Kawasaki Vulcan 900 Custom 2007-2015 Service Repair Manual

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The Vulcan 900 Custom, produced from 2007 to 2015, is a cruiser motorcycle celebrated for its distinctive long and low styling, rider comfort, and the character of its V-twin engine....

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Type: Motorcycle

Vendor:

Sku: 92971

Tags: 2007 2008 2009 2010 2011 2012 2013 2014 2015 Kawasaki Misc Motorcycle Motorcycles Vulcan 900 Custom

Product variants

Description

The Vulcan 900 Custom, produced from 2007 to 2015, is a cruiser motorcycle celebrated for its distinctive long and low styling, rider comfort, and the character of its V-twin engine. This model is a popular choice for riders who appreciate customization potential and a smooth, reliable riding experience. Its design emphasizes a classic cruiser aesthetic, making it a standout in the middleweight segment, known for its approachable performance and fuel efficiency. This comprehensive service repair manual provides in-depth guidance for the complete maintenance, servicing, and repair of the Vulcan 900 Custom. It covers all essential systems, including the engine, transmission, electrical components, chassis, suspension, brakes, and fuel system, detailing procedures from routine maintenance and troubleshooting to full component overhauls. With clear, step-by-step instructions and detailed specifications, this manual is an indispensable resource for owners, technicians, and enthusiasts seeking to maintain their vehicle's optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Vulcan 900 Custom

Year Start:

Year End:

Codes

Model Code Range:

VN900B7F to VN900BGF (typical manufacturer coding)

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Owners, Technicians, Enthusiasts seeking in-depth maintenance and repair information

Competitive Analysis

Niche:

Popular middleweight cruiser known for its customization potential and smooth ride.

Key Features

Vehicle Appeal:

Styling, rider comfort, V-twin engine character, fuel efficiency, customization options

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service and Repair for Kawasaki Vulcan 900 Custom

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Specifications

Page Count

Estimated Pages:

Approx. 600+

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Full overhaul, inspection, tuning, lubrication, cooling, fuel system (EFI), ignition system, exhaust system

Transmission:

Gearbox internal inspection and repair, clutch operation and adjustment, final drive (belt drive system) maintenance

Electrical:

Battery, charging system (alternator, regulator/rectifier), starting system, ignition system, lighting, instruments, wiring diagrams, ECU diagnostics

Chassis Suspension:

Front fork (telescopic) overhaul and adjustment, rear suspension (monoshock) inspection and service, steering system maintenance

Brakes:

Front and rear disc brake systems, hydraulic components, bleeding procedures, pad replacement, rotor inspection

Fuel System:

Electronic Fuel Injection (EFI) system, fuel pump, injectors, throttle body, sensors, diagnostics

Bodywork:

Frame inspection, body panels, fenders, seating, fuel tank removal and installation

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain/belt adjustment, brake fluid changes, spark plug service

Troubleshooting:

Diagnostic flowcharts for common and intermittent problems, electrical system troubleshooting, engine performance issues

Repair:

Detailed step-by-step repair instructions for all major components, including engine internal, transmission, suspension, and electrical systems

Disassembly Assembly:

Comprehensive instructions for disassembly and reassembly of all vehicle systems

Specifications:

Torque values, clearances, fluid capacities, electrical specifications, tire pressures

Technical Depth

Depth:

Comprehensive, from basic rider maintenance to complete engine and transmission rebuilds. Includes diagnostic procedures for EFI systems.

