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Kawasaki 2007-2014 Vulcan 900 Custom Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: Vulcan 900 Custom Internal Model Code: VN900B Year: 2007-2014 Codes Vin Prefix Engine Code: VN900 👋 Introduction Market Position Segment: Cruiser motorcycle, middleweight...
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Taper: Motorcycle
Distributeur:
UGS: 64174
Kawasaki 2007-2014 Vulcan 900 Custom Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Vulcan 900 Custom
Internal Model Code:
VN900B
Year:
2007-2014
Codes
Vin Prefix Engine Code:
VN900
👋 Introduction
Market Position
Segment:
Cruiser motorcycle, middleweight segment, customization-focused model.
Competitive Analysis
Key Competitors:
Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series, Harley-Davidson Sportster models (depending on specific market positioning and price).
Key Features
Design Philosophy:
Emphasizes a minimalist, custom bobber-inspired aesthetic with a focus on rider personalization and a comfortable riding experience.
Unique Selling Points:
Sleek, low-slung profile, abundant chrome accents, wide handlebars, spoke wheels, liquid-cooled V-twin engine.
📋 Manual Details
Coverage Areas
Covered Years:
2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014
Covered Models:
Vulcan 900 Custom (VN900B)
Page Count
Page Count:
564 pages
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine System:
Complete engine overhaul, internal components, valve train, ignition system, fuel injection, cooling system, lubrication system.
Transmission Clutch:
Clutch operation, transmission gears, shift mechanism, final drive (belt drive).
Chassis Suspension:
Frame inspection, front fork (suspension, damping), rear shock absorber, swingarm, bearings.
Braking System:
Front and rear disc brakes, hydraulic system, brake pads, fluid replacement, bleeding procedures.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting system, ignition coils, wiring diagrams, troubleshooting.
Fuel System:
Fuel pump, fuel injectors, throttle body, fuel tank, evaporative emission control system.
Cooling System:
Radiator, fan, coolant, thermostat, hoses.
Exhaust System:
Exhaust pipes, mufflers, catalytic converter (if applicable).
Wheels Tires:
Wheel removal and installation, tire mounting and balancing, tire pressure recommendations.
Bodywork Fittings:
Fairings, fenders, seat removal, handlebars, controls.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacement, spark plug replacement, air filter service, brake fluid flush, coolant flush, belt inspection/tensioning, general lubrication.
Troubleshooting Diagnostics:
Fault diagnosis for engine performance, electrical issues, fuel delivery problems, braking system malfunctions, using diagnostic codes (if applicable).
Repair Procedures:
Engine disassembly and reassembly, transmission repair, suspension fork service, brake caliper overhaul, electrical component replacement.
Technical Specifications Data:
Torque specifications for all fasteners, engine clearances, fluid capacities, electrical system resistance values, valve clearances.
Wiring Diagrams:
Detailed electrical schematics for all systems.
Technical Depth
Depth Of Coverage:
Comprehensive; covers everything from basic scheduled maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Resolution:
High-resolution (suitable for printing and screen viewing).
Clarity:
Clear, legible text and diagrams.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Text Searchable:
Yes (typically within PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, SOHC, V-twin
Displacement:
892 cc (54.5 cubic inches)
Bore X Stroke:
92.0 x 84.0 mm
Compression Ratio:
9.5:1
Valve Train:
SOHC, 4 valves per cylinder (2 intake, 2 exhaust)
Performance
Horsepower Approx:
Approx. 57 HP @ 6,500 RPM (manufacturer claims vary, actual dyno results may differ)
Torque Approx:
Approx. 78 Nm (57.5 lb-ft) @ 3,500 RPM (manufacturer claims vary, actual dyno results may differ)
Fuel System
Fuel Delivery:
Fuel Injection, Dual 34mm throttle bodies with sub-throttle valves
Fuel Type:
Unleaded gasoline, minimum 87 octane
Cooling System
Cooling Method:
Liquid-cooled
Lubrication System
Oil Capacity:
3.7 L (3.9 US qt) with filter change (refer to manual for exact specification and oil type).
Ignition System
Ignition:
Digital CDI with electronic advance
🔧 Transmission
Standard
Transmission Type:
Constant mesh 5-speed
Optional
Optional Transmission:
N/A (Standard 5-speed manual)
Features
Clutch Type:
Wet, multi-disc
Final Drive:
Belt Drive
Transmission Oil Type:
API GL-4, SAE 75W-90 (refer to manual for precise specification).
