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    Kawasaki Custom VN 900 2007-2015 Workshop Service Manual

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    The VN900 Custom is a cruiser motorcycle known for its classic styling and comfortable riding experience. Produced from 2007 to 2015, this model (chassis code VN900B) features a 853 cc,...
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    Taper: Motorcycle
    Distributeur:
    UGS: 85109
    The VN900 Custom is a cruiser motorcycle known for its classic styling and comfortable riding experience. Produced from 2007 to 2015, this model (chassis code VN900B) features a 853 cc, liquid-cooled, V-twin engine with electronic fuel injection, paired with a 5-speed transmission and a belt drive for smooth power delivery. Its design philosophy emphasizes a blend of traditional cruiser aesthetics with modern engineering, making it a popular choice for riders seeking reliable performance and a distinctive look. Key features include a double-cradle steel frame for stability, a low seat height for accessibility, and petal disc brakes for effective stopping power, all contributing to its appeal in the cruiser segment. This comprehensive workshop service manual provides detailed information for the maintenance and repair of the VN900 Custom, covering models from 2007 through 2015. It encompasses a wide range of systems, including the engine, transmission, chassis, and electrical components, along with bodywork and accessories. Owners and technicians will find step-by-step procedures for routine maintenance, such as oil changes and filter replacements, as well as in-depth instructions for troubleshooting common issues and performing major repairs, including engine and transmission overhauls. The manual also includes essential technical specifications, torque values, and wiring diagrams, ensuring that all aspects of the vehicle's upkeep and repair are thoroughly addressed.
    🏷️ Basic Information
    Identification
    Make:
    Kawasaki
    Model:
    VN900 Custom
    Model Variant:
    Custom
    Years Covered:
    2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015
    Codes
    Chassis Codes:
    VN900B (Custom)
    👋 Introduction
    Market Position
    Segment:
    Cruiser Motorcycle
    Target Audience:
    Owners and technicians performing maintenance and repair on Kawasaki VN900 Custom models
    Competitive Analysis
    Competitors:
    Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series
    Key Features
    Motorcycle Type:
    Cruiser
    Design Philosophy:
    Classic styling with modern reliability and performance, tailored for comfortable cruising
    📋 Manual Details
    Coverage Areas
    Geographical Coverage:
    Global (specifications may vary slightly by region, but manual is comprehensive)
    Page Count
    Estimated Pages:
    500-700 (typical for comprehensive workshop manuals)
    Manual Type
    Type:
    Workshop Service Manual
    Language
    Language:
    English
    Format
    Format:
    PDF Download
    📖 Manual Coverage
    Systems Covered
    Powertrain:
    Engine, Transmission, Drivetrain, Fuel System, Ignition System, Cooling System
    Chassis:
    Frame, Suspension (Front & Rear), Steering, Brakes (Front & Rear), Wheels & Tires
    Electrical:
    Ignition System, Lighting System, Charging System, Starting System, Instruments, Switches, Wiring Diagrams
    Bodywork And Accessories:
    Body Panels, Fenders, Seat, Fuel Tank, Exhaust System, Controls, Accessories
    Procedures Included
    Maintenance:
    Scheduled maintenance, Oil and filter changes, Spark plug replacement, Air filter cleaning/replacement, Brake pad inspection/replacement, Chain maintenance
    Troubleshooting:
    Diagnostic procedures, Common problems and solutions, Fault codes (if applicable)
    Repair:
    Engine disassembly and reassembly, Transmission repair, Carburetor overhaul, Brake system overhaul, Suspension component replacement, Electrical component diagnosis and replacement
    Technical Data And Specs:
    Torque specifications, Clearances, Fluid capacities, Electrical component specifications
    Technical Depth
    Depth:
    Comprehensive (covering routine maintenance to complete engine and transmission rebuilds)
    📊 Manual Specifications
    File Format
    Format:
    PDF
    Searchable:
    Yes (typically for official PDF manuals)
    Print Quality
    Quality:
    High-resolution (designed for clarity and readability)
    Binding Type
    Binding:
    N/A (Digital PDF format)
    Paper Type
    Paper:
    N/A (Digital PDF format)
    ⚙️ Engine Specifications
    Primary Engine
    Engine Type:
    4-stroke, SOHC, V-twin
    Displacement:
    853 cc
    Bore X Stroke:
    85.0 x 74.5 mm
    Cooling System:
    Liquid-cooled
    Valve Configuration:
    2 valves per cylinder
    Performance
    Horsepower Estimated:
    50 HP @ 5700 rpm (approximate, varies by market and tuning)
