Kawasaki VN900 Custom 2007-2015 Service Repair Manual

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This manual covers the VN900 Custom, a V-Twin cruiser model produced from 2007 to 2015. Known for its stylish design and comfortable riding experience, the VN900 Custom embodies a legacy...

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Type: Motorcycle

Vendor:

Sku: 92969

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

Product variants

Description

This manual covers the VN900 Custom, a V-Twin cruiser model produced from 2007 to 2015. Known for its stylish design and comfortable riding experience, the VN900 Custom embodies a legacy of quality engineering and reliability. Its 903cc liquid-cooled V-twin engine, equipped with electronic fuel injection, provides smooth power delivery, while the belt drive system ensures efficient and clean operation. This model is designed for riders who appreciate classic cruiser aesthetics combined with modern performance and dependability. This comprehensive factory service repair manual, written in English, provides in-depth information for maintaining and repairing the VN900 Custom. It details scheduled maintenance, fluid services, and component replacements, along with step-by-step instructions for disassembly and reassembly of all major systems, including the engine, fuel system, chassis, and electrical components. Troubleshooting guidance for common issues and detailed technical specifications are also included, making this manual an essential resource for both owners and professional technicians to ensure optimal performance and longevity of their motorcycle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

VN900 Custom

Engine Type:

V-Twin Cruiser

Codes

Model Codes:

VN900C (specific codes may vary by region and sub-model)

👋 Introduction

Market Position

Target Audience:

Owners of Kawasaki VN900 Custom motorcycles seeking to perform maintenance and repairs themselves, as well as professional motorcycle technicians.

Competitive Analysis

Advantage Over Paper:

Convenience, cost-effectiveness, ease of navigation, ability to print specific sections, digital storage and access across multiple devices, no risk of physical damage.

Key Features

Content Richness:

Hundreds of pages filled with detailed explanations, procedures, and technical data, accompanied by numerous photos and illustrations.

User Friendliness:

Written in a clear, step-by-step manner, making complex procedures accessible to DIYers.

📋 Manual Details

Coverage Areas

Model Years Covered:

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

Page Count

Estimated Page Count:

Hundreds of Pages (as stated in product description)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

General Information, Fuel System, Cooling System, Engine Top End, Clutch, Lubrication System, Engine Removal/Installation, Crankshaft/Transmission

Chassis Systems:

Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame

Electrical System:

Electrical System

Ancillary Systems:

Appendix (likely includes specifications, torque values, wiring diagrams)

Procedures Included

Maintenance Procedures:

Scheduled maintenance, fluid checks and changes, filter replacements, general inspections

Repair Procedures:

Step-by-step instructions for disassembly, repair, and reassembly of all major components and systems

Troubleshooting:

Diagnostic procedures for common issues and performance problems

Bodywork Procedures:

Fairings, fenders, fuel tank, seat, side covers, exhaust system removal and installation.

Suspension Procedures:

Front fork overhaul, rear shock absorber replacement and adjustment.

Wheel And Tire Procedures:

Wheel removal and installation, tire mounting and balancing, spoke tension adjustment (if applicable).

Brake System Procedures:

Brake fluid replacement, caliper service, pad replacement, rotor inspection and replacement.

Electrical System Procedures:

Battery maintenance, charging system testing, ignition system troubleshooting, lighting and accessory wiring.

Technical Depth

Depth:

Comprehensive factory-level detail, suitable for both DIY enthusiasts and professional mechanics

Diagnostic Tools:

Information will include specifications for diagnostic tools or methods used for EFI systems and fault code retrieval if applicable.

