🏷️ Basic Information

Make:

Kawasaki

Model:

Vulcan VN900 Custom

Model Variant:

Custom

Model Year Start:

2007

Model Year End:

2010

Kawasaki Model Code Prefix:

VN900

👋 Introduction

Motorcycle Segment:

Cruiser

Target Audience:

Riders seeking a stylish, customizable, and comfortable cruiser for touring and everyday riding.

Key Competitors:

Honda Shadow, Yamaha V-Star, Suzuki Boulevard.

Styling:

Sleek, low-slung profile, custom elements like spoke wheels, sculpted tank, and wide handlebars.

Engine Type:

V-twin, liquid-cooled engine known for its tractable power delivery.

Ride Comfort:

Ergonomic riding position and suspension tuned for comfort on longer rides.

📋 Manual Details

Manual Type:

Factory Service & Repair Workshop Manual

Language:

English

Format:

Downloadable PDF

Coverage Scope:

Complete factory documentation

Estimated Page Count:

400-500 pages (typical for this model range and manual type)

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, inspection, internal components (pistons, rings, valves, camshafts, crankshaft), cylinder head, lubrication system, cooling system.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel lines, fuel tank, troubleshooting fuel delivery.

Ignition System:

Ignition coils, spark plugs, ECU control, timing specifications, troubleshooting ignition faults.

Transmission:

Clutch operation and adjustment, gearbox disassembly and assembly, gear shifting mechanism, transmission fluid.

Drivetrain:

Final drive belt system, belt tension adjustment, sprocket inspection and replacement.

Brake System:

Front and rear brake calipers, master cylinders, brake lines, brake pads, rotor inspection, bleeding procedures, ABS system (if equipped).

Suspension:

Front fork (telescopic, cartridge type), rear shock absorber (monoshock or dual shocks), spring preload adjustment, fork oil replacement and specifications, shock absorber service.

Electrical System:

Wiring diagrams, battery specifications, charging system (alternator/stator, rectifier/regulator), starter motor, lighting system (headlight, taillight, indicators), horn, fuses, relays, ECU diagnostics.

Chassis And Frame:

Frame inspection, steering head bearings, wheel bearing inspection and replacement, swingarm pivot, alignment checks.

Bodywork And Trim:

Fender removal and installation, fuel tank removal, seat removal, side covers, handlebar assembly, control cables.

Maintenance:

Scheduled maintenance checks, oil and filter changes, air filter replacement, spark plug replacement, brake fluid replacement, coolant checks, drive belt inspection and adjustment.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for engine performance, electrical issues, starting problems, braking issues, and suspension concerns.

Repair:

Detailed step-by-step instructions for engine overhaul, transmission repair, suspension overhaul, brake system overhaul, electrical component replacement, and bodywork repairs.

Diagnostics:

Information on reading diagnostic trouble codes (DTCs) if applicable, electrical system testing using multimeters, and common failure points.

Disassembly Assembly:

Comprehensive procedures for the complete disassembly and reassembly of all major motorcycle components.

Depth Of Information:

Comprehensive, covering basic to advanced mechanical and electrical repairs, engine rebuilds, and detailed component diagnostics.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Typically text-searchable PDF for easy navigation and information retrieval.

Printability:

Designed for printing, allowing users to create physical copies of sections or the entire manual.

Binding Type Digital:

N/A (Digital download)

Paper Type Digital:

N/A (Digital download)

⚙️ Engine Specifications

Engine Type:

4-stroke, V-twin, SOHC, 8-valve, liquid-cooled

Displacement:

903 cc (55.1 cu. in.)

Bore X Stroke:

88.0 x 74.3 mm (3.46 x 2.93 in.)

