🏷️ Basic Information

Make:

Kawasaki

Model:

KLV1000

Model Code:

A1

Year:

2004

Type:

Sport Touring Motorcycle

Chassis Code:

KLV1000A1

👋 Introduction

Vehicle Segment:

Adventure Touring / Sport Touring

Target Audience:

Riders seeking versatility for long-distance touring and spirited riding, often drawing parallels to the Suzuki V-Strom 1000.

Key Competitors:

Suzuki DL1000 V-Strom, BMW R1150GS/R1200GS, Honda ST1300.

Engine Platform:

Shared platform with the Suzuki TL1000R/S models, utilizing the V-twin engine.

Design Philosophy:

Combines the practicality of an adventure bike with the performance characteristics of a sportbike.

Versatility:

Capable of handling varied road conditions and long-distance travel.

📋 Manual Details

Primary Coverage:

Full Service and Repair

Secondary Coverage:

Troubleshooting, Diagnostics, Maintenance

Estimated Page Count:

500+

Manual Type:

Service Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine:

Complete disassembly, assembly, inspection, and repair procedures for all engine components.

Fuel System:

Fuel injection system, throttle bodies, injectors, fuel pump, fuel pressure regulation, and evaporative emission control.

Cooling System:

Radiator, coolant flow, thermostat, water pump, and fan operation.

Ignition System:

Spark plugs, ignition coils, ECU control, and timing.

Transmission:

Clutch operation, gearbox disassembly, reassembly, gear inspection, and shift mechanism.

Drivetrain:

Final drive sprocket, chain maintenance, and lubrication.

Braking System:

Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, discs, and ABS (if equipped).

Suspension:

Front telescopic forks (including adjustable preload, compression, and rebound damping), rear monoshock absorber (including adjustable preload and rebound damping), linkage, and bearings.

Steering:

Handlebar, steering stem, head bearings, and adjustments.

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting, indicators, horn, and sensor functions.

Frame And Bodywork:

Frame inspection, fairing removal/installation, seat, fuel tank, body panels, and luggage systems.

Instruments And Controls:

Instrument cluster, switches, levers, cables, and electronic controls.

Diagnostics:

Troubleshooting guides, fault codes, and diagnostic procedures.

Scheduled Maintenance:

Detailed steps for all scheduled maintenance items, including oil changes, filter replacements, chain adjustments, and valve clearance checks.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair, with torque specifications.

Troubleshooting Guides:

Systematic approaches to diagnosing and resolving common and uncommon problems.

Technical Specifications:

Comprehensive listing of all relevant technical data, including torque values, clearances, capacities, and electrical specifications.

Wiring Diagrams:

Complete and detailed electrical system wiring diagrams.

Depth Of Coverage:

Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts.

Diagnostic Capability:

Advanced diagnostic procedures for electrical and mechanical systems.

Rebuild Instructions:

Detailed instructions for complete engine and transmission rebuilds.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for easy workshop use.

Image Resolution:

High-resolution images, diagrams, and illustrations.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

V-Twin, Four-stroke, Liquid-cooled, DOHC

Displacement:

996 cc (60.8 cu in)

Bore X Stroke:

98.0 x 66.0 mm (3.86 x 2.60 in)

Compression Ratio:

11.3:1

Horsepower Estimated:

98 hp @ 8,000 rpm (approx.)

Torque Estimated:

74.5 lb-ft @ 6,000 rpm (approx.)

Fuel Delivery:

Digital Fuel Injection with Dual 42mm Throttle Bodies

Fuel Type:

Unleaded gasoline, 91-octane or higher recommended

Oil Type:

SAE 10W-40 API SG or SH JASO MA

Oil Capacity:

3.0 L (3.2 US qt) without filter change; 3.1 L (3.3 US qt) with filter change

🔧 Transmission

Transmission Type:

6-speed, constant mesh

Clutch Type:

Wet, multi-disc

Final Drive:

Sealed chain (525 pitch)

Transmission Oil Type:

Kawasaki Genuine Transmission Oil G7 or equivalent API GL-4 SAE 75W/90

Transmission Oil Capacity:

N/A (Sealed unit, requires specific check procedure)

📐 Dimensions

Overall Length:

2,220 mm (87.4 in)

Overall Width:

825 mm (32.5 in)

Overall Height:

1,405 mm (55.3 in)

Wheelbase:

1,535 mm (60.4 in)

Ground Clearance:

175 mm (6.9 in)

Seat Height:

830 mm (32.7 in)

Dry Weight:

207 kg (456 lbs)

Wet Weight:

227 kg (500 lbs) (approx., with all fluids and standard equipment)

Fuel Capacity:

22 L (5.8 US gal)

🛡️ Safety Features

ABS:

Optional

Braking System Type:

Dual 310mm petal discs with four-piston calipers (front), Single 270mm petal disc with two-piston caliper (rear)

Tire Size Front:

110/80R19M/C 59H

Tire Size Rear:

150/70R17M/C 69H

💡 Technology Features

Instrument Cluster:

Analog tachometer, digital speedometer, odometer, trip meters, clock, fuel gauge, and indicator lights.

ABS System:

Optional anti-lock braking system for enhanced safety.

Diagnostic Ports:

On-board diagnostics connector for fault code retrieval.

🔧 Maintenance

Oil Change Interval:

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

Oil Filter Change Interval:

Every 12,000 km (7,500 miles) or 12 months.

Air Filter Cleaning:

Every 6,000 km (3,700 miles).

Valve Clearance Check:

Every 12,000 km (7,500 miles).

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after riding in wet conditions.

Coolant Type:

Kawasaki Genuine Coolant or equivalent ethylene glycol based coolant with distilled water (50/50 mix)

Coolant Capacity:

Approximately 2.0 L (2.1 US qt)

Brake Fluid Type:

DOT 4

Common Wear Items:

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

Potential Electrical Gremlins:

Wiring harness connections, regulator/rectifier reliability (common on many bikes of this era).

Engine Characteristics:

V-twin torque delivery, can be prone to vibrations if not properly maintained; some owners report valve train noise if not adjusted correctly.

📚 Vehicle History

Kawasaki Motorsports:

Kawasaki has a long and distinguished history in motorcycle racing and performance engineering, often transferring technology from its racing divisions.

Design Basis:

The KLV1000 (also known as the Versys in some markets, though this is the earlier iteration with a different design philosophy) was developed using components and engineering from Suzuki's V-twin platform, a collaborative effort in its initial development phase.

Production Period:

Early to mid-2000s (specific model year coverage of this manual is 2004).

Manufacturing Location:

Japan (typically for Kawasaki major models)

🏆 Awards & Recognition

Market Reception:

Praised for its strong V-twin engine and comfortable touring ergonomics, often considered a value alternative to more premium European adventure bikes.

Reliability:

Generally considered reliable with proper maintenance, as with most Japanese motorcycles.