Kawasaki VN 900 Classic 2006-2013 Workshop Service Manual

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The VN900 Classic, also known as the Vulcan 900 Classic, is a mid-size cruiser motorcycle that combines timeless styling with modern engineering. Produced from 2006 through 2013, this model is...

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Taper: Motorcycle

Distributeur:

UGS: 80648

Mots clés: 2006 2007 2008 2009 2010 2011 2012 2013 Kawasaki Misc Motorcycle Motorcycles VN 900 Classic

Variantes de produits

Description

The VN900 Classic, also known as the Vulcan 900 Classic, is a mid-size cruiser motorcycle that combines timeless styling with modern engineering. Produced from 2006 through 2013, this model is celebrated for its classic cruiser aesthetics, featuring abundant chrome accents, spoked wheels, and a distinctive teardrop fuel tank. Powered by a liquid-cooled, 892 cc V-twin engine with SOHC and four valves per cylinder, it delivers approximately 57 horsepower and 76 Nm of torque, paired with a smooth belt drive for a low-maintenance and refined riding experience. Its comfortable ergonomics and reliable performance make it an ideal choice for riders seeking an authentic cruiser experience for both daily rides and longer journeys. This comprehensive workshop service and repair manual covers the VN900 Classic for the model years 2006 to 2013. Within its 587 pages, you will find detailed procedures for routine maintenance, such as oil changes, filter replacements, and belt adjustments, alongside in-depth instructions for engine overhaul, fuel system servicing, transmission repair, and suspension rebuilds. The manual also includes vital information on the braking system, electrical diagnostics, and chassis components, complete with technical specifications, tightening torques, and troubleshooting guides. This resource is designed to assist owners, mechanics, and technicians in accurately maintaining, diagnosing, and repairing the VN900 Classic, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

VN900 Classic

Model Nickname:

Vulcan 900 Classic

Model Variant:

Classic

Generation

Generation Code:

VN900-A1/A2/A3/A4/A5/A6/A7

Codes

Chassis Code:

VN900B

👋 Introduction

Market Position

Segment:

Mid-size cruiser motorcycle

Target Audience:

Riders seeking classic styling with modern reliability and performance, suitable for cruising and touring.

Competitive Analysis

Key Competitors:

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

Key Features

Styling:

Classic cruiser aesthetics with generous chrome accents, spoked wheels, and a teardrop fuel tank.

Engine Type:

Liquid-cooled, V-twin, SOHC, 4-valve per cylinder.

Drivetrain:

Belt drive for low maintenance and smooth power delivery.

Ergonomics:

Comfortable riding position for long distances.

📋 Manual Details

Coverage Areas

Covered Years:

2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly of the engine and its components.

Fuel System:

Carburetor (if applicable, though VN900 is FI), fuel injection system, fuel pump, fuel filter, and fuel tank servicing.

Ignition System:

Spark plugs, ignition coils, CDI unit, and timing.

Transmission And Drivetrain:

Gearbox inspection, repair, clutch operation, final drive (belt drive system), and lubrication.

Suspension System:

Front fork (telescopic) disassembly, seal replacement, oil levels, rear shock absorber adjustment and replacement.

Braking System:

Front and rear disc brake service, caliper overhaul, pad replacement, fluid flush and bleeding, master cylinder inspection.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator/stator), starter motor, lighting, instrumentation, and diagnostic connectors.

Cooling System:

Engine coolant, radiator, fan operation, and water pump.

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement.

Frame And Bodywork:

Frame integrity checks, body panel removal and installation, seat, fenders, and fuel tank mounting.

Wheels And Tires:

Wheel bearing inspection and replacement, tire pressure, tire wear, and wheel balancing.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain/belt adjustments, brake checks, and general inspection procedures.

Troubleshooting:

Diagnostic guides for common and uncommon problems, symptom-based troubleshooting flowcharts.

Engine Repair:

Detailed steps for cylinder head removal, piston inspection, valve adjustment, crankshaft and connecting rod checks.

Fuel System Repair:

Fuel injector cleaning and testing, throttle body inspection, fuel pressure checks.

Transmission Overhaul:

Gearbox disassembly and reassembly, shift drum and fork inspection.

Suspension Rebuild:

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

Brake System Service:

Bleeding procedures, caliper piston retraction, brake line inspection.

