Kawasaki Custom Vulcan 900 07-13 Workshop Service Manual

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The Vulcan 900 Custom (VN900B) is a cruiser motorcycle designed to offer a blend of classic aesthetics and modern engineering. Produced for the model years 2007 through 2013, this model...

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Tipo: Motorcycle

Proveedor:

SKU: 85198

Etiquetas: 2007 2008 2009 2010 2011 2012 2013 Kawasaki Misc Motorcycle Motorcycles Vulcan 900

Variantes de producto

Descripción

The Vulcan 900 Custom (VN900B) is a cruiser motorcycle designed to offer a blend of classic aesthetics and modern engineering. Produced for the model years 2007 through 2013, this model is characterized by its stripped-down appearance, featuring spoke wheels, custom-style handlebars, and a low-slung profile, making it an attractive option for riders seeking personalization. Built upon a long-standing heritage in motorcycle manufacturing, the Vulcan 900 Custom emphasizes accessible performance and a comfortable riding experience, positioning it as a strong contender in the cruiser market. Its 892 cc V-twin engine, coupled with a belt drive system, contributes to its smooth operation and characteristic cruiser feel. This comprehensive workshop service manual provides in-depth guidance for the maintenance, repair, and troubleshooting of the Vulcan 900 Custom. It covers all essential systems, including detailed procedures for the engine, fuel system, transmission, drivetrain, electrical components, chassis, braking, and suspension. The manual is structured to assist owners, mechanics, and technicians by offering clear instructions, diagnostic flowcharts, and precise technical specifications. From routine maintenance tasks such as oil changes and filter replacements to complex engine overhauls and electrical diagnostics, this resource ensures the longevity and optimal performance of the vehicle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Vulcan 900 Custom

Model Variant:

VN900B

Model Years Covered:

2007, 2008, 2009, 2010, 2011, 2012, 2013

Codes

Chassis Code:

VN900B

👋 Introduction

Market Position

Vehicle Segment:

Cruiser motorcycle, known for its comfortable riding position and custom styling.

Competitive Analysis

Key Competitors:

Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series.

Key Features

Design Philosophy:

Combines classic cruiser aesthetics with modern engineering for accessible performance and style.

Custom Appeal:

Features a stripped-down look with spoke wheels, custom-style handlebars, and a low-slung profile, appealing to riders seeking personalization.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

Refer to specific product listing for exact page count, typically 500+ pages for a comprehensive workshop manual.

📖 Manual Coverage

Systems Covered

Engine Mechanics:

Detailed instructions for engine overhaul, piston, cylinder, crankshaft, valve train, timing, lubrication, and cooling systems.

Fuel System:

Comprehensive coverage of fuel injection system (EFI), fuel pump, injectors, sensors, and throttle body.

Transmission Drivetrain:

In-depth information on clutch operation, gearbox disassembly and reassembly, final drive belt maintenance, and related components.

Electrical System:

Wiring diagrams, starter system, charging system (alternator/stator, regulator/rectifier), ignition system, lighting, and instrument cluster.

Chassis Frame:

Frame inspection, front fork disassembly and assembly, rear shock absorber service, steering system.

Braking System:

Front and rear brake caliper service, master cylinder repair, brake fluid bleeding, disc and pad replacement.

Suspension:

Front fork specifications, seal replacement, oil levels, and rear suspension shock absorber servicing.

Wheels Tires:

Wheel bearing service, tire mounting and balancing, spoke tension adjustment (if applicable).

Bodywork Trim:

Fender, tank, seat, and other body panel removal and installation procedures.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment (if applicable, though belt drive).

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for common issues.

Engine Rebuild:

Complete engine disassembly, inspection, measurement, and reassembly with torque specifications.

Electrical Diagnostics:

Step-by-step procedures for diagnosing electrical faults using multimeters and wiring diagrams.

Suspension Overhaul:

Front fork seal replacement, rear shock absorber servicing.

Brake System Overhaul:

Caliper rebuilds, master cylinder replacement, line bleeding.

Efi System Service:

Throttle body synchronization, sensor testing, injector cleaning.

Technical Depth

Diagnostic Level:

Advanced diagnostics with component testing procedures and expected values.

Repair Level:

Comprehensive repair procedures, from minor adjustments to complete component overhauls.

Specification Detail:

Includes detailed torque specifications, clearances, fluid capacities, and electrical resistance values.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Typically yes, allowing for quick navigation of topics.

