Instruction/ maintenance manual of the product KLV1000 (2004) Kawasaki
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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.
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GENERAL INFORMA TION 1-1 General Information Contents WARNING/CAUTION/NOTE ......................................................................................... Base Manual GENERAL PRECAUTIONS ......................................................
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.
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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.
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.
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 .
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 cauti.
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 .
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 .
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 .
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- 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.
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.
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.
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 # .
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.
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.
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.
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.
2-10 PER IODIC M A INTENA NCE (INTAKE SIDE).
PERI O DI C MAI NT EN ANCE 2 -1 1 (EXHAU ST SI DE).
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.
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.
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 " .
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.
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.
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.
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.
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.
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.
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 .
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.
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 .
An important point after buying a device Kawasaki KLV1000 (2004) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kawasaki KLV1000 (2004) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kawasaki KLV1000 (2004) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kawasaki KLV1000 (2004) you will learn all the available features of the product, as well as information on its operation. The information that you get Kawasaki KLV1000 (2004) will certainly help you make a decision on the purchase.
If you already are a holder of Kawasaki KLV1000 (2004), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kawasaki KLV1000 (2004).
However, one of the most important roles played by the user manual is to help in solving problems with Kawasaki KLV1000 (2004). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kawasaki KLV1000 (2004) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
