This manual covers the VN900 Classic, a motorcycle model produced from 2006 through 2013. Known for its classic styling and rider-friendly performance, the VN900 Classic is built upon an esteemed legacy in motorcycle manufacturing, originating from Japan. It features a 92.0 x 84.0 mm, 892 cc liquid-cooled, 4-stroke, SOHC, V-twin engine, a 5-speed transmission with a wet, multi-disc clutch, and a belt final drive, all supported by a stable steel double-cradle frame and reliable disc brakes front and rear. The motorcycle is designed for comfortable cruising and embodies the tradition of the VN series, offering a blend of classic aesthetics and dependable engineering.
This comprehensive workshop service manual provides detailed, step-by-step instructions for the repair and overhaul of the VN900 Classic. It covers all major components, including full engine disassembly, tuning, and lubrication system maintenance, as well as transmission overhaul, complete electrical system diagnostics with wiring diagrams, and bodywork procedures. The manual also includes routine maintenance, troubleshooting guides, and assembly/disassembly instructions, using distinct symbols to highlight critical safety information and identifying special tools. This resource is designed to assist mechanical technicians, experienced mechanics, and knowledgeable owners in maintaining and repairing the vehicle, mirroring the authoritative information found in authorized dealer service departments.
Model Years Covered:
2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Target Audience:
Mechanical technicians familiar with BRP products, experienced motorcycle mechanics, and knowledgeable DIY owners.
Manual Value Proposition:
Provides authoritative information mirroring authorized dealer service departments, enabling quality service and cost savings for owners.
Safety Emphasis:
Emphasizes safety precautions and the use of proper safety equipment, including torque wrenches.
Special Tools:
Identifies and illustrates recommended or required special tools by Kawasaki part number.
Safety Symbols:
Uses distinct symbols and wording (WARNING, CAUTION, NOTE) to highlight critical information.
Coverage Scope:
Comprehensive repair and overhaul
Manual Type:
Workshop Service Manual
Engine:
Full engine disassembly, overhaul, tuning, lubrication system, fuel system, ignition system, exhaust system.
Transmission:
Full transmission disassembly and overhaul.
Electrical:
Complete electrical system diagnostics, wiring diagrams, component testing.
Bodywork:
Body panel removal and installation, frame maintenance.
Maintenance Servicing:
Routine maintenance, tune-ups, lubrication, fluid changes.
Repair Overhaul:
Detailed step-by-step repair and overhaul procedures for all major components.
Diagnostics:
Troubleshooting guides, diagnostic procedures for common and complex issues.
Assembly Disassembly:
Step-by-step instructions for assembly and disassembly of all vehicle sub-systems.
Depth Level:
Advanced diagnostics and complete rebuilds, suitable for professional technicians and skilled DIYers.
Proprietary Components:
Includes instructions for proprietary Kawasaki components and references manufacturer instructions for non-Kawasaki proprietary parts.
Printability:
Yes, printable pages
Binding Type:
Not applicable (Digital PDF)
Paper Type:
Not applicable (Digital PDF)
Delivery Method:
Fast and free electronic delivery via Email
Engine Type:
Liquid-cooled, 4-stroke, SOHC, V-twin
Displacement:
892 cc (54.4 cu in)
Bore X Stroke:
92.0 x 84.0 mm (3.6 x 3.3 in)
Horsepower:
Approximately 50-55 HP (specific dyno results vary)
Torque:
Approximately 52-55 lb-ft (specific dyno results vary)
Fuel Delivery:
Fuel Injection (DFI) with dual 36mm throttle bodies
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
20.0 L (5.3 US gal)
Ignition:
Digital CDI with electronic advance
Lubrication Type:
Forced lubrication, wet sump
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multi-disc
Overall Length:
2405 mm (94.7 in)
Overall Width:
945 mm (37.2 in)
Overall Height:
1120 mm (44.1 in)
Wheelbase:
1610 mm (63.4 in)
Ground Clearance:
140 mm (5.5 in)
Curb Weight:
265 kg (584.2 lbs)
Front Tire Size:
80/90-21M/C 48H
Rear Tire Size:
180/70-15M/C 76H
Front Brake:
276 mm disc with 2-piston caliper
Rear Brake:
270 mm disc with 1-piston caliper
Safety Features Commentary:
Manual emphasizes user safety during maintenance and repair. Specific vehicle safety ratings are not typically provided for motorcycles in service manuals.
Braking System:
Disc brakes front and rear for reliable stopping power.
Chassis Design:
Steel double-cradle frame for stability and rider confidence.
Infotainment Features:
N/A (Focus is on mechanical and electrical systems, not typically equipped with advanced infotainment).
Rider Assistance:
N/A (Focus is on mechanical and electrical systems, not typically equipped with rider-assistance electronics beyond standard braking).
Connectivity Features:
N/A
Oil Change Interval:
Refer to manual for specific mileage/time intervals (typically 6,000 km / 4,000 miles or 12 months).
Filter Replacement Interval:
Refer to manual for specific mileage/time intervals, often coincides with oil changes.
Spark Plug Replacement:
Refer to manual for specific mileage/time intervals.
Engine Oil Type:
API SG, SF or SE classification, SAE 10W-40 viscosity recommended. Refer to manual for exact specifications.
Engine Oil Capacity:
Approx. 3.0 L (3.2 US qt) without filter change, 3.2 L (3.4 US qt) with filter change.
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol based) with distilled water (50:50 mix).
Common Wear Items:
Tires, brake pads, drive belt, spark plugs, air filter, clutch plates (depending on usage).
Potential Service Points:
Regular inspection of the drive belt tension and condition, fuel injector cleaning, cooling system flush, and valve clearance adjustment.
Kawasaki Motorcycle Legacy:
Kawasaki has a long-standing reputation for building robust and performance-oriented motorcycles, with a strong lineage in the cruiser segment.
Vn Series Heritage:
The VN series represents Kawasaki's commitment to the cruiser market, offering classic styling with modern technology. The VN900 Classic builds on this tradition with a focus on comfort and rider-friendly performance.
Manufacturing Origin:
Japan
Model Awards:
Specific awards for the VN900 Classic are not widely publicized. It's known for its reliable performance and classic styling, making it a popular choice in its segment.