Kawasaki VN900 Custom 2006-2015 Workshop Service Manual

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Type: Motorcycle

Vendor:

Sku: 69639

Tags: 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Kawasaki Motorcycle Motorcycles VN900 Custom Vulcan

Product variants

Description

The VN900 Custom, produced from 2006 to 2015, is a distinguished cruiser motorcycle known for its custom styling, comfortable riding position, and the characteristic V-twin engine. This model, part of a long-standing series, offers a blend of classic cruiser aesthetics with modern engineering, including fuel injection and liquid cooling for reliable performance. Its appeal lies in its customization potential and its suitability for both cruising and everyday riding, embodying the spirit of the cruiser segment. This comprehensive workshop service manual provides detailed instructions for the maintenance, repair, and troubleshooting of the VN900 Custom. It covers all essential systems, including the engine, transmission, drivetrain, chassis, suspension, brakes, and electrical components. With step-by-step procedures, diagnostic guidance, and technical specifications, this manual serves as an indispensable resource for owners, technicians, and mechanics aiming to preserve the optimal condition and longevity of their VN900 Custom.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

VN900 Custom

Model Variant:

Custom

Product Type:

Workshop Service Manual

Product Name:

Kawasaki VN900 Custom 2006-2015 Workshop Service Manual PDF Download

Codes

Chassis Code Range:

VN900B (likely, common for VN900 series)

Generation

Generation:

First Generation VN900 Series

👋 Introduction

Market Position

Motorcycle Segment:

Cruiser

Competitive Analysis

Key Competitors:

Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series, Harley-Davidson Sportster series (in spirit).

Key Features

Model Appeal:

Custom styling, comfortable riding position, V-twin engine character, reliable performance for its class, customization potential.

📋 Manual Details

Coverage Areas

Applicable Years:

2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015

Page Count

Page Count:

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

File Format:

Delivery Method:

Instant Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly, assembly, inspection, troubleshooting, lubrication system, cooling system (if applicable), fuel system (carburetion/injection), ignition system, exhaust system, engine tuning, performance adjustments.

Transmission And Drivetrain:

Clutch operation, transmission disassembly and assembly, gear inspection, final drive (belt drive maintenance, adjustment, inspection), troubleshooting.

Chassis And Suspension:

Frame inspection, front fork disassembly, assembly, and adjustment; rear shock absorber inspection and replacement; swingarm inspection and maintenance; wheel bearing service.

Brakes:

Brake caliper service, master cylinder service, brake fluid replacement, brake pad replacement, brake hose inspection, troubleshooting.

Electrical System:

Battery maintenance, charging system (stator, regulator/rectifier), lighting system (headlight, taillight, turn signals), ignition system wiring, starter system, fuse box, diagnostic codes (if applicable), component testing.

Bodywork And Trim:

Fender removal/installation, tank cover removal, seat assembly, handlebar replacement, minor body panel adjustments.

Controls And Cables:

Throttle cable adjustment and replacement, clutch cable adjustment and replacement, brake lever service, lever replacement.

Procedures Included

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, drive belt inspection/adjustment, brake fluid flush, coolant flush (if liquid-cooled), valve clearance checks.

Repair Procedures:

Complete engine overhaul, transmission rebuild, fork seal replacement, brake system overhaul, electrical component replacement, drive belt replacement, wheel bearing replacement.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, identifying causes of poor performance, starting problems, electrical faults.

Adjustment Procedures:

Carburetor synchronization (if applicable), idle speed adjustment, ignition timing (if adjustable), clutch lever free play, throttle cable free play.

Disassembly And Assembly:

Step-by-step instructions for removing and reinstalling all major and minor components.

Special Tools:

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

Technical Depth

Depth Of Information:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed diagrams and specifications.

📊 Manual Specifications

File Format

File Quality:

High-resolution PDF, printable pages, zoomable diagrams.

