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Kawasaki KLV1000 (2004) manual

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Table of contents for the manual

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    SYMBOL SUZUKI DEFINITION KA W ASAKI DEFINITION Apply or use brake fluid, m Measure in voltage range. m Measure in resistance range. m Measure in current range. m Measure in diode test range. Use a suitable commercially available digital multi meter for a diode tester and measure in diode test range. Measure in continuity test range. m Use special t[...]

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    GENERAL INFORMA TION 1-1 General Information Contents WARNING/CAUTION/NOTE ......................................................................................... Base Manual GENERAL PRECAUTIONS .......................................................................................... 1-2 KAW ASAKI L V1000-A1 .....................................[...]

  • Page 9

    GENERAL INFORMA TION 1-2 GENERAL PRECAUTIONS CAUTION  If part s replacement is necessary , replace the p arts with KA W ASAKI Genuine Parts or their equivalent.  When removing parts tha t are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.  Be sure to use s[...]

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    1- 4 G ENERA L IN FORM ATI O N SU Z UKI DL1000K2 (’02-MO DEL) * Dif f erenc e be t wee n ph oto g rap hs and act ual mot orc ycl es dep en ds o n the mar k et s. SERIAL NUMBER LO CATION The fr ame serial num ber or V.I.N . (Veh i cle Identi f icati o n Num ber)  is s t amped on the r i ght sid e of the stee r ing head pipe. The engine serial n[...]

  • Page 52

    GEN ERAL INFO R M A TIO N 1 - 5 ENGI NE OIL Us e a premium q uality 4-st r oke mot or oil to ensure lon ger ser- vic e life of y o ur mo torcycle. Use only oils w hich are ra ted SF or SG u nder the AP I serv i ce class ification. T he reco mmended v i s- cosity i s SAE 10W-40. If an SAE 10W-40 mo t or oil i s not avail - abl e , selec t an alterna[...]

  • Page 53

    1- 6 G ENERA L IN FORM ATI O N BREAK-lN P R OCEDURES Dur i ng m anufactur e onl y the be s t po s sible materials a r e us ed and al l ma chined parts are fini s hed to a very high standard b ut it is still necessar y to a l low th e moving parts to “BREAK-IN” before subject ing the engine to max imum str e sses . Th e future pe r form a nce an[...]

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    GEN ERAL INFO R M A TIO N 1 - 7 INFORMATI ON LABELS Noise label (F or E-03, 24, 33) Inf ormation label (For E-03, 28, 33) ICES Canada label (F or E-28) V acuum hose routing label (For E-33) Fuel caution label (F or E-02, 24) Manual notice label (F or E-03, 33) Tire pressure label W arning safety label Rear carrier warning label F rame caution label[...]

  • Page 55

    1- 8 G ENERA L IN FORM ATI O N SPECIFI CATIONS DIMENSIONS AND DRY MASS Over all lengt h ............ .................. ................... ...... 2 2 95 mm ( 90.4 i n ) Over all widt h ...... ............. ................... ............ ...... 865 mm (34 . 1 in) Over all heigh t ............ .................. ................... ...... 1 3 35 m[...]

  • Page 56

    GEN ERAL INFO R M A TIO N 1 - 9 CHASSIS Fro n t su s pens ion ............... ................... ............ ... In v erte d telesc opic, coil s p rin g , oil d amped Rear suspens ion ......... ................... ............ ......... Link t y pe, c oil spring, oil dam ped Ste e rin g angl e ....... ............ ................... ............[...]

  • Page 57

    1-10 GE N ER AL INF ORMA TION COUNTRY AND AREA CODES The foll o wing code s stand for the appl i cabl e cou n try ( -ies) a nd area( - s). COD E COU NTR Y o r ARE A E-02 E-03 E-19 E-24 E-28 E-33 U. K. U . S . A. ( Ex ce p t f or Ca l if orni a) EU Aus tra lia Can ada Cal if or ni a ( U . S. A . )[...]

  • Page 58

    2 6 P ERIOD I C MA I NTENA NCE 2 - 1 CONTENTS PERIOD I C MAINTENANCE PERIODIC MAINT ENANCE SCHEDULE ............... ......... .......... ......... . 2- 2 PERIODIC MAINT ENANCE CHART .............. ......... ................... . 2 - 2 LUBRICATION POINTS ...... ......... .......... ......... ................... ......... . 2- 3 MAINTENANCE AND TUNE-[...]

