Kawasaki Vulcan 900 VN 900 Custom Service Manual 2007- 2015

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Distributeur:

UGS: 89306

Mots clés: 2007 2008 2009 2010 2011 2012 2013 2014 2015 Kawasaki Misc Motorcycle Motorcycles VN 900 Custom Vulcan 900

Variantes de produits

Description

The Vulcan 900 Custom (VN900C) is a cruiser motorcycle from the first generation, produced between 2007 and 2015. It is recognized for its distinctive custom styling, featuring spoked wheels, drag-style handlebars, and a bobbed fender design, all powered by a torquey, liquid-cooled, 892 cc V-twin engine. This model is engineered for riders seeking a comfortable riding position and smooth power delivery characteristic of classic cruisers, blended with modern fuel injection and reliable performance. Its accessible seat height and manageable weight contribute to its appeal among a wide range of riders looking for a stylish and dependable machine for cruising. This comprehensive service manual provides detailed technical information and step-by-step procedures for the maintenance, repair, and troubleshooting of the Vulcan 900 Custom (VN900C) models from 2007 to 2015. It covers all major systems, including engine mechanicals, fuel and ignition systems, transmission, suspension, brakes, and the electrical system. The manual includes essential preventive maintenance schedules, diagnostic guides, component replacement instructions, and electrical wiring diagrams. Its in-depth coverage is designed to assist both professional technicians and experienced owners in keeping the vehicle in optimal condition, ensuring its longevity and performance.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Vulcan 900 Custom

Model Code:

VN900C

Generation

Generation Name:

First Generation

Generation Years:

2007-2015

Codes

Product Code Identifier:

VN900C

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Riders seeking a stylish, comfortable, and reliable cruiser with classic styling and modern features. Also targets motorcycle enthusiasts and DIY mechanics.

Competitive Analysis

Key Competitors:

Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series, Harley-Davidson Sportster (entry-level).

Key Features

Styling:

Distinctive custom styling with spoked wheels, drag-style handlebars, teardrop fuel tank, and bobbed fenders.

Engine Character:

Torquey V-twin engine delivering smooth power delivery, ideal for relaxed cruising.

Ergonomics:

Comfortable riding position with forward-mounted footpegs and swept-back handlebars.

Accessibility:

Relatively accessible seat height and manageable weight make it suitable for a wide range of riders.

📋 Manual Details

Coverage Areas

Vehicle Years Covered:

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

Specific Models Covered:

Kawasaki Vulcan 900 Custom (VN900C)

Page Count

Estimated Page Count:

Approximately 500-700 (typical for this type of comprehensive service manual)

Manual Type

Manual Type:

Official Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, disassembly, inspection, assembly, valve adjustments, piston and ring replacement, cylinder head service, timing chain and sprocket service, lubrication system.

Fuel System:

Fuel injection system (EFI) components, throttle body service, fuel pump diagnosis and replacement, fuel pressure checks, injector cleaning and testing.

Ignition System:

Ignition coils, spark plugs, CDI unit, ignition timing, troubleshooting ignition system faults.

Transmission:

Clutch operation and service, gearbox disassembly and assembly, gear inspection, shifting mechanism, final drive belt inspection and replacement, belt tensioning.

Suspension:

Front fork service (oil change, seal replacement, spring inspection), rear shock absorber inspection and replacement, linkage components.

Brakes:

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

Electrical System:

Wiring diagrams, battery service, charging system (alternator, regulator/rectifier), starting system (starter motor, starter clutch), lighting systems (headlight, taillight, turn signals), instrumentation, horn, fuses and relays, sensor diagnostics (MAP, TPS, IAT, Crankshaft Position).

Chassis And Body:

Frame inspection, steering system service (headstock bearings), wheel bearing replacement, handlebar and control lever adjustments, seat and body panel removal/installation, fender service, exhaust system inspection and replacement.

Cooling System:

Liquid cooling system service, radiator inspection and cleaning, coolant replacement, fan operation, thermostat service (if applicable).

Procedures Included

Preventive Maintenance:

Detailed maintenance schedules, oil change intervals, filter replacement procedures, lubrication points, torque specifications for routine checks.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, error code interpretation (if applicable).

Repair Procedures:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly for all major vehicle systems.

Component Replacement:

Detailed guides for replacing wear items (e.g., brake pads, tires, spark plugs, filters) and major components.

Technical Adjustments:

Carburetor synchronization (if applicable), idle speed adjustment, clutch lever free play adjustment, cable adjustments.

Wiring Diagram Interpretation:

Comprehensive electrical schematics with detailed component identification and circuit tracing.

Technical Depth

Depth Of Information:

Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers diagnostics, repair, and overhaul to factory specifications.

Diagnostic Capabilities:

Advanced diagnostic information, including specifications for testing sensors, actuators, and electronic control units (ECUs).

Rebuild Procedures:

Detailed instructions for complete engine and transmission rebuilds, including clearances, tolerances, and assembly sequences.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Typically text-searchable PDF for easy navigation and information retrieval.

Printability:

Printable for workshop use.