    Torque Estimated:
    72 Nm (53.1 lb-ft) @ 3500 rpm (approximate)
    Fuel System
    Fuel Delivery:
    Fuel Injection (EFI)
    Carburetion Type:
    Electronic Fuel Injection (EFI) with dual 34mm throttle bodies
    Fuel Type:
    Unleaded gasoline
    Ignition
    Ignition System:
    Digital CDI
    Lubrication
    Lubrication System:
    Forced lubrication, wet sump
    Engine Oil Type
    Recommended Oil Grade:
    SAE 10W-40 API SG or higher (confirm with manual for specific recommendations)
    Engine Oil Capacity
    Oil Capacity With Filter Change:
    3.1 L (3.3 US qt) (approximate, verify in manual)
    🔧 Transmission
    Standard
    Transmission Type:
    5-speed constant mesh
    Optional
    Optional Transmission:
    N/A (only 5-speed available)
    Features
    Clutch Type:
    Wet, multiple disc
    Drivetrain
    Final Drive:
    Belt drive
    Gear Ratios
    Gear Ratios:
    Detailed in manual (typically includes 1st through 5th gear ratios and final drive ratio)
    📐 Dimensions
    Exterior
    Overall Length:
    2305 mm (90.7 in)
    Overall Width:
    895 mm (35.2 in)
    Overall Height:
    1110 mm (43.7 in)
    Wheelbase:
    1600 mm (63.0 in)
    Ground Clearance:
    140 mm (5.5 in)
    Seat Height:
    705 mm (27.8 in)
    Weights
    Curb Weight:
    265 kg (584.2 lbs)
    Fuel Tank Capacity:
    20 L (5.3 US gal)
    Wheels Tires
    Front Tire Size:
    80/90-21M/C 48H
    Rear Tire Size:
    180/70R15M/C 76H
    Front Brake Type:
    Single 300mm petal disc
    Rear Brake Type:
    Single 270mm petal disc
    Wheel Bolt Pattern:
    N/A (Cast wheels with hub assembly)
    🛡️ Safety Features
    Ratings
    Safety Ratings:
    Not applicable (motorcycle safety ratings are not standardized like automobiles)
    Active Features
    Braking System:
    Dual petal disc brakes (front and rear) for improved heat dissipation and performance
    Lighting:
    Halogen headlight, LED taillight and stoplight, standard turn signals
    Passive Features
    Frame Construction:
    Double-cradle steel frame for stability and rigidity
    Ergonomics:
    Low seat height and forward-mounted footpegs for comfortable rider control
    💡 Technology Features
    Infotainment
    Infotainment System:
    Basic instrumentation: speedometer, odometer, trip meter, fuel gauge, neutral indicator, high-beam indicator, turn signal indicators, engine coolant temperature indicator.
    Driver Assistance
    Driver Assistance Features:
    N/A (No electronic rider aids like ABS or traction control on standard models of this era).
    Connectivity
    Connectivity Features:
    N/A (No Bluetooth or smartphone integration on these models).
    🔧 Maintenance
    Service Intervals
    Oil Change Interval:
    Every 6,000 km (3,700 miles) or 6 months (typical, verify in manual)
    Air Filter Check Interval:
    Every 6,000 km (3,700 miles) (typical, verify in manual)
    Spark Plug Replacement Interval:
    Every 12,000 km (7,500 miles) (typical, verify in manual)
    Drive Belt Inspection:
    Every 12,000 km (7,500 miles) or annually (typical, verify in manual for tension and condition)
    Fluid Specifications
    Brake Fluid Type:
    DOT 4 (verify in manual)
    Coolant Type:
    Kawasaki All Season Motorcycle Coolant or equivalent ethylene glycol-based coolant (verify in manual for specific mix ratio)
    Fork Oil Type:
    Kawasaki Fork Oil G10 or SAE 10W (verify in manual for viscosity and quantity)
    Known Issues
    Common Wear Items:
    Tires, brake pads, clutch plates, drive belt, spark plugs, air filter
    Potential Issues:
    Fuel sensor readings (rare), minor electrical connections, exhaust system components (corrosion on older models)
    Part Numbers
    Oil Filter Part Number:
    Kawasaki 16097-0003 (verify specific application)
    📚 Vehicle History
    Brand Heritage
    Kawasaki Motorcycles:
    Kawasaki Heavy Industries has a long and respected history in motorcycle manufacturing, known for performance and reliability across various segments, including cruisers.
    Model Evolution
    Vn900 Lineage:
    The VN900 series, introduced in 2006, built upon Kawasaki's cruiser heritage, offering a modern interpretation of classic styling with a liquid-cooled V-twin engine and belt drive.
    Custom Variant Distinction:
    The 'Custom' variant typically features unique styling elements such as a larger front wheel (21-inch), different handlebars, and often more chrome or distinctive paint schemes compared to the Classic variant.
    Production
    Manufacturing Location:
    Japan (typically, final assembly locations can vary)
    🏆 Awards & Recognition
    Recognitions
    Industry Awards:
    While specific awards are not widely documented for this particular model year, the VN900 series has generally received positive reviews for its styling, comfortable ride, and value in the mid-size cruiser segment.
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