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    2- 2 P ER IO DI C M AIN T E NANCE PERIODIC MAINTENANCE SCHEDULE The chart b e low l ists the recomm ended i nter v als for all the r e q u ired p er iod i c s e rvice work n e cess a ry to keep the mo torcycle op erating at pea k p e rforma nce and ec onomy. M i leages a r e e xpr es sed in terms o f kilom e - ters , miles and ti m e for y our conv[...]

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    P ERI OD I C MA INT ENA NCE 2- 3 LUBRICAT ION POINTS Proper l ubricati on is import ant for smooth operatio n and long l ife of each worki ng par t of the motorcycl e. M a jor lu bri ca t ion po ints are ind i cated below. NOT E: * Befo r e lubr i catin g each pa r t, c l ean off any rus t y spot s and wipe off any gre a se, o i l, di r t or g r im[...]

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    2- 4 P ER IO DI C M AIN T E NANCE MAINTENANCE AND T UNE-UP P R O- CEDURES Thi s secti on des cr ibe s the s ervic ing proc edures fo r eac h item o f the P eriodic M aintenance r equi rements. AIR CLEANER • R emove th e seat. (  6- 4 ) • R emove th e fuel tan k. (  4-52) • R emove th e air clean er box cap  . • R emove th e air cle[...]

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    P ERI OD I C MA INT ENA NCE 2- 5 NOT E: Wh en cleaning th e air cle aner elemen t, drain w a ter from the air clean er by remo ving th e drain plug. SPARK PLUG NO .1 (FRON T) S P AR K PLUG REM OVAL • Rem ove the sp ar k p lug moun ting bolts " an d # . • Move the rad i ator for ward. • Rem ove the sp ar k p lug cap  . NOT E: Be carefu[...]

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    2- 6 P ER IO DI C M AIN T E NANCE NO. 2 ( R EAR) SPA RK P LU G RE MOV AL • R emove th e seat. (  6- 4 ) • L i ft and suppor t the fuel tank. (  4- 51) • R emove th e spark p l ug ca p. • R emove th e spark p l ug w ith a spar k plug wr ench. HEA T RA NGE • C heck to s e e the heat r ange of the plug. CARB O N DEP OS IT • C heck to[...]

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    P ERI OD I C MA INT ENA NCE 2- 7 SP ARK P L UG AND PL UG CA P INST ALLAT I ON  • Instal l the spar k plugs to the c yl ind e r head s by fing er tigh t, and then tighte n them to the spe ci fie d torque. " Spar k plu g: 11 N·m (1 .1 kgf- m, 8.0 l b-f t) NOT E: Wh en fitting the sp ark plu g ca ps, front and r ear, face th e triangle ma r[...]

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    2- 8 P ER IO DI C M AIN T E NANCE • Rem ove the ge nerator co ver plug  and t i mi ng in s p ec ti on pl ug  . • T urn the cr an ks haft to set th e No.1 (F ront ) cyl inder at T DC of com pression s t roke. ( Alig n the “F | T ” li n e on the generator roto r to the inde x mark of val v e timin g insp ection hole an d also bring th e[...]

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    P ERI OD I C MA INT ENA NCE 2- 9 TAP PET C LEA RANCE ADJU STMENT The clearanc e is adjus t ed by repl aci ng the ex isting tappet s h im by a thicker or thinner s h im. • Rem ove the int ake or e x haust camsha fts. (  3- 20) • Rem ove the t appet and s h im by finger s or mag netic h and. • Che c k the fi gures printed on the s him . Thes[...]

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    2-10 PER IODIC M A INTENA NCE (INTAKE SIDE)[...]

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    PERI O DI C MAI NT EN ANCE 2 -1 1 (EXHAU ST SI DE)[...]

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    2-12 PER IODIC M A INTENA NCE FUEL HOSE Insp ect the f uel feed h o se " for damag e and fuel l eaka ge. If any defects ar e found, th e fuel hos es must be replace d . ENGINE OIL AND OIL FIL T ER Oil should be ch anged w h ile th e engine i s war m. Oil filter replac ement at the a bove inter vals, sh ould be done toge ther with the engi ne o[...]

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    PERI O DI C MAI NT EN ANCE 2 -1 3 • Star t up the en gine and all o w it to run for sever a l m i nutes at idli ng speed. • Turn off the eng i ne and wai t about one mi nute, then c heck the oil l e vel thr ough the inspe ction win dow " . If the le vel is bel ow mark “L” , add oil to “F” level. If the level is above mark “F”, [...]