Printable:

Yes, PDF format allows for printing specific sections or the entire manual.

Print Quality

Image Resolution:

High-resolution diagrams and illustrations for clarity.

Binding Type

Binding:

Not applicable (PDF format).

Paper Type

Paper Quality:

Not applicable (PDF format).

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, liquid-cooled, SOHC, V-twin

Displacement:

892 cc (54.5 cu. in.)

Bore X Stroke:

92.0 x 68.0 mm (3.62 x 2.68 in.)

Compression Ratio:

9.5:1

Performance

Horsepower:

Approx. 50-55 HP (at crankshaft, subject to specific market tuning)

Torque:

Approx. 50-55 lb-ft (at crankshaft, subject to specific market tuning)

Fuel System

Fuel Delivery:

Fuel Injection (EFI) with dual 34mm throttle bodies

Fuel Tank Capacity:

20.0 L (5.3 gal)

Lubrication

Oil Type:

SAE 10W-40 API SG or SH, JASO MA

Oil Capacity:

3.8 L (4.0 US qt) with filter change

Ignition

Ignition System:

Digital CDI

Cooling

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Final Drive:

Belt drive

Features

Clutch:

Wet, multi-disc

📐 Dimensions

Exterior

Overall Length:

2,415 mm (95.1 in.)

Overall Width:

930 mm (36.6 in.)

Overall Height:

1,110 mm (43.7 in.)

Wheelbase:

1,635 mm (64.4 in.)

Weights

Curb Weight:

Approx. 260 kg (573.2 lbs)

Dry Weight:

Approx. 247 kg (544.5 lbs)

Weight Distribution:

Designed for stable handling and a low center of gravity.

Wheels Tires

Front Tire:

80/90-21M/C 48H

Rear Tire:

180/70R15M/C 76H

Front Wheel:

Spoked 21-inch

Rear Wheel:

Spoked 15-inch

🛡️ Safety Features

Ratings

Crash Safety Ratings:

Not applicable for motorcycles in traditional automotive safety rating systems.

Active Features

Braking System:

Hydraulic front disc brake, drum brake rear.

Passive Features

Lighting:

Halogen headlight, LED taillight and brake light.

Ergonomics:

Low seat height for rider confidence and control.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog speedometer, digital odometer, trip meter, clock, fuel gauge, and indicator lights.

Driver Assistance

Traction Control:

Not equipped

Connectivity

Bluetooth Support:

Not equipped

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 7,500 km (4,500 miles) or 12 months, whichever comes first.

Air Filter Cleaning:

Every 7,500 km (4,500 miles), replace if necessary.

Spark Plug Replacement:

Every 15,000 km (9,000 miles).

Coolant Check And Change:

Check coolant level every 7,500 km (4,500 miles); change every 2 years or 24,000 km (15,000 miles).

Belt Drive Inspection:

Inspect belt tension and condition every 7,500 km (4,500 miles).

Fluid Specifications

Engine Oil:

SAE 10W-40 API SG or SH, JASO MA

Coolant:

Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant (50% mixture with distilled water)

Brake Fluid:

DOT 4

Known Issues

Rear Drive Belt Wear:

While generally robust, proper tensioning and alignment are crucial to prevent premature wear or snapping of the belt.

Fuel Injector Cleaning:

Over time, injectors can become fouled, leading to rough idle or poor performance; periodic cleaning or servicing may be required.

Electrical Connections:

As with many motorcycles, ensuring clean and secure electrical connections, particularly around the battery and charging system, is vital for consistent operation.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki Heavy Industries, Ltd. has a long history of motorcycle manufacturing, known for performance and reliability across various segments.

Model Evolution

Vulcan Lineage:

The Vulcan line has been a staple in Kawasaki's cruiser offerings since the 1980s, evolving through various displacements and styles.

Vn900 Introduction:

The Vulcan 900 series (including the Classic, Custom, and Classic LT) was introduced in 2006, offering a modern take on classic cruiser styling with a fuel-injected V-twin engine.

Production

Manufacturing Location:

Japan (Primary manufacturing facility for Kawasaki motorcycles).

🏆 Awards & Recognition

Recognitions

Industry Accolades:

While specific awards for this model year may not be widely publicized, the Vulcan 900 platform is generally well-regarded for its value, styling, and reliability within the cruiser segment.