HLE Kavlyr
Heavy-duty chassis, serious capacity. Up to 35 passengers + 10 wheelchair positions — built to order in Wakarusa, Indiana, sold and supported by BRBS.
The Kavlyr, In Plain Terms
The Kavlyr is what you buy when the E-Series runs out of bus. Ford F-550 and F-600 chassis carry more passengers, more wheelchair positions, and more GVWR headroom — in gas or diesel — without stepping up to a freight chassis.
It’s built for high-utilization work: transit contractors, campus loops, large senior living campuses, and routes where 29 passengers plus luggage is a Tuesday, not a special event.
Best fit for
Chassis Options
| Chassis | GVWR | Power |
|---|---|---|
| Ford F-550 | 19,550 lb GVWR | Gas (gaseous prep) or diesel |
| Ford F-600 | 22,000 lb GVWR | Gas or diesel |
205" to 267" wheelbase · Body lengths from 241" to 318" (HLE-27 through HLE-37). Specifications from HLE's 2026 order program and the manufacturer's published spec tables — confirm final configuration with BRBS.
Standard on Every Kavlyr
- Electric passenger entry door with interior light and step light
- 36" passenger door rough opening (42" available)
- Welded, powder-coated steel-cage construction
- PerformMAX 500 composite subfloor — 7-year / unlimited-mile warranty
- One-piece Filon sidewalls, roofline to skirt + Impact Guard roof
Kavlyr Specifications
The numbers fleet managers and boards ask for, as published by High Level Enterprises. Every Kavlyr is built to order, so exact figures depend on chassis and floor plan — we confirm them on your quote.
| Passenger capacity | Up to 35 passengers · up to 10 wheelchair positions |
|---|---|
| Model sizes | HLE-27 – HLE-37 |
| Chassis | Ford F-550 · Ford F-600 |
| Engine | Diesel or gas |
| GVWR | 19,550 lb (F-550) · 22,000 lb (F-600) |
| Fuel options | Gas · diesel · propane · CNG |
| Fuel tank | 40 gal |
| Alternator | 410 A |
| Wheelbase | 205 – 267 in |
| Body length | 241 – 318 in |
| Body width (mirrors excluded) | 96 in |
| Interior width | 92 in, wall to wall |
| Overall height | 126 in without roof-mounted A/C |
| Interior standing height | 79.5 in (raised floor) |
| Entry | 4-step · 11.25 in ground to first step |
| Aisle width | 17 in seat to seat |
| Entry door | 36 in rough opening (33 in clear) · 42 in optional · 82 in opening height |
| Wheelchair lift | Braun 800 – 1,000 lb · 34×51 to 37×54 in platforms |
| Passenger seats | 17.5 in standard · 19 in upgrade · 26 – 42 in spacing |
| Air conditioning | 70,000 – 170,000 BTU |
| Body structure | 1.5 × 1.5 in welded steel cage, fully powder-coated |
| Sidewalls (dual-door builds) | Molded fiberglass lower skirt over the same one-piece wall |
| Insulation | 1.5 in closed-cell EPS, cut to fill each cavity · R-5.85 |
| Luggage | Rear compartment · overhead · interior rack |
| Testing | FMVSS compliant · being built for the FTA Altoona test track |
| Typical build time | 90–120 days from order (2026 average: 92 days) |
Warranty — Three Terms, Nothing Prorates
- Bumper-to-bumper
- 3 years / 36,000 miles
- Body & conversion
- 5 years / 100,000 miles — body structure, framing, roof and sidewalls, floor structure, body attachment, HLE-built interior components, HLE-installed electrical, HLE paint workmanship (Revision 1, September 2026)
- PerformMAX 500 subfloor
- 7 years / unlimited miles — the longest floor coverage in the shuttle bus market (owner inspects sealants every six months and keeps records)
- Proration
- None. Coverage in year five is worth what it was on day one.
Chassis, lift, and HVAC carry their own manufacturers' warranties; HLE covers its installation of them. BRBS sets up warranty work with a qualified shop near you. Full documents at the manufacturer's warranty page.
Testing
FMVSS compliant · being built for the FTA Altoona test track
Buy America certification is provided per order for federally funded purchases (49 CFR 661). HLE holds state transit contracts in Washington (WSDOT), Oregon, and Minnesota.
From the Manufacturer
High Level Enterprises publishes the full spec sheet, 133 filterable seating layouts, and the complete options catalog. Browse there, then tell us the plan number — we quote it.
Kavlyr Gallery
Floor Plans to Start From
Real build examples — every Kavlyr is built to order, so seating, wheelchair positions, and luggage flex to your routes. Tell us the mission and we'll lay it out.
Ford F-550
Click any floor plan to open the full-size image.
Price a Kavlyr for Your Operation
Tell us when you need it and where it's going. You get a real number for the configuration you're looking at, the current build slot (90 to 120 days from order to delivery; HLE's 2026 average is 92 days), and a call from a BRBS rep within 5 minutes during business hours.
Replacing a bus? We take trades and buy outright.
Want the full document? Download the 2026 Kavlyr brochure (PDF)
Other models
Get Your Price on the Kavlyr
Thirty seconds. Real number, current build slot.
Got it — your written price lands today.
Built to order — 90 to 120 days from order to delivery
A BRBS rep will call within 5 minutes during business hours (Mon–Fri, 9–5 Eastern) with the number, and you'll have it in writing in your inbox the same day. Financing is available through our lender partner.
Ready to talk?
Whether you know exactly what you need or you’re just kicking tires, we’ll listen first and quote second.
3175 East Andrew Johnson Hwy, Greeneville, TN 37745 · Mon–Fri 9–5 · [email protected]