Print Quality

Image Resolution:

High-resolution, ensuring clarity of diagrams, illustrations, and photographs.

Binding Type

Binding Type:

Not applicable for PDF download (digital format)

Paper Type

Paper Type:

Not applicable for PDF download (digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, V-twin, 8-valve

Displacement:

892 cc (54.5 cu. in.)

Bore X Stroke:

88.0 x 74.5 mm (3.46 x 2.93 in.)

Compression Ratio:

9.5:1

Cooling Method:

Liquid-cooled

Ignition System:

Digital CDI with electronic timing advance

Performance

Horsepower Output:

Approx. 57 HP @ 6,000 RPM (manufacturer quoted, may vary)

Torque Output:

Approx. 59 lb-ft @ 3,000 RPM (manufacturer quoted, may vary)

Fuel System

Fuel Induction:

Fuel injection with dual 34mm throttle bodies

Fuel Tank Capacity:

20 Liters (5.3 US gal)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Primary Drive:

Final Drive:

Belt drive

Features

Clutch Type:

Wet, multi-disc

📐 Dimensions

Exterior

Overall Length:

2,415 mm (95.1 in.)

Overall Width:

925 mm (36.4 in.)

Overall Height:

1,110 mm (43.7 in.)

Wheelbase:

1,620 mm (63.8 in.)

Ground Clearance:

135 mm (5.3 in.)

Seat Height:

720 mm (28.3 in.)

Weights

Curb Weight:

Approx. 252 kg (555.6 lbs)

Gross Vehicle Weight Rating:

Not specified in product info, typically found in full manual

🛡️ Safety Features

Ratings

Safety Ratings:

Motorcycles are not typically assigned crash test ratings like cars. Focus is on rider safety features and handling.

Active Features

Braking System:

Front: 300mm disc, 2-piston caliper. Rear: 270mm disc, 2-piston caliper. Optional ABS available on some markets/years, though not explicitly stated for 'Custom' model without specific VIN check.

Lighting:

Halogen headlight, LED taillight.

Passive Features

Frame Construction:

Steel, double-cradle frame for stability.

Tire Specifications:

Front: 80/90-21M/C 48H. Rear: 180/70R15M/C 76H. Tubeless tires.

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer, digital tachometer, LCD multi-function display (fuel gauge, clock, trip meters, odometer), indicator lights.

Lighting Technology:

Halogen headlight for clear illumination, LED taillight for visibility and longevity.

Driver Assistance

ABS Availability:

Anti-lock Braking System (ABS) was optional on certain models or markets during this production run, enhancing braking control.

Connectivity

Connectivity Features:

No integrated smartphone connectivity or advanced electronic rider aids in the modern sense. Focus is on core mechanical and electrical systems.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first. (Refer to manual for exact interval and conditions).

Air Filter Cleaning:

Every 12,000 km (7,500 miles) or annually. Replacement as needed.

Spark Plug Replacement:

Every 12,000 km (7,500 miles). (Specific plug type required).

Coolant Replacement:

Every 24,000 km (15,000 miles) or 2 years. (Specific coolant type required).

Belt Drive Inspection:

Regular inspection for wear, damage, and proper tension. Replacement interval varies based on usage and maintenance.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or SH with JASO MA specification. (Consult manual for precise recommendation).

Engine Oil Capacity:

Approx. 3.0 L (3.2 US qt) without filter change, 3.2 L (3.4 US qt) with filter change. (Verify in manual).

Brake Fluid Type:

DOT 4.

Coolant Type:

High-quality ethylene glycol-based coolant with long-life additives. Mixture of 50% coolant and 50% distilled water.

Known Issues

Common Wear Items:

Brake pads, tires, clutch plates (with high mileage), drive belt (wear and tension).

Potential Electrical:

Some owners have reported regulator/rectifier issues on various Kawasaki models over the years, though not a widespread epidemic for the VN900. Manual is crucial for diagnostics.

Fuel System Maintenance:

Regular use of quality fuel and occasional cleaning of fuel injectors can prevent performance issues.

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycles:

Kawasaki Heavy Industries Motorcycle & Engine Company has a long history of producing innovative and high-performance motorcycles since the 1960s.

Model Evolution

Vulcan Lineage:

The Vulcan line has been Kawasaki's primary cruiser offering, known for its V-twin engines and classic styling. The 900 series was introduced as a mid-size cruiser that blended traditional looks with modern technology.

Vn900 Custom Introduction:

The VN900 Custom was launched in 2007, differentiating itself from the Classic models with its unique spoke wheels, drag handlebars, and custom-oriented aesthetics.

Production

Manufacturing Location:

Primarily manufactured in Japan by Kawasaki Heavy Industries.

🏆 Awards & Recognition

Recognitions

Model Awards:

While specific model awards for the VN900 Custom are not prominently advertised, the Vulcan line has consistently received positive reviews for its value, styling, and reliability within the cruiser segment.

Ratings

Owner Satisfaction:

Generally high owner satisfaction for its segment, appreciated for its balance of classic styling and modern engineering.

Certifications

Emissions Compliance:

Compliant with relevant emissions standards for the years of manufacture in major markets.