Kawasaki Vulcan 900 VN 900 Custom Service Manual 2007 2008 2

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The Vulcan 900 Custom (VN900B) is a cruiser motorcycle introduced in 2007, known for its distinctive custom styling, including a sculpted fuel tank and minimalist front end. Powered by a...

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Taper: Motorcycle

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UGS: 67271

Mots clés: 2007 2008 Custom Kawasaki Misc Motorcycle Motorcycles VN 900 Vulcan 900

Variantes de produits

Description

The Vulcan 900 Custom (VN900B) is a cruiser motorcycle introduced in 2007, known for its distinctive custom styling, including a sculpted fuel tank and minimalist front end. Powered by a 903cc liquid-cooled, SOHC V-twin engine featuring electronic fuel injection and a smooth belt drive, it offers accessible V-twin performance for riders seeking a stylish and reliable cruiser. This model is part of a long-standing Vulcan lineage, building upon decades of cruiser manufacturing expertise. This factory service manual provides comprehensive guidance for the Vulcan 900 Custom, covering model years 2007 through 2015. It details all essential maintenance procedures, from routine oil changes and filter replacements to advanced engine and transmission overhauls. The manual includes in-depth information on the fuel, cooling, electrical, braking, and suspension systems, along with troubleshooting guides, diagnostic procedures, and detailed technical specifications such as torque values and clearances. Its purpose is to assist owners, mechanics, and technicians in performing accurate repairs, maintenance, and diagnostics to ensure the optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Vulcan 900 Custom

Model Code:

VN900B

Generation

Generation:

First Generation

Codes

Product Code:

KAW-VN900C-0715-SM-PDF

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Riders seeking a stylish, accessible cruiser with a focus on customizability and reliable V-twin performance.

Competitive Analysis

Key Competitors:

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

Key Features

Distinctive Styling:

Unique 'custom' look with a sculpted fuel tank, teardrop side covers, and minimalist front end.

Engine Configuration:

903cc (55 cubic inch) liquid-cooled, SOHC, 8-valve, 52-degree V-twin engine.

Drivetrain:

Belt drive for low maintenance and smooth power delivery.

📋 Manual Details

Coverage Areas

Model Years Covered:

2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015

Trim Levels Covered:

Custom (VN900C)

Page Count

Estimated Page Count:

Approx. 400-500 pages (typical for this model's comprehensive service manual)

Manual Type

Manual Type:

Factory Service Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine disassembly, assembly, diagnosis, and tuning for the 903cc V-twin engine.

Fuel System:

Fuel injection system (EFI), throttle body, fuel pump, fuel filter, fuel injectors, and related sensors.

Cooling System:

Liquid cooling system, radiator, thermostat, coolant pump, hoses, and fan operation.

Transmission System:

Clutch operation, gearbox, final drive (belt drive system), and lubrication.

Electrical System:

Ignition system, charging system (alternator, regulator/rectifier), starter system, lighting, battery, wiring diagrams, fuses, relays, and electronic control unit (ECU).

Brakes:

Front and rear brake systems, hydraulic components, master cylinders, calipers, brake pads, rotors, and bleeding procedures.

Suspension:

Front fork (telescopic) disassembly, assembly, oil specifications, and rear shock absorber inspection and replacement.

Steering:

Handlebar, steering stem bearings, and related components.

Frame And Bodywork:

Frame inspection, body panel removal and installation, fenders, seat, fuel tank, and exhaust system.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment (belt drive tension), brake fluid replacement, coolant checks, and air filter service.

Troubleshooting:

Diagnostic procedures for common starting issues, engine performance problems, electrical faults, and braking system anomalies.

Engine Repair:

Complete engine rebuilds, piston and ring replacement, valve adjustments, cylinder head service, and crankshaft inspection.

Transmission Repair:

Clutch plate replacement, gearbox component inspection and replacement, and final drive belt replacement and tensioning.

Electrical Diagnostics:

Fault finding using wiring diagrams, testing sensors, actuators, and ignition coil performance.

Brake System Service:

Brake bleeding, pad replacement, rotor inspection, and hydraulic system maintenance.

Suspension Overhaul:

Front fork seal replacement, oil changes, and rear shock absorber adjustment/replacement.

Bodywork Repairs:

Panel alignment, fairing repair, and mounting procedures.

Technical Depth

Depth Of Information:

Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission overhauls.

Diagnostic Codes:

Includes diagnostic procedures, potential error codes (if applicable to the ECU), and troubleshooting trees.