📊 Manual Specifications

File Format

Compatibility:

Compatible with all versions of Windows and macOS, accessible via web browser on any device

Readability Requirements:

Adobe PDF Reader and WinZip (free software)

Print Quality

Printability:

Fully printable, allowing users to print specific pages or the entire manual

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Quality:

N/A (Digital PDF format, intended for printing on user's preferred paper)

⚙️ Engine Specifications

Primary Engine

Engine Configuration:

903cc, V-twin, SOHC, 4-valve per cylinder, liquid-cooled

Bore X Stroke:

92.0 x 84.0 mm (estimated for VN900 engine)

Compression Ratio:

9.5:1 (estimated for VN900 engine)

Engine Cooling:

Liquid-cooled

Performance

Horsepower:

Approx. 50-55 HP (at crankshaft, specific figure to be confirmed within manual)

Torque:

Approx. 58-60 lb-ft (at crankshaft, specific figure to be confirmed within manual)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual 34mm Keihin throttle bodies

Fuel Type:

Unleaded gasoline (Octane rating to be specified in manual)

Fuel Tank Capacity:

Approx. 5.5 liters (1.45 US gal)

Throttle Body Size:

34mm (dual)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Optional

Optional Types:

N/A (VN900 Custom is typically equipped with a standard 5-speed)

Features

Drive Type:

Belt Drive

Clutch Type:

Wet, multi-disc

Final Drive Type:

Belt Drive

📐 Dimensions

Exterior

Overall Length:

Approx. 2405 mm (94.7 in)

Overall Width:

Approx. 945 mm (37.2 in)

Overall Height:

Approx. 1135 mm (44.7 in)

Wheelbase:

Approx. 1645 mm (64.8 in)

Weights

Curb Weight:

Approx. 271 kg (597.5 lbs)

🛡️ Safety Features

Ratings

Safety Certifications:

Meets all applicable safety standards for motorcycles in its class and target markets.

Active Features

Braking System:

Hydraulic disc brakes front and rear (specific caliper and rotor sizes to be detailed in manual)

Optional ABS on certain model years/trims (to be verified for specific year coverage)

Passive Features

Lighting:

Halogen headlight, LED taillight and brake light.

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer, digital tachometer, fuel gauge, clock, trip meter, indicator lights. Style often features a tank-mounted instrument cluster.

Driver Assistance

ABS Availability:

ABS was an optional feature on some VN900 Custom models, enhancing braking control.

Connectivity

Connectivity Features:

No integrated smartphone connectivity or advanced electronic rider aids typically found on modern motorcycles. Focus is on mechanical simplicity and classic cruiser experience.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 4,000 miles or 6 months (refer to manual for exact specifications and oil type)

Spark Plug Replacement:

Typically every 7,500-15,000 miles (refer to manual for specific spark plug type and gap)

Belt Drive Tension:

Regular inspection and adjustment as per manual recommendations

Fluid Specifications

Engine Oil Type:

10W-40 or 20W-50 API SG or higher (refer to manual for exact specification and capacity)

Coolant Type:

Kawasaki Genuine Coolant or equivalent mixture of ethylene glycol and distilled water (refer to manual for mix ratio and capacity)

Brake Fluid Type:

DOT 4 recommended (refer to manual for exact specification)

Gear Oil Type:

Refer to manual for specific transmission fluid requirements.

Known Issues

Common Wear Items:

Tires, brake pads, clutch plates, drive belt, spark plugs, fork seals (detailed inspection and replacement procedures covered in manual).

Potential Electrical Concerns:

Corrosion on connectors, rectifier/stator issues (diagnostic procedures and troubleshooting covered in electrical section).

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki Heavy Industries has a long and storied history in motorcycle manufacturing, known for innovation, performance, and reliability across various segments including cruisers.

Model Evolution

Vn900 Custom Origins:

The VN900 Custom was introduced as part of Kawasaki's Vulcan line, offering a more stylized and customizable cruiser option. It builds upon the cruiser heritage of the Vulcan series with modern engineering and design cues.

Production

Production Period:

2007-2015 (as per manual coverage)

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

While specific awards for the 2007-2015 VN900 Custom may not be widely publicized, the Vulcan series has consistently been recognized for its value, styling, and comfortable riding experience within the cruiser segment.