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KAWASAKI VN900 VULCAN 900 Custom 2007-2015 Service Repair Manual

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The Kawasaki VN900 Vulcan 900 Custom is a cruiser motorcycle produced between 2007 and 2015, celebrated for its classic styling, reliable V-twin engine, and comfortable ride. This model, part of...
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KAWASAKI VN900 VULCAN 900 Custom 2007-2015 Service Repair Manual
The Kawasaki VN900 Vulcan 900 Custom is a cruiser motorcycle produced between 2007 and 2015, celebrated for its classic styling, reliable V-twin engine, and comfortable ride. This model, part of Kawasaki's esteemed Vulcan lineage, features a liquid-cooled, 892 cc V-twin engine, electronic fuel injection, and a 5-speed transmission, delivering approximately 50 HP and 70 Nm of torque. Its design emphasizes customizable aesthetics, making it a popular choice for riders seeking a blend of traditional cruiser appeal and modern engineering. The VN900 Custom is known for its smooth performance and high owner satisfaction, solidifying its position in the cruiser motorcycle segment. This comprehensive Service Repair Manual provides detailed information for the Kawasaki VN900 Vulcan 900 Custom (model code VN900B) across its production years. It covers all essential systems, including engine overhaul, fuel injection, transmission, drivetrain, suspension, brakes, and electrical systems, along with chassis and bodywork. The manual includes procedures for regular maintenance, troubleshooting common and uncommon issues, and step-by-step repair instructions for all major components. With accurate, clear text and high-quality diagrams, this professional technical manual is designed to empower owners, experienced mechanics, and repair shops to effectively maintain and repair the vehicle, ensuring its longevity and optimal performance.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
VN900 Vulcan 900 Custom
Model Code:
VN900B
Years Covered:
2007-2015
Codes
Chassis Code:
VN900B
👋 Introduction
Market Position
Segment:
Cruiser Motorcycle segment
Competitors:
Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series
Key Features
Value Proposition:
Comprehensive service and repair information, empowering owners to perform maintenance and repairs themselves, saving time and money.
Accessibility:
Instant download access for immediate use, ideal for on-the-trail or roadside repairs via smart devices.
📋 Manual Details
Coverage Areas
Product Type:
Service Repair Manual
Target Audience:
Do-it-yourself owners, experienced mechanics, local service repair shops
Page Count
Estimated Page Count:
Detailed, comprehensive (actual page count not specified but implied to be extensive)
Manual Type
Type:
Professional Technical Manual
Language
Language:
English
Format
Format:
PDF (Portable Document Format)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, tuning, troubleshooting, lubrication systems, cooling system
Fuel System:
Fuel injection system (EFI), throttle body, fuel pump, fuel filter, fuel tank service
Transmission:
Clutch system, gear shift mechanism, internal transmission components, lubrication
Drivetrain:
Belt drive system, rear wheel drive, final drive inspection and adjustment
Suspension:
Front fork (telescopic) service, rear shock absorber replacement and adjustment, linkage inspection
Brakes:
Front and rear brake system service, hydraulic system, caliper overhaul, pad replacement, rotor inspection
Electrical System:
Ignition system, starting system, charging system (alternator, regulator/rectifier), lighting, wiring diagrams, battery service, ECU diagnostics
Chassis:
Frame inspection, steering system service (headset bearings), wheel bearings, tire service
Bodywork And Fittings:
Fender replacement, seat service, handlebar installation/adjustment, fuel tank mounting, exhaust system maintenance
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, lubrication points, brake fluid changes, coolant checks
Troubleshooting:
Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides
Repair:
Step-by-step repair instructions for all major components and systems, including complete disassembly and reassembly
Diagnostics:
Fault code interpretation (if applicable), sensor testing, electrical system diagnostics