📐 Dimensions
Exterior
Overall Length:
Approx. 2405 mm (94.7 in)
Overall Width:
Approx. 915 mm (36.0 in)
Overall Height:
Approx. 1110 mm (43.7 in)
Wheelbase:
Approx. 1690 mm (66.5 in)
Ground Clearance:
Approx. 140 mm (5.5 in)
Seat Height:
Approx. 705 mm (27.8 in)
Weights
Curb Weight:
Approx. 260 kg (573 lbs)
Fuel Capacity:
20.0 L (5.3 US gal)
Wheels Tires
Front Tire Size:
80/90-21M/C 48H
Rear Tire Size:
180/70-15M/C 76H
Front Wheel:
Spoked, 21-inch
Rear Wheel:
Spoked, 15-inch
Wheelbase:
1690 mm (66.5 in)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles typically do not have standardized crash ratings like automobiles)
Active Features
Braking System Type:
Dual front disc brakes, single rear disc brake.
ABS Availability:
Optional on some later models, standard on specific trims if offered. Check specific bike's VIN for ABS.
Passive Features
Lighting:
Halogen headlight, LED taillight, incandescent turn signals.
💡 Technology Features
Infotainment
Infotainment System:
N/A (This model does not feature integrated infotainment systems like radios or Bluetooth connectivity). Primarily focused on the riding experience.
Driver Assistance
Driver Assistance Features:
N/A (No electronic rider aids beyond ABS if equipped).
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 12 months, whichever comes first (refer to manual for specific oil type and grade).
Air Filter Inspection:
Inspect every 6,000 km (3,700 miles), replace as needed or every 12,000 km (7,500 miles).
Spark Plug Replacement:
Replace every 12,000 km (7,500 miles) or as recommended by manual based on condition.
Belt Drive Inspection:
Inspect tension and condition every 6,000 km (3,700 miles).
Brake Fluid Replacement:
Replace every 24 months regardless of mileage.
Fluid Specifications
Engine Oil Type:
JASO MA, API SG, SAE 10W-40 (Kawasaki recommends their own branded oil or equivalent; check manual for exact specs).
Coolant Type:
Permanent type ethylene glycol based coolant, 50% solution with distilled water (refer to manual for specific type).
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Brake pads, tires, clutch plates (under heavy use), belt drive components.
Potential Electrical Issues:
Less common, but regulator/rectifier or stator issues can occur with age, though generally considered reliable.
Engine Performance Notes:
Known for smooth, reliable power delivery. Some riders report a desire for more power, often addressed through aftermarket exhaust and tuning.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycle Legacy:
Kawasaki Heavy Industries, Ltd. has a long-standing reputation for producing high-performance and reliable motorcycles across various segments since the 1960s, including iconic sportbikes and cruisers.
Model Evolution
Vulcan Lineage:
The Vulcan nameplate has been a staple in Kawasaki's cruiser lineup for decades, evolving through various displacements and styles to cater to different rider preferences. The 900 Custom builds upon the success of the earlier Vulcan 800 and the standard Vulcan 900 Classic, offering a more stylized, stripped-down appearance.
Production
Manufacturing Location:
Primarily manufactured in Japan.
Introduction Year For 900 Platform:
The 900cc platform was introduced in 2006 with the Vulcan 900 Classic, with the Custom variant following shortly thereafter.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews And Awards:
While specific awards are not frequently highlighted for this model, it consistently receives positive reviews for its styling, comfort, reliability, and value within the cruiser segment. Frequently praised for its 'custom' look at an affordable price point.
Ratings
Reliability Ratings:
Generally considered a very reliable motorcycle with good longevity when properly maintained. Kawasaki's V-twin engines are known for their durability.
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