Kawasaki VN 900 Custom 2007-2015 Workshop Service Manual

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Taper: Motorcycle

Distributeur:

UGS: 80650

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

Variantes de produits

Description

This workshop service manual covers the cruiser motorcycle, produced for the model years 2007 through 2015. Engineered for reliability and rider comfort, the Custom features a liquid-cooled, 892 cc V-twin engine paired with a 5-speed transmission and a belt drive for smooth power delivery. Its distinctive styling, comfortable riding position, and customizable nature make it a popular choice for cruising. The motorcycle is equipped with a reliable fuel injection system, a robust braking setup, and essential instrumentation designed for rider convenience and information. This comprehensive 617-page English-language manual provides detailed instructions for the maintenance, repair, and diagnostics of your Custom. It covers all major systems, including engine mechanicals and electrical components, fuel and transmission systems, drivetrain, brakes, suspension, steering, and frame/bodywork. The manual includes scheduled maintenance procedures, troubleshooting guides for common issues, step-by-step repair instructions, and essential technical specifications. Its purpose is to empower owners and professional technicians with the knowledge needed to keep the Custom in optimal condition, ensuring its longevity and performance.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

VN900 Custom

Model Variant:

Custom

Product Type:

Workshop Service Manual

👋 Introduction

Market Position

Market Segment:

Cruiser motorcycle

Target Audience:

Owners and technicians seeking detailed repair and maintenance information.

Competitive Analysis

Value Proposition:

Provides essential DIY and professional repair knowledge to maintain and service the VN900 Custom effectively.

Key Features

Manual Features:

Instant download, comprehensive coverage, high page count, detailed diagrams and illustrations.

📋 Manual Details

Coverage Areas

Years Covered:

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

Page Count

Page Count:

Manual Type

Manual Type:

Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine teardown, assembly, inspection, and repair for internal components.

Engine Electrical:

Ignition system, charging system, starting system, EFI system diagnostics and troubleshooting.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, and fuel lines.

Transmission:

Clutch operation, gearbox disassembly, assembly, inspection, and maintenance.

Drivetrain:

Final drive system (belt drive), rear wheel hub, and related components.

Brakes:

Front and rear brake system components, hydraulic circuits, disc and caliper servicing, fluid replacement.

Suspension:

Front fork (telescopic) disassembly, assembly, oil replacement, and adjustment; rear shock absorber servicing.

Steering:

Handlebar assembly, steering stem bearings, and related components.

Electrical System:

Wiring diagrams, lighting systems, horn, battery, fuses, relays, and ECU diagnostics.

Frame And Bodywork:

Frame inspection, body panel removal and installation, seat, fenders, and accessories.

Procedures Included

Scheduled Maintenance:

Detailed service intervals for oil changes, filter replacements, chain adjustments, and inspections.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting guides for common issues.

Repair Procedures:

Step-by-step instructions for component removal, installation, and rebuilding.

Diagnostics:

Engine diagnostic codes (if applicable), EFI system checks, and electrical system fault finding.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to full engine rebuilds and complex electrical diagnostics).

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, suitable for printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Searchability:

Searchable text for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, V-twin

Displacement:

892 cc (54.5 cu in)

Bore X Stroke:

88.0 x 74.5 mm

Cooling System:

Liquid-cooled

Compression Ratio:

9.0:1

Performance

Horsepower:

Approx. 45 HP (33.5 kW) @ 5500 rpm (Note: Actual may vary slightly by region and test conditions)

Torque:

Approx. 77 Nm (56.8 lb-ft) @ 3500 rpm (Note: Actual may vary slightly by region and test conditions)

Fuel System

Fuel Delivery:

Fuel injection, DFI (Digital Fuel Injection)

Throttle Body:

Single 34 mm throttle body

Fuel Type:

Unleaded gasoline, 87 octane (90 RON) or higher recommended

Lubrication

Oil Type:

SAE 10W-40 API SG or SH with JMSO MA

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-disc

Features

Final Drive:

Belt drive

Gear Ratios:

Manual provides detailed gear ratios for each speed.

📐 Dimensions

Exterior

Overall Length:

Approx. 2,350 mm (92.5 in)

Overall Width:

Approx. 890 mm (35.0 in)

Overall Height:

Approx. 1,135 mm (44.7 in)

Wheelbase:

Approx. 1,635 mm (64.4 in)

Ground Clearance:

Approx. 135 mm (5.3 in)

Seat Height:

Approx. 705 mm (27.8 in)

Weights

Curb Weight:

Approx. 265 kg (584.2 lbs)

Fuel Capacity:

20 litres (5.3 US gal)

🛡️ Safety Features

Ratings

Safety Ratings:

Motorcycles are subject to different safety regulations than automobiles; manual focuses on mechanical and operational safety.

Active Features

Braking System:

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

Passive Features

Lighting:

Halogen headlight, LED taillight, and standard turn signals.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a cruiser motorcycle, typically without advanced infotainment systems).

Driver Assistance

Rider Aids:

No electronic rider aids (ABS was optional on some later models or different variants, but not standard on the Custom for this period).

Connectivity

Connectivity Features:

Instrumentation

Instrument Cluster:

Analog speedometer, digital display for odometer, trip meters, clock, and fuel gauge. Indicator lights for turn signals, high beam, neutral, and engine diagnostics.

🔧 Maintenance

Service Intervals

Engine Oil Change:

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

Air Filter Cleaning:

Every 6,000 km (3,700 miles) or 6 months; replace as needed.

Spark Plug Replacement:

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

Brake Fluid Change:

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

Fluid Specifications

Engine Oil Specification:

SAE 10W-40 API SG or SH, JASO MA

Coolant Type:

Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant, 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4

Gear Oil Specification:

Refer to manual for specific gearbox lubricant, often a specific gear oil is not listed as it shares engine oil.

Known Issues

Common Wear Items:

Belt drive, tires, brake pads, clutch plates (subject to riding style).

Potential Problems:

While generally reliable, potential issues can include fuel sensor malfunctions or minor electrical gremlins if not maintained. Manual covers diagnostics for these.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

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

Model Evolution

Vn900 Lineage:

The VN900 Custom is part of Kawasaki's popular Vulcan cruiser line, evolving from earlier V-twin models, emphasizing style and customizable features.

Production

Manufacturing Location:

Typically manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Model Awards:

Specific awards for the VN900 Custom vary, but the Vulcan line consistently receives positive reviews for styling and value in the cruiser segment.