Segment:
Mid-size cruiser motorcycle.
Target Audience:
Riders seeking a stylish, reliable, and customizable cruiser with a V-twin engine, suitable for commuting and touring.
Competitors:
Honda Shadow 750, Yamaha V-Star 950, Suzuki Boulevard C50, Indian Scout (though the Scout is a more premium offering).
Styling:
Sleek, modern custom cruiser aesthetic with a low seat height, prominent V-twin engine, and often featuring chrome accents, custom handlebars, and unique paint schemes.
Engine:
Liquid-cooled, 852cc (approx. 52 cu in) SOHC V-twin engine known for its smooth power delivery and torquey feel.
Drivetrain:
Reliable belt drive system for low maintenance and smooth power transfer.
Customization:
Designed for personalization, with a wide range of genuine Kawasaki and aftermarket accessories available.
Years Covered:
2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015
Estimated Page Count:
Approximately 300-400 pages (typical for this type of manual)
Type:
Official Factory Service Manual / Workshop Manual
Engine Mechanical:
Engine disassembly, inspection, assembly, torque specifications, valve clearance, timing, cooling system, lubrication system.
Fuel System:
Fuel injection system, throttle body, injectors, fuel pump, fuel pressure regulation, evaporative emission control.
Ignition System:
Ignition timing, spark plugs, ignition coils, ECU control.
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, final drive (belt drive system), lubrication.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starting system, lighting, indicators, horn, instrument cluster, ECU (Engine Control Unit).
Brakes:
Brake fluid, hydraulic system, brake calipers, master cylinders, brake pads, discs, bleeding procedures.
Suspension:
Front forks (telescopic), rear shock absorber, swingarm, bearing checks and replacement.
Steering:
Handlebar, steering stem, steering bearings, lubrication and adjustment.
Chassis Frame:
Frame inspection, disassembly and reassembly of frame-mounted components.
Bodywork Styling:
Fenders, fuel tank, seat, side covers, exhaust system, detailing of trim components.
Routine Maintenance:
Oil changes, filter replacement, chain/belt adjustment (as applicable), spark plug replacement, air filter cleaning/replacement, brake inspection.
Troubleshooting:
Diagnostic flowcharts, symptom-based problem identification, common fault correction for engine, electrical, and mechanical systems.
Major Repairs:
Engine rebuild, transmission overhaul, suspension fork service, brake system overhauls.
Diagnostics:
Fault code reading (if applicable via diagnostic tool), electrical testing, fuel system pressure testing.
Disassembly Assembly:
Step-by-step instructions for component removal and installation.
Depth:
Comprehensive. Covers everything from basic maintenance to full engine and transmission rebuilds, including detailed electrical schematics and troubleshooting.
Engine Type:
Four-stroke, SOHC, V-twin
Displacement:
852 cc (52.0 cu in)
Bore X Stroke:
88.0 x 72.0 mm (3.46 x 2.83 in)
Cooling System:
Liquid-cooled
Valve Train:
SOHC, 4 valves per cylinder (Desmodromic valve actuation is NOT used)
Horsepower Est:
Approx. 50-55 HP (actual figures vary by tuning and measurement)
Torque Est:
Approx. 50-55 lb-ft (actual figures vary by tuning and measurement)
Fuel Delivery:
Fuel Injection with Dual 34mm Throttle Bodies (Dual throttle valves control intake air flow for precise response)
Fuel Type:
Unleaded gasoline, 87 octane minimum (91 AKI recommended)
Oil Capacity W Filter:
3.1 US qt. (2.9 L)
Ignition System:
Digital CDI with electronic ignition advance
Spark Plug Type:
NGK CR9EK, DENSO U27FER9 (Verify with manual for exact spec)
Crash Test Ratings:
N/A (Motorcycle safety ratings are not standardized like automotive; focus is on design features and component integrity.)
Braking System:
Front: 300mm disc with dual-piston caliper. Rear: 270mm disc with dual-piston caliper. ABS was an optional feature on some models, crucial to verify if present.
Lighting:
Halogen headlight, LED taillight, amber incandescent turn signals (standard for the era).
Frame Construction:
High-tensile steel double-cradle frame designed for stability and rider confidence.
Tire Specifications:
Front: 80/90-21, Rear: 180/70-15 (Tyre pressures and specifications detailed in manual).
Display Features:
Analog speedometer with LCD multi-function display (odometer, trip meter, clock, fuel gauge). Indicator lights for engine, oil, neutral, turn signals, high beam.
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature for some model years. The manual will differentiate procedures if ABS is equipped.
Connectivity Features:
None (This is a traditional motorcycle design without modern connectivity features like Bluetooth or smartphone integration).
Oil Change Interval:
Every 3,000 miles or 6 months, whichever comes first (Verify with manual for exact recommendations).
Chain Belt Tension Check:
Check every 3,000 miles or 6 months. Belt drive requires minimal tension adjustment.
Air Filter Inspection:
Inspect every 3,000 miles or 6 months; clean or replace as needed.
Spark Plug Replacement:
Recommend replacement every 7,500 miles (Verify with manual).
Valve Clearance Check:
First check at 6,000 miles, then every 7,500 miles thereafter (Crucial for engine health).
Engine Oil Type:
SAE 10W-40, API SG or SH, JASO MA certified motorcycle oil.
Brake Fluid Type:
DOT 4 (Verify with manual for specific recommendations).
Coolant Type:
Kawasaki All Season Motorcycle Coolant or a premium quality ethylene glycol-based coolant with a 50/50 mix of distilled water.
Common Wear Items:
Brake pads, tires, clutch plates (depending on usage), fork seals, and belt drive may require eventual replacement.
Potential Electrical:
While generally reliable, occasional issues with regulator/rectifier or battery connections can occur, especially in older units. The manual's electrical diagnostics are vital.
Fuel System Maintenance:
Regular fuel stabilizer use and occasional injector cleaning can prevent minor performance issues.
Kawasaki Legacy:
Kawasaki has a long and rich history in motorcycle manufacturing, known for its performance-oriented motorcycles across various segments, including cruisers, sportbikes, and off-road bikes.
Vulcan Lineage:
The Vulcan nameplate has been a cornerstone of Kawasaki's cruiser lineup since the 1980s, evolving through various displacements and styles to meet rider preferences. The 900 Custom represents a modern interpretation of the classic cruiser, focusing on clean lines and a personalized look.
Manufacturing Location:
Primarily manufactured in Japan, with assembly sometimes occurring in other global locations.
