🏷️ Basic Information

Make:

Kawasaki

Model:

VN900CA Vulcan Custom

Year:

2010

Product Type:

Service Repair Workshop Manual

👋 Introduction

Segment:

Cruiser Motorcycle

Target Audience:

Owners, independent mechanics, and service technicians seeking detailed repair information.

Value Proposition:

Provides professional-level repair and maintenance guidance, enabling owners to perform complex tasks, reducing reliance on dealerships and saving on service costs.

Manual Utility:

Essential for diagnosing and rectifying issues, performing scheduled maintenance, and completing major repairs.

📋 Manual Details

Coverage Scope:

Complete service, repair, and maintenance

Estimated Page Count:

Likely 400-600 pages (typical for comprehensive service manuals)

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine System:

Engine assembly, disassembly, inspection, tuning, lubrication, cooling, fuel delivery, ignition, exhaust

Transmission System:

Clutch operation, gearbox overhaul, gear selection mechanism, final drive (belt)

Chassis System:

Frame inspection, suspension (front fork, rear shock absorber) overhaul and adjustment, steering system

Braking System:

Front and rear brake system inspection, disassembly, assembly, hydraulic components, fluid replacement

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), ignition system, lighting, instrumentation, starter motor, EFI system components

Fuel System:

Fuel tank, fuel pump, fuel injectors, throttle body, ECU controlled fuel injection system

Bodywork And Fittings:

Body panels, fenders, seats, handlebars, controls, exhaust system removal/installation

Maintenance Procedures:

Regular inspection, lubrication points, oil and filter changes, air filter replacement, spark plug replacement, drive belt tensioning and inspection

Troubleshooting:

Diagnostic procedures, common fault finding, symptom-based problem solving

Repair Procedures:

Detailed step-by-step instructions for component overhaul, replacement, and adjustment

Engine Rebuild:

Piston removal/installation, cylinder inspection, valve timing, crankshaft and connecting rod inspection

Suspension Adjustment:

Fork preload, compression, and rebound damping adjustments; rear shock preload and damping adjustments

Depth Of Information:

Comprehensive, covering from basic maintenance to complete engine and transmission overhauls, including electrical diagnostics and EFI system troubleshooting.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely searchable text (depending on PDF creation)

Printability:

Printable

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, V-twin

Displacement:

892 cc (54.5 cubic inches)

Bore X Stroke:

92.0 mm x 84.0 mm

Valvetrain:

SOHC, 4 valves per cylinder

Compression Ratio:

9.5:1

Horsepower:

Approx. 50-55 HP (rated)

Torque:

Approx. 55-60 lb-ft (rated)

Fuel Delivery:

Fuel Injection (EFI)

Ignition System:

Digital CDI

Oil Type:

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

Cooling Method:

Liquid-cooled

Coolant Type:

Ethylene glycol based coolant, 50/50 mix with distilled water

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-disc

Final Drive:

Belt Drive

Transmission Oil Type:

Kawasaki Genuine Gear Oil 75W-90 API GL-4

📐 Dimensions

Overall Length:

Approx. 2405 mm (94.7 in)

Overall Width:

Approx. 925 mm (36.4 in)

Overall Height:

Approx. 1110 mm (43.7 in)

Wheelbase:

Approx. 1635 mm (64.4 in)

Dry Weight:

Approx. 251 kg (553 lbs)

Curb Weight:

Approx. 261 kg (575 lbs)

Fuel Tank Capacity:

20 Liters (5.3 US gal)

🛡️ Safety Features

Safety Certification:

Meets applicable safety standards for motorcycles in its class.

Braking System Type:

Dual disc front, single disc rear

Brake Calipers:

2-piston front, 1-piston rear

Lighting System:

Halogen headlight, LED taillight

💡 Technology Features

Instrumentation:

Analog speedometer, digital odometer, trip meter, clock, fuel gauge, indicator lights.

Efi System:

Electronic Fuel Injection (EFI) provides precise fuel metering for optimal performance, fuel economy, and emissions control.

Diagnostic Port:

Likely includes a diagnostic connector for Kawasaki's electronic diagnosis system (KDS) for advanced troubleshooting.

🔧 Maintenance

Engine Oil Change:

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

Air Filter Inspection:

Every 6,000 km (3,700 miles)

Spark Plug Replacement:

Every 12,000 km (7,500 miles)

Drive Belt Inspection:

Every 6,000 km (3,700 miles)

Engine Oil Capacity:

3.2 L (3.4 US qt) without filter change, 3.4 L (3.6 US qt) with filter change

Coolant Capacity:

Approx. 1.6 L (1.7 US qt)

Common Concerns:

Potential for drive belt wear over time (inspect regularly), occasional minor electrical connector issues, but generally considered reliable.

Torque Wrench Specifications:

Manual will specify torque values for all critical fasteners (e.g., cylinder head bolts, crankcase bolts, wheel axle nuts).

📚 Vehicle History

Manufacturer History:

Kawasaki Heavy Industries, Ltd. is a Japanese public multinational corporation founded in 1896, renowned for its motorcycles, heavy equipment, aerospace, and defense products.

Vn900 Lineage:

The VN900 platform, introduced in 2006, is an evolution of Kawasaki's long-standing Vulcan cruiser line, known for its reliable V-twin engines and classic styling. The Vulcan Custom (VN900CA) variant distinguishes itself with unique styling cues such as spoke wheels, a smaller headlight, and different handlebars.

Manufacturing Location:

Likely manufactured in Japan or Thailand.

🏆 Awards & Recognition

Model Achievements:

While specific awards for the 2010 VN900CA are not widely publicized, the Vulcan line has consistently received positive reviews for its styling, comfort, and value within the cruiser segment.