🏷️ Basic Information

Make:

Kawasaki

Model:

Vulcan 900 LT

Model Variant:

LT (Limited Touring)

Year Start:

2006

Year End:

2013

Model Code Range:

VN900B6F to VN900B13F (approximate, subject to regional variations)

👋 Introduction

Positioning:

The Kawasaki Vulcan 900 LT (Limited Touring) is positioned as an entry-level to mid-range cruiser, offering a balance of classic styling, rider comfort, and accessible performance for touring and everyday riding.

Competitors:

Competes with models such as the Honda Shadow series, Suzuki Boulevard S40/S50, Yamaha V-Star 650/950, and Harley-Davidson Sportster/Softail models in its class.

Features:

Liquid-cooled V-twin engine, fuel injection, belt drive, comfortable ergonomics with forward controls and passenger backrest, saddlebags, and windshield for touring.

Value:

This manual provides essential technical knowledge for owners and technicians to maintain, diagnose, and repair the Vulcan 900 LT, ensuring optimal performance, longevity, and safety, while potentially saving on labor costs.

📋 Manual Details

Coverage Scope:

Comprehensive workshop service and repair for Kawasaki Vulcan 900 LT models.

Estimated Pages:

500-700 (typical for this type of manual, actual may vary)

Type:

Workshop Service Manual

Language:

English

Format:

PDF Download

Scope:

Full factory workshop manual coverage.

📖 Manual Coverage

Engine:

Complete engine overhaul, disassembly, assembly, diagnosis, tuning, specific components (pistons, rings, valves, crankshaft, camshafts, timing system).

Fuel System:

Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel filter, sensors, pressure testing, troubleshooting.

Transmission:

Gearbox disassembly and assembly, clutch operation, shift mechanism, lubrication, troubleshooting.

Drivetrain:

Belt drive system, final drive belt inspection, tensioning, replacement, pulley inspection.

Brakes:

Hydraulic brake system (front and rear), calipers, master cylinders, brake lines, pads, rotors, bleeding procedure, troubleshooting.

Suspension:

Front telescopic forks (oil change, seal replacement, internal components), rear shock absorber unit (preload adjustment, removal, inspection).

Electrical System:

Ignition system, starting system, charging system (alternator, regulator/rectifier), lighting, battery, fuses, wiring diagrams, ECU diagnostics, sensor identification.

Frame And Bodywork:

Chassis inspection, frame components, body panels (fenders, tank, side covers), seat, fairing, windshield installation and removal.

Cooling System:

Radiator, coolant, fan, hoses, thermostat, troubleshooting (Note: Vulcan 900 is liquid-cooled).

Exhaust System:

Exhaust pipes, muffler, mounting, gasket replacement, inspection.

Wheels And Tires:

Wheel bearing inspection and replacement, tire mounting and balancing, rim inspection.

Controls:

Handlebar, levers, cables (throttle, clutch), foot controls, linkage adjustments.

Scheduled Maintenance:

Detailed instructions for all scheduled maintenance tasks, including oil changes, filter replacements, chain/belt adjustments, brake checks, spark plug replacement.

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon issues, including fault codes, symptom analysis, and step-by-step repair instructions.

Disassembly Assembly:

Complete instructions for dismantling and reassembling all major components and systems, with torque specifications.

Rebuilds Overhauls:

Detailed guidance for complete engine and transmission rebuilds, including component specifications and tolerances.

Wiring Diagrams:

Comprehensive electrical wiring schematics with component identification and color coding.

Special Tools:

Identification and usage instructions for specialized tools required for specific procedures.

Adjustments:

All necessary adjustments for engine, brakes, clutch, suspension, and controls.

Depth:

Full workshop level, covering basic maintenance to complete engine and transmission overhauls, advanced diagnostics, and component-level repair.

📊 Manual Specifications

Format Details:

Digital PDF, optimized for searchability and readability on various devices.

Quality:

High-resolution, ensuring clear text and legible diagrams/illustrations.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

Text Search:

Yes, text-searchable PDF allowing quick navigation to specific topics.

Print Option:

Yes, pages can be printed for physical reference.

⚙️ Engine Specifications

Type:

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

Displacement:

852 cc

Bore X Stroke:

88.0 x 69.2 mm

Compression Ratio:

9.5:1

Valve Train:

SOHC, 4 valves per cylinder

Horsepower Est:

Approx. 50-55 HP (at crank)

Torque Est:

Approx. 52-55 lb-ft (at crank)

System:

Electronic Fuel Injection (EFI) with sub-throttle, Mikuni DFI

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Type:

Digital CDI

🔧 Transmission

Type:

5-speed constant mesh

Clutch:

Wet, multi-plate

Drive System:

Belt Drive

Final Drive Ratio:

2.176 (60/21T, standard)

📐 Dimensions

Length:

2405 mm (94.7 in)

Width:

945 mm (37.2 in)

Height:

1455 mm (57.3 in)

Wheelbase:

1645 mm (64.8 in)

Ground Clearance:

140 mm (5.5 in)

Seat Height:

705 mm (27.8 in)

Curb Weight:

Approx. 282 kg (622 lbs)

Fuel Capacity:

20 liters (5.3 US gal)

🛡️ Safety Features

Crash Test Info:

N/A (Motorcycle specific safety is based on design and rider responsibility, no official ratings like cars)

Braking System:

Dual piston front caliper with 300mm disc, single piston rear caliper with 270mm disc.

Lighting:

Halogen headlamp, LED taillight, turn signals.

Ergonomics:

Low seat height and forward-mounted controls contribute to rider stability and comfort, indirectly enhancing safety.

💡 Technology Features

System:

Basic instrumentation: speedometer, odometer, trip meter, fuel gauge, clock. No advanced infotainment features.

Features:

N/A (No electronic rider aids beyond ABS on some optional models, not typically standard on the LT)

Features:

N/A (No Bluetooth, smartphone integration, or similar connectivity features)

🔧 Maintenance

Oil Change Interval:

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

Air Filter Interval:

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

Spark Plug Replacement:

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

Belt Tension Check:

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

Valve Clearance Check:

Every 24,000 km (15,000 miles).

Engine Oil:

SAE 10W-40, API SG, JASO MA certified motorcycle oil. Capacity: 3.5 L (3.7 US qt) with filter change.

Coolant:

Permanent type ethylene glycol coolant (50% solution with distilled water). Capacity: Approx. 1.7 L (1.8 US qt).

Brake Fluid:

DOT 4 hydraulic brake fluid.

Final Drive Fluid:

N/A (Belt drive system requires no lubrication fluid).

Common Wear Items:

Belt drive wear (can be subject to premature wear if not maintained correctly), brake pads, tires, fork seals.

Potential Electrical:

Occasional reports of regulator/rectifier failures or battery charging issues, particularly on higher mileage units.

Fuel System Notes:

As with many EFI systems, fuel quality and occasional injector cleaning might be beneficial for optimal performance.

📚 Vehicle History

Heritage Note:

Kawasaki has a long and successful history in motorcycle manufacturing, known for innovation and performance across various segments, including cruisers with the Vulcan line.

Evolution Summary:

The Vulcan 900 platform was introduced in 2006, evolving from earlier Vulcan models. The LT variant specifically added touring amenities like a windshield and saddlebags, enhancing its long-distance capability.

Production Period:

2006 - Present (platform continues with updates)

🏆 Awards & Recognition

Award History:

While specific awards for the 900 LT might not be widely publicized, the Vulcan line generally receives positive reviews for its value, styling, and reliability within the cruiser segment.