki KLV1000 2003-2005 models.

Page Count:

525

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Systems Covered:

Engine (including disassembly, assembly, and internal components), Fuel System, Ignition System, Transmission, Drivetrain, Clutch, Cooling System, Lubrication System, Suspension (Front and Rear), Brakes (Front and Rear), Electrical System (Wiring Diagrams, Components), Chassis, Frame, Bodywork, Instruments, Controls, Exhaust System, Wheels, Tires.

Procedures Included:

Routine Maintenance, Scheduled Service, Troubleshooting, Diagnostics, Component Removal and Installation, Disassembly and Assembly, Adjustments, Repairs, Specifications, Torque Values, Diagrams, Illustrations, Pictorials, Special Tool Usage, Wear Limits.

Technical Depth:

Detailed step-by-step procedures, including basic maintenance to complex engine and electrical system repairs. Covers factory specifications, allowable limits, and diagnostic flowcharts. Suitable for both novice DIY mechanics and experienced technicians.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

Printable pages, allowing users to print individual sections or the entire manual. Quality is dependent on the user's printer.

Binding Type:

Digital Download (No physical binding, user printable)

Paper Type:

Not applicable (Digital format)

⚙️ Engine Specifications

Primary Engine:

90-degree V-twin, four-stroke, liquid-cooled, DOHC, 4 valves per cylinder.

Displacement:

996 cc (60.8 cubic inches)

Bore X Stroke:

98.0 mm x 66.0 mm (3.86 in x 2.60 in) - Aligned with DL1000 specifications.

Compression Ratio:

11.3:1 - Aligned with DL1000 specifications.

Horsepower:

Approx. 98 HP (73 kW) at 7,600 rpm (varies slightly by region/tuning) - Aligned with DL1000 specifications.

Torque:

Approx. 76 lb-ft (103 Nm) at 6,400 rpm (varies slightly by region/tuning) - Aligned with DL1000 specifications.

Fuel System:

Electronic Fuel Injection (EFI) with twin throttle bodies.

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2 / AKI 87.

Lubrication System:

Wet sump, forced lubrication.

Cooling System:

Liquid-cooled.

Ignition System:

Digital CDI with electronic ignition timing advance.

🔧 Transmission

Transmission Type:

6-speed constant mesh, sequential manual.

Optional Transmission:

None.

Clutch Type:

Wet, multiple-disc, manual operation.

Final Drive:

O-ring sealed chain drive.

📐 Dimensions

Overall Length:

Approx. 2,270 mm (89.4 in) - Aligned with DL1000 specifications.

Overall Width:

Approx. 850 mm (33.5 in) - Aligned with DL1000 specifications.

Overall Height:

Approx. 1,385 mm (54.5 in) - Aligned with DL1000 specifications.

Wheelbase:

Approx. 1,535 mm (60.4 in) - Aligned with DL1000 specifications.

Dry Weight:

Approx. 207 kg (456 lbs) - Aligned with DL1000 specifications.

Wet Weight:

Approx. 230 kg (507 lbs) (fully fueled) - Aligned with DL1000 specifications.

Fuel Capacity:

22 liters (5.8 US gal) - Aligned with DL1000 specifications.

🛡️ Safety Features

Safety Ratings:

No specific independent safety ratings typically provided for motorcycles of this era in the same way as automobiles. Focus is on manufacturer-specified safety features and design.

Active Features:

Dual disc front brakes with 310mm rotors, single disc rear brake with 260mm rotor. Optional ABS available on some models/markets.

Passive Features:

Sturdy chassis construction, integrated fairing for wind protection, hand guards, substantial lighting for visibility.

💡 Technology Features

Infotainment Features:

Basic instrumentation with analogue tachometer, digital speedometer, odometer, trip meter, fuel gauge, and clock. No advanced infotainment systems.

Driver Assistance Features:

Optional ABS (Anti-lock Braking System) available on some models. Otherwise, standard mechanical and electrical systems.

Connectivity Features:

None.

🔧 Maintenance

Initial Service:

Typically around 600-1000 miles (1000-1600 km) for first service, including oil and filter change, chain adjustment, and general inspection.

Regular Maintenance Interval:

Annual or every 3,750 miles (6,000 km), whichever comes first, for checks like valve clearance, spark plugs, air filter, and brake fluid.

Engine Oil Type:

SAE 10W-40, API SG or higher, JASO MA certified. Recommended brands include Kawasaki Genuine Oil, Motul, Castrol, Mobil 1. (Consult manual for precise OEM recommendations).

Engine Oil Capacity:

Approx. 3.4 liters (3.6 US qt) without filter change; Approx. 3.6 liters (3.8 US qt) with filter change. (Verify in manual).

Coolant Type:

Ethylene glycol based coolant with anti-corrosion additives, mixed 50/50 with distilled water. (Consult manual for specific Kawasaki or Suzuki approved coolant).

Brake Fluid Type:

DOT 4.

Transmission Oil Capacity:

Not applicable, transmission shares engine oil.

Fork Oil Type:

SAE 10W fork oil (typically around 470-480 ml per leg). (Verify exact specification and volume in manual).

Known Issues:

Stator failures (leading to charging system issues), rear shock absorber wear, occasional cam chain tensioner noise, clutch judder under certain conditions. Regular maintenance is key to mitigating these.

Oil Filter Part Number:

Kawasaki: 16097-1001 or equivalent aftermarket like Hiflofiltro HF138 or K&N KN-138.

Air Filter Part Number:

Kawasaki: 11013-1287 or equivalent aftermarket like K&N KA-9900.

📚 Vehicle History

Brand Heritage:

Kawasaki has a long history in motorcycle manufacturing, known for performance and innovation across various segments, including sportbikes, cruisers, and off-road machines. The KLV1000 represented their entry into the adventure touring market through a strategic partnership/rebadging.

Model Evolution:

The KLV1000 is essentially a rebadged Suzuki DL1000 V-Strom. This arrangement allowed Kawasaki to quickly offer a competitor in the burgeoning adventure touring segment without the extensive development costs. The underlying platform was designed by Suzuki.

Production Period:

Kawasaki KLV1000 produced for model years 2004-2006. The platform itself (Suzuki DL1000) had a longer production run starting in 2002.

🏆 Awards & Recognition

Recognitions:

While the Kawasaki KLV1000 itself may not have specific awards, the underlying Suzuki DL1000 V-Strom platform received positive reviews from motorcycling publications for its versatility and value in the adventure touring segment.

User Ratings:

Generally well-regarded by owners for its comfort, reliability (with proper maintenance), and capable V-twin engine. Long-distance comfort is often highlighted.

Certifications:

Meets all relevant emissions and safety certifications for the respective model years in the markets where it was sold.