📊 Manual Specifications

File Format

File Type:

Digital PDF

Searchability:

Searchable text for quick information retrieval

Printability:

Printable pages for workshop use

Print Quality

Image Resolution:

High-resolution images and diagrams

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type:

4-stroke, liquid-cooled, V-twin

Displacement:

853 cc (52.0 cu in)

Bore X Stroke:

88.0 x 69.2 mm (3.46 x 2.72 in)

Valve Train:

SOHC, 2 valves per cylinder

Performance

Horsepower Est:

Approx. 50-55 HP @ 5500 RPM (wheel horsepower)

Torque Est:

Approx. 52-55 lb-ft @ 3500 RPM (wheel torque)

Fuel System

Induction:

Fuel Injection (DFI) with dual 34mm throttle bodies

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Lubrication

Oil Type Spec:

SAE 10W-40 API SG, JASO MA

Cooling

Cooling Method:

Liquid-cooled

Starting

Starter System:

Electric starter

🔧 Transmission

Standard

Type:

5-speed constant mesh

Final Drive:

Belt drive

Features

Clutch:

Wet, multi-disc

Maintenance

Transmission Oil Type:

Refer to Kawasaki Genuine Oil or equivalent API GL-4, SAE 80W-90

📐 Dimensions

Exterior

Overall Length:

93.1 in (2365 mm)

Overall Width:

36.4 in (925 mm)

Overall Height:

43.1 in (1095 mm)

Wheelbase:

64.8 in (1645 mm)

Ground Clearance:

5.7 in (145 mm)

Seat Height:

26.9 in (685 mm)

Weights

Curb Weight:

Approx. 631 lbs (286 kg)

Fuel Capacity:

5.5 US qt (5.2 L)

Wheels Tires

Front Tire:

80/90-21M/C 44S

Rear Tire:

180/70-15M/C 76H

Front Wheel Size:

21 x 2.15 in

Rear Wheel Size:

15 x 3.50 in

Bolt Pattern:

N/A (cast wheels)

🛡️ Safety Features

Ratings

Safety Features Design:

Designed to meet federal motorcycle safety standards. ABS not typically available on this model/trim during these years.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Passive Features

Lighting:

Halogen headlight, LED taillight, incandescent turn signals.

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer with LCD multi-function display (odometer, trip meters, clock, fuel gauge). Indicator lights for turn signals, oil pressure, neutral, high beam, engine.

Driver Assistance

ABS Availability:

ABS was an optional feature on some models/years, but not standard across the entire 2007-2015 range.

Connectivity

Connectivity Features:

N/A (No integrated Bluetooth or smartphone connectivity on this model range).

🔧 Maintenance

Service Intervals

Engine Oil Change:

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

Air Filter Inspection:

Every 3,700 miles (6,000 km), clean/replace as needed.

Spark Plug Replacement:

Every 7,500 miles (12,000 km)

Belt Drive Inspection:

Inspect tension and condition every 3,700 miles (6,000 km). Adjust as per manual specifications.

Brake Fluid Flush:

Every 2 years or 12,500 miles (20,000 km).

Coolant Replacement:

Every 2 years or 12,500 miles (20,000 km).

Fluid Specifications

Engine Oil Capacity:

Approx. 3.2 US qt (3.0 L) with filter change.

Coolant Type:

Kawasaki Motorcycle Coolant (anti-rust, anti-freeze) or equivalent (50/50 mix of ethylene glycol and distilled water).

Known Issues

Common Wear Items:

Tires, brake pads, belt drive (eventual replacement), clutch plates (high mileage).

Potential Recalls Tsbs:

Refer to official Kawasaki service bulletins for specific recalls or technical service bulletins related to the model years covered.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long-standing reputation for building reliable and performance-oriented motorcycles across various segments, including cruisers.

Model Evolution

Vulcan Lineage:

The Vulcan line has been Kawasaki's primary cruiser offering for decades, evolving with modern technology while retaining classic styling cues. The 900 Custom is a modern interpretation focused on a distinctive, long and low aesthetic.

Production

Introduction Year:

The Vulcan 900 platform was introduced in 2006, with the Custom variant being a key model within the range.

🏆 Awards & Recognition

Recognitions

Segment Awards:

While specific awards for the 900 Custom are not as commonly cited as some competitors, the Vulcan 900 platform generally receives positive reviews for its balance of style, performance, and value in the middleweight cruiser segment.