Electrical Diagnostics:

Fault code retrieval (if applicable), multimeter usage for circuit testing, component testing.

Belt Drive Maintenance:

Belt tension adjustment and inspection, pulley alignment checks.

Specifications And Torques:

Tightening torques for all critical fasteners, critical component clearances.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, electrical diagnostics, and chassis component repair.

📊 Manual Specifications

File Format

File Type:

Print Quality

Print Readability:

High resolution, clear diagrams and text, suitable for printing.

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Quality:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Displacement:

892 cc (54.4 cu in)

Bore X Stroke:

92.0 x 68.0 mm

Compression Ratio:

9.0:1

Valvetrain:

SOHC, 4 valves per cylinder

Performance

Horsepower:

Approximately 57 hp @ 6,500 rpm (claimed)

Torque:

Approximately 76 Nm (56 lb-ft) @ 3,500 rpm (claimed)

Fuel System

Fuel Delivery:

Fuel injection, Dual 34mm throttle bodies

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Fuel Tank Capacity:

20 liters (5.3 US gal)

Lubrication

Oil Type:

API SG, SF or SH with JASO MA, MA1 or MA2 recommended (e.g., SAE 10W-40)

Oil Capacity With Filter Change:

3.1 L (3.3 US qt)

Cooling System

Coolant Type:

Kawasaki All-Season Motorcycle Coolant or equivalent (50/50 ethylene glycol and deionized water mix)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Optional Transmission:

Features

Clutch Type:

Wet, multi-disc

Final Drive:

Belt drive

📐 Dimensions

Exterior

Overall Length:

2,420 mm (95.3 in)

Overall Width:

980 mm (38.6 in)

Overall Height:

1,120 mm (44.1 in)

Wheelbase:

1,635 mm (64.4 in)

Ground Clearance:

140 mm (5.5 in)

Seat Height:

705 mm (27.8 in)

Weights

Curb Weight:

268 kg (591 lbs)

Dry Weight:

249 kg (549 lbs)

🛡️ Safety Features

Ratings

Safety Features:

Disc brakes front and rear, modern chassis design for stability.

Active Features

Braking System Type:

Dual disc front, single disc rear

Front Brake Spec:

272mm petal disc

Rear Brake Spec:

272mm petal disc

Passive Features

Frame Material:

High-tensile steel, Double-cradle

Lighting:

Halogen headlight, LED taillight.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This model focuses on core motorcycling experience, not integrated infotainment).

Driver Assistance

Rider Aids:

No electronic rider aids such as traction control or ABS typically found on this model/generation (check specific market variations).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Engine Oil And Filter Change:

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

Air Filter Cleaning:

Every 6,000 km (3,700 miles). Replacement as needed.

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Belt Tension Check And Adjustment:

Every 12,000 km (7,500 miles).

Brake Fluid Replacement:

Every 24 months (regardless of mileage).

Coolant Replacement:

Every 24 months (regardless of mileage).

Fluid Specifications

Engine Oil Viscosity:

SAE 10W-40

Brake Fluid Type:

DOT 4

Fork Oil Type:

Kawasaki KHL15-10W (or equivalent 10W fork oil)

Fork Oil Capacity Per Leg:

368 ml (12.4 US fl oz)

Known Issues

Common Concerns:

Some owners report a slightly firm initial engagement of the clutch. Occasional reports of front brake lever 'pump-up' at high mileage which can be addressed by a caliper service and fluid flush.

Maintenance Tips:

Regularly inspect the belt for wear and proper tension. Ensure cooling system is flushed and refilled at recommended intervals to prevent overheating.

📚 Vehicle History

Brand Heritage

Kawasaki Cruiser Lineage:

Kawasaki has a long history of producing iconic cruiser motorcycles, dating back to models like the KZ series and the early Vulcan line.

Model Evolution

Vn900 Introduction:

The VN900 platform was introduced in 2006 as a successor and enhancement to the popular VN800 series, offering a larger displacement and updated features.

Model Variants:

The VN900 Classic is part of a family that includes the VN900 Custom (with different wheels, handlebars, and styling) and the VN900LT (Light Tourer, with windshield and saddlebags).

Production

Production Period:

2006-present (with updates and variants)

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

Consistently praised by reviewers and owners for its authentic cruiser styling, comfortable ride, and reliable V-twin engine. A strong contender in its displacement class for its value and accessibility.