2007-2015 KAWASAKI VULCAN 900 VN 900 Custom Service Manual

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Tipo: Motorcycle

Proveedor:

SKU: 90236

Etiquetas: 2007 2008 2009 2010 2011 2012 2013 2014 2015 Kawasaki Misc Motorcycle Motorcycles VN 900 Custom VULCAN 900

Variantes de producto

Descripción

The Kawasaki Vulcan 900 Custom, produced between 2007 and 2015, represents a refined cruiser motorcycle designed for riders who appreciate classic styling blended with modern engineering. Powered by a liquid-cooled, 892cc V-twin engine, it offers a smooth and reliable riding experience, making it a popular choice for both leisurely rides and longer journeys. Its robust construction, featuring a double-cradle steel frame and a belt drive system, contributes to its reputation for durability and low maintenance. This model, along with its variants like the Classic and Classic LT, has been recognized for its comfortable ergonomics and distinctive aesthetic, positioning it as a strong contender in the mid-size cruiser segment against competitors such as the Honda Shadow and Yamaha V-Star. This comprehensive Factory Service Manual provides in-depth guidance for the complete service and repair of the Kawasaki Vulcan 900 Custom (VN900B) and its related variants. It covers all essential systems, including the engine, drivetrain, chassis, brakes, and electrical components, detailing routine maintenance, complex repairs, and component removal and installation. Within its approximately 400-600 pages, owners and technicians will find essential technical specifications, diagnostic procedures, and information on required special tools. The manual is designed to empower users to effectively maintain their vehicle, ensuring optimal performance and longevity, and is presented in English for broad accessibility.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Vulcan 900 VN 900 Custom

Year Range:

2007-2015

Codes

Vin Prefix:

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Owners seeking to perform maintenance and repairs, independent repair shops

Competitive Analysis

Competitors:

Harley-Davidson Sportster, Honda Shadow, Yamaha V-Star

Key Features

Vehicle Design Philosophy:

Classic cruiser styling with modern technology and a reliable V-twin engine

Manual Value Proposition:

Comprehensive guide to maintaining and repairing the Vulcan 900 Custom, enabling DIY service and reducing reliance on dealerships.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service and Repair

Vehicle Variants:

VN900B (Custom), VN900C (Classic), VN900D (Classic LT)

Page Count

Estimated Pages:

Approximately 400-600 pages (typical for this model's official manual)

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, lubrication, cooling, fuel injection, ignition, exhaust, starting system

Drivetrain:

Clutch, transmission, final drive (belt)

Chassis:

Frame, front suspension (forks), rear suspension (swingarm, shock absorber), wheels, tires, steering

Brakes:

Front and rear brake systems (hydraulic, calipers, master cylinders, lines, pads, rotors)

Electrical:

Battery, charging system (alternator, regulator/rectifier), lighting, ignition, instrumentation, ECU, wiring diagrams

Bodywork:

Fenders, fuel tank, seat, handlebars, controls, body panels, fairings (if applicable)

Procedures Included

Routine Maintenance:

Oil change, filter replacement, air filter service, spark plug replacement, lubrication points, chain adjustment (if applicable for earlier models or specific variants)

Troubleshooting:

Diagnostic procedures, fault codes (if applicable), symptom-based troubleshooting guides

Major Repairs:

Engine disassembly and reassembly, transmission overhaul, suspension fork rebuild, brake system bleeding and overhaul

Component Removal Installation:

Detailed steps for removing and installing all major and minor components

Technical Depth

Diagnostic Capabilities:

Advanced diagnostic procedures, electrical system testing, fuel system analysis

Rebuild Specifications:

Detailed torque specifications, clearances, tolerances for engine and transmission components

Special Tools:

Identification of required special tools for specific procedures

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable (OCR'd or native digital format)

Print Quality

Resolution:

High-resolution, suitable for printing

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Type:

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

Displacement:

892 cc (54.4 cu in)

Bore X Stroke:

88.0 x 74.2 mm

Compression Ratio:

9.5:1

Performance

Horsepower:

Approx. 47.5 HP @ 5,700 RPM (claimed)

Torque:

Approx. 57.8 lb-ft @ 3,500 RPM (claimed)

Fuel System

Induction:

Digital Fuel Injection (DFI) with dual 34mm throttle bodies

Fuel Type:

Unleaded gasoline, 87 octane or higher

Ignition

System:

Digital CDI

Lubrication

System:

Wet sump

Cooling

System:

Liquid-cooled

🔧 Transmission

Standard

Type:

5-speed constant mesh

Optional

Optional Gearbox:

Features

Clutch:

Wet, multi-disc

Final Drive:

Belt drive (reinforced carbon fiber belt)

📐 Dimensions

Exterior

Overall Length:

Approx. 97.0 in (2,465 mm)

Overall Width:

Approx. 37.0 in (940 mm)

Overall Height:

Approx. 43.1 in (1,095 mm)

Wheelbase:

Approx. 64.8 in (1,645 mm)

Ground Clearance:

Approx. 5.7 in (145 mm)

Weights

Curb Weight:

Approx. 575.4 lbs (261 kg)

Dry Weight:

Approx. 531.4 lbs (241 kg)

Fuel Capacity:

5.5 US gal (20.8 L)

Wheels Tires

Front Tire:

80/90-21M/C 44S

Rear Tire:

180/70-15M/C 76S

Front Wheel:

21 x 2.15 in (spoked, 60-spoke)

Rear Wheel:

15 x 3.50 in (spoked, 54-spoke)

🛡️ Safety Features

Ratings

Safety Features Certification:

N/A (Motorcycle safety standards vary by region, manual covers operational safety)

Active Features

Braking System:

Hydraulic front disc brake, rear disc brake

Lighting:

Halogen headlight, LED taillight, incandescent turn signals

Passive Features

Frame Construction:

Double-cradle steel frame

💡 Technology Features

Infotainment

Audio System:

N/A (typically no integrated infotainment system on this model)

Instrumentation:

Analog speedometer, digital tachometer, fuel gauge, clock, trip meters, indicator lights

Driver Assistance

Not typically equipped as standard on this model within the specified year range.

Connectivity

Bluetooth Usb:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,700 miles (6,000 km) or 6 months, whichever comes first

Air Filter Inspection:

Every 3,700 miles (6,000 km)

Spark Plug Replacement:

Every 7,500 miles (12,000 km)

Belt Drive Inspection:

Every 7,500 miles (12,000 km)

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher (Kawasakis's recommendation is typically semi-synthetic or full synthetic)

Engine Oil Capacity:

Approx. 3.2 US qt (3.0 L) with filter change

Coolant Type:

Ethylene glycol-based antifreeze (50/50 mix with distilled water)

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid

Known Issues

Common Wear Items:

Brake pads, tires, clutch plates, belt drive components

Potential Issues:

Occasional regulator/rectifier failures (as with many air/liquid-cooled V-twins), fuel injector cleaning, belt tension adjustment

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycle Legacy:

Kawasaki Heavy Industries has a long history of producing motorcycles, known for innovation and performance across various segments.

Model Evolution

Vulcan Lineage:

The Vulcan line has been a staple of Kawasaki's cruiser offerings for decades, evolving from smaller displacement models to the popular 900cc platform.

Vulcan 900 Introduction:

The Vulcan 900 platform was introduced in 2006 (as a 2006 model for some variants), establishing a successful mid-size cruiser segment for the brand.

Production

Manufacturing Location:

Japan (typically)

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for the 2007-2015 VN 900 Custom are not widely publicized, the Vulcan 900 platform has received positive reviews for its styling, comfort, and value within the cruiser market.