Compression Ratio:

9.5:1

Horsepower Estimated:

Approx. 50-55 HP @ 5500 RPM (subject to market and regulatory variations)

Torque Estimated:

Approx. 57-60 lb-ft @ 3500 RPM (subject to market and regulatory variations)

Fuel Delivery:

Fuel Injection with Dual Throttle Valves (DFI)

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Lubrication System:

Forced lubrication, wet sump

Cooling Method:

Liquid-cooled

Ignition System:

Digital CDI (Capacitor Discharge Ignition)

Starter:

Electric starter

🔧 Transmission

Transmission Type:

5-speed constant mesh

Transmission Options:

N/A (single transmission configuration)

Clutch Type:

Wet, multi-disc

Final Drive:

Belt Drive

Gear Ratios:

Refer to manual for specific gear ratios (e.g., 1st: 3.15, 2nd: 2.15, 3rd: 1.60, 4th: 1.27, 5th: 1.04)

📐 Dimensions

Overall Length:

Approx. 2435 mm (95.9 in.)

Overall Width:

Approx. 930 mm (36.6 in.)

Overall Height:

Approx. 1135 mm (44.7 in.)

Wheelbase:

Approx. 1690 mm (66.5 in.)

Ground Clearance:

Approx. 140 mm (5.5 in.)

Seat Height:

Approx. 685 mm (27.0 in.)

Curb Weight:

Approx. 263 kg (580 lbs.)

Fuel Tank Capacity:

20 Liters (5.3 US gal.)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycles are not rated by organizations like NHTSA or Euro NCAP in the same way as cars).

Braking System:

Dual hydraulic disc brakes (front), Single hydraulic disc brake (rear). ABS may be an option on certain markets/trims.

Lighting:

Halogen headlight, LED taillight, front and rear turn signals.

Frame Construction:

Steel frame and swingarm designed for stability.

Tire Design:

Tubeless tires for improved puncture resistance. Front: 80/90-21M/C 48H, Rear: 180/70-15M/C 76H.

💡 Technology Features

Instrument Cluster:

Analog speedometer, digital display for odometer, trip meters, clock, fuel gauge, and indicator lights.

ABS:

Optional Anti-lock Braking System (ABS) available on some models/trims within these years.

Connectivity Features:

N/A (Motorcycle does not feature advanced connectivity like Bluetooth or smartphone integration in this generation).

ECU:

Engine Control Unit (ECU) manages fuel injection and ignition timing.

🔧 Maintenance

Engine Oil Change:

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

Oil Filter Replacement:

At every engine oil change.

Air Filter Cleaning:

Inspect every 6,000 km (3,700 miles), clean or replace as needed. Replace every 18,000 km (11,200 miles).

Spark Plug Replacement:

Inspect every 12,000 km (7,500 miles), replace as needed. Specific replacement interval might be higher depending on plug type.

Drive Belt Inspection Tension:

Every 12,000 km (7,500 miles). Adjust tension as per manual specifications.

Brake Fluid Replacement:

Every 24,000 km (15,000 miles) or 2 years, whichever comes first.

Engine Oil Type:

SAE 10W-40 API SG, JASO MA or MA2. Refer to manual for specific recommendations.

Engine Oil Capacity:

3.4 L (3.6 US qt) with filter change.

Cooling System Coolant:

Permanent type antifreeze (50% solution of ethylene glycol) mixed with deionized water. Kawasaki Coolant recommended.

Brake Fluid Type:

DOT 4.

Transmission Fluid:

Not applicable, engine oil lubricates the transmission.

Common Wear Items:

Drive belt, brake pads, tires, clutch plates (with high mileage), spark plugs.

Potential Electrical:

Battery terminals, charging system components (rectifier/regulator) under heavy use or with age.

Engine Performance:

Occasional throttle response tuning might be needed; EFI system is generally robust.

📚 Vehicle History

Kawasaki Heritage:

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

Vulcan Lineage:

The Vulcan nameplate has been a cornerstone of Kawasaki's cruiser lineup for decades, with the VN900 Custom being a modern iteration focusing on customizable styling and comfortable cruising.

Manufacturing Location:

Typically assembled in Japan or at overseas manufacturing facilities.