Kawasaki 900 Custom Vulcan 2007-2015 Workshop Service Manual

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Distributeur:

UGS: 80590

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

Variantes de produits

Description

The Kawasaki Vulcan 900 Custom, produced from 2007 to 2015, represents a significant entry in the mid-size cruiser motorcycle segment. This model is renowned for its classic cruiser styling, featuring a V-twin engine, and is designed for riders seeking a blend of comfortable rideability and timeless aesthetics. Its engineering emphasizes reliability and a distinctive visual appeal, positioning it as a strong competitor within its class against other established cruiser lines. This comprehensive 617-page Workshop Service Manual provides in-depth guidance for the repair, maintenance, and troubleshooting of the Kawasaki Vulcan 900 Custom. It covers all essential systems, including the V twin engine, fuel injection, transmission, drivetrain, chassis, suspension, steering, braking, and electrical systems. Detailed procedures for routine maintenance, component disassembly and reassembly, diagnostics, and electrical system repair are included, along with critical technical specifications and wiring diagrams, making it an indispensable resource for owners and technicians alike.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Vulcan 900 Custom

Year:

2007-2015

Codes

Engine Code:

V twin, SOHC, 4-valve

Chassis Code:

VN900C

👋 Introduction

Market Position

Segment:

Cruiser motorcycle, mid-size class

Target Audience:

Riders seeking a stylish, comfortable, and reliable cruiser with a classic aesthetic and modern performance

Competitive Analysis

Competitors:

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

Key Features

Design Philosophy:

Classic cruiser styling with a modern V-twin engine, focus on comfort and rideability

Model Variations:

Includes standard Vulcan 900 Classic and the more stylized Vulcan 900 Custom with different styling cues and features.

📋 Manual Details

Coverage Areas

Coverage:

Repair, maintenance, troubleshooting, diagnostics, electrical systems, mechanical systems, chassis, bodywork

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Fuel injection, ignition, lubrication, cooling, internal engine components (cylinder head, piston, crankshaft, connecting rods), engine disassembly and assembly

Transmission Drivetrain:

Clutch operation and adjustment, gear shifting mechanisms, final drive (belt drive) inspection and maintenance

Chassis Suspension Steering:

Front fork service (oil change, seal replacement), rear shock absorber inspection, steering head bearing service, wheel and tire maintenance

Braking System:

Front and rear brake caliper service, hydraulic system bleeding, brake pad replacement, brake disc inspection

Electrical System:

Battery service, charging system (alternator, regulator/rectifier), lighting system, starter motor, ignition system diagnostics, wiring diagrams, ECU diagnostics

Fuel System:

Fuel pump, fuel injectors, throttle body, fuel lines, fuel tank maintenance and inspection

Bodywork And Trim:

Fairing removal and installation, seat removal, fender inspection, accessory mounting points

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, drive belt tension adjustment, brake fluid changes, coolant checks

Troubleshooting:

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

Repair And Rebuild:

Detailed step-by-step instructions for component disassembly, repair, and reassembly for major vehicle systems

Specifications And Tolerances:

Torque specifications for all fasteners, engine clearances, suspension settings, and other critical measurements

Wiring Diagrams:

Comprehensive electrical schematics for all circuits, aiding in diagnosis and repair

Technical Depth

Depth:

Comprehensive from basic owner maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable (allows finding information quickly by keyword)

Print Quality

Print Quality:

High-resolution scans suitable for printing individual pages or the entire document

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-twin, four-stroke

Displacement:

892 cc (54.4 cu in)

Bore X Stroke:

88.0 x 74.2 mm (3.46 x 2.92 in)

Valve Train:

SOHC, 8 valves (2 per cylinder)

Cooling System:

Liquid-cooled

Performance

Horsepower Est:

Approx. 50 hp (at crankshaft, may vary by model year and tuning)

Torque Est:

Approx. 76 Nm (56 lb-ft) (at crankshaft, may vary by model year and tuning)

Fuel System

Fuel Delivery:

Digital fuel injection (EFI) with dual 34mm throttle bodies

Fuel Type:

Unleaded gasoline, minimum 87 octane

Fuel Tank Capacity:

20 liters (5.3 US gal)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-disc

Features

Final Drive:

Sealed belt drive

📐 Dimensions

Exterior

Length Overall:

Approx. 2400 mm (94.5 in)

Width Overall:

Approx. 930 mm (36.6 in)

Height Overall:

Approx. 1120 mm (44.1 in)

Wheelbase:

Approx. 1645 mm (64.8 in)

Ground Clearance:

Approx. 135 mm (5.3 in)

Weights

Dry Weight:

Approx. 262 kg (578 lbs)

Wet Weight:

Approx. 281 kg (619 lbs) (fully fueled)

Seat Height:

Approx. 705 mm (27.8 in)

🛡️ Safety Features

Active Features

Braking System:

Hydraulic disc brakes front and rear

Lighting:

Halogen headlight, LED taillight, incandescent turn signals

Passive Features

Frame Construction:

Double-cradle, high-tensile steel frame

💡 Technology Features

Infotainment

Audio System:

N/A (No factory audio system)

Display:

Analog speedometer with digital odometer, trip meter, clock, and indicator lights

Driver Assistance

ABS was an optional feature on some later models, but not standard across the entire 2007-2015 range. The manual will cover ABS diagnosis if equipped.

Connectivity

Smart Phone Integration:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 6,000 miles (10,000 km) or 12 months

Air Filter Inspection Cleaning:

Every 6,000 miles (10,000 km)

Spark Plug Replacement:

Every 12,000 miles (20,000 km)

Drive Belt Tension Check:

Every 6,000 miles (10,000 km)

Brake Fluid Replacement:

Every 24,000 miles (40,000 km) or 24 months

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher, JASO MA approved (e.g., Kawasaki Genuine Oil)

Engine Oil Capacity:

3.2 L (3.4 US qt) without filter change; 3.5 L (3.7 US qt) with filter change

Coolant Type:

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

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Tires, brake pads, drive belt, fork seals, battery

Potential Faults:

While generally reliable, potential issues can include regulator/rectifier failures (common in many bikes of this era), and drive belt wear if not properly maintained.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long history of producing reliable and performance-oriented motorcycles, including iconic cruisers.

Model Evolution

Vulcan Lineage:

The Vulcan 900 Custom is part of Kawasaki's long-standing Vulcan cruiser line, known for its accessible styling and V-twin power.

Production

Production Period:

2006 to present (model covered 2007-2015)

Manufacturing Location:

Japan