Torque Specifications:

Detailed torque values for all critical fasteners.

Clearances And Tolerances:

Specifications for valve clearances, piston ring gaps, and other critical component measurements.

Wiring Diagrams:

Detailed and accurate electrical wiring diagrams for all systems.

📊 Manual Specifications

File Format

File Type:

Searchability:

Typically text-searchable for quick information retrieval.

Print Quality

Image Resolution:

High resolution for clear illustrations, diagrams, and photographs.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, V-twin

Displacement:

903 cc (55.1 cu in.)

Bore X Stroke:

88.0 x 74.5 mm

Cooling System:

Liquid-cooled

Valve Train:

SOHC, 8 valves (4 per cylinder)

Compression Ratio:

9.0:1

Performance

Horsepower Estimate:

Approx. 50-55 HP (at crankshaft)

Torque Estimate:

Approx. 50-55 lb-ft (at crankshaft)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves

Fuel Tank Capacity:

20 L (5.3 gal)

Recommended Fuel:

Unleaded gasoline, 87 octane or higher

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch:

Wet, multi-disc, cable-actuated

Final Drive:

Belt drive

Features

Gear Ratios:

Refer to manual for specific gear ratios (typically: 1st: 2.750, 2nd: 1.933, 3rd: 1.435, 4th: 1.150, 5th: 0.913)

Transmission Fluid Type:

Kawasaki Genuine Gear Oil (GL-4) or equivalent API GL-4 hypoid gear oil SAE 80W-90

📐 Dimensions

Exterior

Length:

2405 mm (94.7 in.)

Width:

870 mm (34.3 in.)

Height:

1110 mm (43.7 in.)

Wheelbase:

1645 mm (64.8 in.)

Ground Clearance:

140 mm (5.5 in.)

Seat Height:

705 mm (27.8 in.)

Weights

Dry Weight:

251 kg (553.4 lbs)

Curb Weight:

275 kg (606.3 lbs)

Front Tire:

80/90-21M/C 48H

Rear Tire:

180/70-15M/C 76H

Wheelbase Specification:

1645 mm (64.8 in.)

🛡️ Safety Features

Ratings

Safety Features:

ABS optional on some models/markets, focus on stable cruiser handling.

Active Features

Braking System:

Front: 300mm disc with dual piston caliper; Rear: 270mm disc with dual piston caliper. ABS available on select configurations.

Passive Features

Lighting:

Halogen headlight, LED tail light, incandescent turn signals.

💡 Technology Features

Infotainment

Instrumentation:

Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, and indicator lights.

Driver Assistance

Optional Anti-lock Braking System (ABS) available on select model years and configurations.

Connectivity

Connectivity Features:

No integrated smartphone connectivity or advanced electronic rider aids beyond optional ABS.

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Air Filter Service:

Inspect every 6,000 km (3,700 miles), clean or replace as needed.

Belt Tension Check:

Check belt tension and condition every 12,000 km (7,500 miles).

Spark Plug Replacement:

Replace every 12,000 km (7,500 miles) or as needed.

Brake Fluid Replacement:

Replace every 24,000 km (15,000 miles) or 2 years.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or SH, or Jaso MA certified oil. Capacity: 3.0 L (3.2 US qt) without filter, 3.2 L (3.4 US qt) with filter change.

Coolant Type:

Kawasaki Motorcycle Antifreeze (or equivalent ethylene glycol-based coolant with corrosion inhibitor), mixed 50/50 with distilled water. Capacity: 1.6 L (1.7 US qt).

Fork Oil Type:

SAE 10W fork oil. Capacity: 481 ml (16.3 fl oz) per fork leg.

Known Issues

Common Wear Items:

Front fork seals, brake pads, tires, and belt drive components due to normal wear and tear.

Potential Electrical Faults:

While generally reliable, occasional issues with regulator/rectifier units or battery terminals can occur. Manual provides diagnostic steps.

📚 Vehicle History

Brand Heritage

Kawasaki Heritage:

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

Model Evolution

Vulcan Lineage:

The Vulcan nameplate has been a cornerstone of Kawasaki's cruiser lineup since the 1980s, evolving through various displacements and styles. The VN900 Custom represents a modern take on the classic cruiser formula.

Production

Production Period:

The VN900 Custom was introduced in 2007 and has remained a popular model in Kawasaki's lineup, with the manual covering models up to 2015 as indicated.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for this model year aren't widely publicized, the Vulcan 900 platform is consistently praised for its value, styling, and user-friendly V-twin power delivery in enthusiast reviews.