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    2-14 PER IODIC M A INTENA NCE ENGINE IDLE SPE ED NOT E: Mak e th i s adj u stm ent when th e engine i s ho t. • St a rt u p the engine and set its id l e spe ed to the sp ec ified rang e by turning the thr ottle stop scr ew " .  En gine idle speed: 1 2 00 ± 10 0 r/min THROTTLE CABLE PL AY Ad j ust the throttle c able p l ay " wi th [...]

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    PERI O DI C MAI NT EN ANCE 2 -1 5 MA J OR A D JU ST ME N T • Rem ove the f uel tank. (  4-52) • Rem ove the a i r clean et box. (  4-60) • Loose n the loc knut  of the th r ottl e returning cable. • T urn the re turning cab l e adjuster  t o ob t ai n pr op e r c ab le pl ay. • Loose n the loc knut  of the th r ottl e pulli[...]

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    2-16 PER IODIC M A INTENA NCE CLUTCH CLUT C H FLUID L EVEL • Keep the motor cycle u pright and pla ce the ha ndlebars straig ht. • C heck the clutch fluid le vel by ob s e r ving the lower limit l ine o n the c lutch fl uid reserv oi r. • If the level is foun d to b e low e r th an the lower mar k, reple n ish wi th BRAKE F LUID that th e fol[...]

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    PERI O DI C MAI NT EN ANCE 2 -1 7 COOLING SYSTEM ENG INE COOL ANT L EVEL CHE CK • Keep th e motorcycle upright. • Che c k the engi ne coolant leve l by o b serv i ng the full an d l ower lines on the e ngine cool ant reser v e tan k. " Full li ne # Lowe r l ine • If the level is be l o w the lower line, add engine c oolant to th e ful l [...]

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    2-18 PER IODIC M A INTENA NCE AIR BLEED ING TH E ENG I NE C OOL ANT CIR CUIT • B le ed ai r fr o m th e a i r bl ee d er bo lt  . • T ighten th e ai r bl eeder bo l t  to th e spec i fied to rque. " Ai r b leeder b olt: 13 N· m (1.3 kg f-m, 9.5 l b -ft) • Ad d engine coolan t up to the r a dia t or inl e t. • Support t he m otor[...]

  • Page 76

    PERI O DI C MAI NT EN ANCE 2 -1 9 RADI AT O R HOSE S Chec k to see the rad i ator hos e s for crac k, damage o r engine co ol an t l eak a g e. If any defects a r e found, rep l ace the r adi ator hoses with new ones . DRIVE CHAIN Visu al ly c heck the dr ive chain f o r the p ossible de fects liste d bel o w. ( Suppo r t the mo torcycle b y a jack[...]

  • Page 77

    2-20 PER IODIC M A INTENA NCE • C ount out 21 pi ns ( 20 pi tches) on the chain and measu re the dista nce betwe en the tw o points. If the dis tanc e exceeds the serv ice limit, th e chain must be rep l ac ed.  Driv e ch ain 20-pi t ch l engt h Ser vice Lim i t: 3 19.4 mm ( 12.6 in) AD JUS TI NG • L oosen or ti ght en both chai n adjuster s[...]

  • Page 78

    PERI O DI C MAI NT EN ANCE 2 -2 1 CL EANI NG A ND LUBR I CA TING • Was h the chain w i th ker o sene . If the chain ten ds to rust quickly, the inter vals must be short ened.  • After washing and d r ying the cha i n, oil it with a heavy- weight mo tor oil .  BRAKE BRAK E FL UI D L EVE L C HECK • Keep the mot orc ycl e upright and plac [...]

  • Page 79

    2-22 PER IODIC M A INTENA NCE # # • R emove th e brake c a liper . (Front ) BRAK E P ADS The e x tent o f br ak e pad wear can be chec ked by obs erving th e groo v ed l i mit " on the pad . When th e wear exc eeds th e groo v ed l imit, rep l ace the pads wi th new o nes. (  6- 57 , 67 )  The brake sys t em o f t his m ot o rcycl e is[...]

  • Page 80

    PERI O DI C MAI NT EN ANCE 2 -2 3 BRAK E P EDA L HE IG HT • Loose n the locknut  a nd ro tate the push rod  to loca te bra k e p edal 20 – 30 mm (0.8 – 1.2 i n) " be l o w the top fac e of the f ootrest. • Reti ghten th e locknu t  to secur e the push ro d  in th e pro per position .  Brake pe dal heig ht " : 2 0 ?[...]