Print Quality

Printability:

Yes, all pages are printable.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Software Requirements

Required Software:

Adobe Reader

Operating System Compatibility:

Windows, Mac, Linux OS

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-twin, four-stroke, SOHC, 8-valve

Displacement:

892 cc

Bore X Stroke:

92.0 x 84.0 mm

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approximately 50-55 HP (estimate, actual figures vary based on tuning and market)

Torque:

Approximately 76 Nm (56.1 lb-ft) at 3,000 RPM (estimate)

Fuel System

Fuel Delivery:

Fuel Injection (EFI) with dual throttle valves (likely Suzuki Dual Throttle Valve system or similar Kawasaki implementation)

Fuel Tank Capacity:

Approximately 15 liters (3.5 gallons)

Lubrication System

Oil Type Recommendation:

Refer to manual for specific API service classification and viscosity (e.g., SAE 10W-40, JASO MA/MA2 recommended)

Ignition System

Ignition Type:

Digital CDI with electronic advance

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Optional Transmission:

Features

Clutch Type:

Wet, multi-disc

Final Drive:

Sealed O-ring type chain, or belt drive depending on specific VN900 model (Custom typically uses belt drive)

📐 Dimensions

Exterior

Overall Length:

Approx. 2400 mm (94.5 in)

Overall Width:

Approx. 930 mm (36.6 in)

Overall Height:

Approx. 1105 mm (43.5 in)

Wheelbase:

Approx. 1645 mm (64.8 in)

Weights

Dry Weight:

Approx. 262 kg (578 lbs)

Curb Weight:

Approx. 271 kg (598 lbs)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety ratings are not typically standardized like automotive safety ratings).

Active Features

Braking System:

Hydraulic disc front and rear brakes.

Passive Features

Lighting:

Halogen headlight, LED taillight and brake light, standard turn signals.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (This is a cruiser, not designed with advanced infotainment systems).

Driver Assistance

Driver Assistance Features:

N/A (Motorcycle equivalent to driver assistance is generally limited to braking systems).

Connectivity

Connectivity Features:

Instrumentation

Instrument Cluster:

Analog speedometer, analog tachometer (may vary by market/trim), LCD display for odometer, trip meter, fuel gauge, clock, and indicator lights.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to periodic maintenance chart, typically every 4,000-6,000 miles or 6 months.

Spark Plug Replacement Interval:

Refer to periodic maintenance chart, typically every 12,000-16,000 miles.

Air Filter Maintenance:

Inspect every 4,000-8,000 miles, clean or replace as needed.

Brake Fluid Flush Interval:

Typically every 2 years or as recommended by mileage.

Fluid Specifications

Engine Oil Viscosity:

SAE 10W-40 recommended (check manual for specific JASO rating, e.g., JASO MA/MA2 for wet clutch compatibility).

Engine Oil Capacity:

Approximately 3.2 - 3.4 liters (3.4 - 3.6 US qt) with filter change (verify in manual).

Coolant Type:

Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4 hydraulic brake fluid (verify in manual).

Known Issues

Common Wear Items:

Tires, brake pads, clutch plates (depending on usage), drive belt (if applicable), suspension bushings.

Potential Electrical Issues:

Regulator/rectifier failures (common in many motorcycles of this era), battery charging issues.

Drive Belt Maintenance:

Crucial to follow manufacturer's tension and alignment recommendations. Belt replacement intervals can vary significantly.

📚 Vehicle History

Brand Heritage

Brand Focus:

Kawasaki Heavy Industries is a diversified industrial manufacturer with a long history in motorcycles, aerospace, and heavy equipment.

Model Evolution

Vn Series Heritage:

The VN series cruisers have been a staple for Kawasaki, known for their V-twin engines and classic styling, evolving from earlier models like the VN750 and VN1500.

Vn900 Introduction:

The VN900 Vulcan Custom was introduced in 2006 as a more modern, stylish cruiser within the VN lineup, featuring fuel injection and liquid cooling for improved performance and emissions.

Production

Production Period:

2006-2015 for this specific manual coverage.

🏆 Awards & Recognition

Recognitions

Awards And Recognition:

While specific awards are not detailed, the VN900 Custom has been a popular choice in the mid-size cruiser market for its value and style.