Technical Depth
Depth:
Comprehensive, covering everything from basic adjustments to full engine rebuilds and electrical system diagnostics
📊 Manual Specifications
File Format
Compatibility:
Requires Adobe PDF Reader for optimal display of images and graphics
Print Quality
Diagrams Quality:
Top quality diagrams, highly detailed exploded pictures and illustrations
Text Clarity:
Accurate, clear, and concise text
Binding Type
Binding:
Digital Download (no physical binding)
Paper Type
Digital Format Benefit:
Printable pages as needed, preventing damage to original manual with grease and dirt
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, Four-stroke, SOHC, 8-valve
Displacement:
892 cc (54.4 cubic inches)
Bore X Stroke:
88.0 mm x 74.0 mm (3.46 in x 2.91 in)
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 50 HP @ 5,700 rpm (specifications vary slightly by region and year)
Torque:
Approx. 70 Nm (52 ft-lb) @ 3,500 rpm (specifications vary slightly by region and year)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle valves
Fuel Type:
Unleaded gasoline, minimum 87 octane (AKI) or 91 octane (RON)
Lubrication
Oil Type Specification:
API SG, SF, SH, SJ, SL, SM or higher, SAE 10W-40 recommended (check specific manual for exact specs)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Optional
Transmission Options:
N/A (standard 5-speed manual)
Features
Clutch:
Wet, multiple-disc, cable-actuated
Final Drive:
Belt drive
Fluid Capacity
Transmission Oil Capacity:
Refer to manual for exact capacity, typically around 1.8-2.0 liters (check specific manual)
📐 Dimensions
Exterior
Overall Length:
Approx. 2,385 mm (93.9 in)
Overall Width:
Approx. 895 mm (35.2 in)
Overall Height:
Approx. 1,135 mm (44.7 in)
Weights
Curb Weight:
Approx. 272 kg (600 lbs)
Fuel Tank Capacity:
20.0 Liters (5.3 US gal)
Wheels And Tires
Front Tire Size:
80/90-21M/C 44H
Rear Tire Size:
180/70-15M/C 76H
Front Wheel Size:
21 x MT2.15
Rear Wheel Size:
15 x MT4.50
🛡️ Safety Features
Ratings
Safety Features:
Dual-piston front brake caliper, single-piston rear brake caliper, integrated braking system (optional on some models, primarily the standard VN900 Vulcan)
Active Features
Braking System:
Hydraulic disc brakes front and rear
Passive Features
Lighting:
Halogen headlamp, LED tail lamp
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer, digital tachometer, fuel gauge, clock, odometer, trip meters, indicator lights.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) available as an option on some models within the VN900 range, but not standard on all VN900 Custom variants.
Connectivity
Connectivity Features:
N/A (focus is on mechanical and electrical systems, not advanced connectivity features like Bluetooth or smartphone integration).
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first (refer to manual for specific interval)
Air Filter Inspection:
Every 6,000 km (3,700 miles) or 6 months
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months
Coolant Replacement:
Every 24,000 km (15,000 miles) or 24 months
Fluid Specifications
Brake Fluid:
DOT 4 (refer to manual for exact specification)
Coolant:
High-quality ethylene glycol-based coolant, 50/50 mix with distilled water
Known Issues
Common Wear Items:
Tires, brake pads, drive belt, clutch plates (dependent on usage and maintenance)
Potential Issues:
Occasional carburetor cleaning required for older models (though VN900 is EFI), potential drive belt wear with aggressive riding.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycles:
Kawasaki Heavy Industries Motorcycle & Engine Company is a Japanese manufacturer with a long history of producing high-performance motorcycles and engines.
Model Evolution
Vulcan Lineage:
The Vulcan series has been a staple in Kawasaki's cruiser lineup since the late 1980s, known for its V-twin engines and classic styling. The VN900 Custom represents a modern iteration focused on customizable aesthetics and reliable performance.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Industry Reputation:
Consistently praised for its smooth V-twin engine, comfortable ride, and classic styling, making it a popular choice for cruiser enthusiasts.
Ratings
Owner Satisfaction:
Generally high owner satisfaction due to reliability and classic cruiser appeal.
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