Segment:
Cruiser Motorcycle
Target Audience:
Riders seeking a stylish, comfortable, and reliable cruiser with classic styling and modern performance.
Key Competitors:
Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series, Harley-Davidson Sportster.
Distinctive Aspects:
V-twin engine, shaft drive, low seat height, classic cruiser styling, rider comfort, fuel injection.
Covered Years:
2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Covered Models:
VN900B Vulcan 900 Custom
Type:
Workshop Service Manual (WSM)
Engine:
Engine assembly, disassembly, lubrication, cooling, fuel system, ignition system, exhaust system, starting system, charging system.
Transmission:
Clutch, gearbox, drive shafts, maintenance and repair.
Chassis:
Frame, suspension (front fork, rear shock absorber), steering system, wheels, tires.
Brakes:
Front and rear brake systems, hydraulic components, fluid specifications.
Electrical:
Wiring diagrams, lighting, indicators, starter, ignition, battery, charging system, fuses, relays, diagnostic codes.
Bodywork:
Body panel removal and installation, fenders, seat, fuel tank, accessories.
Maintenance:
Regular inspections, lubrication, fluid changes, filter replacements, spark plug service, drive belt inspection/replacement.
Troubleshooting:
Diagnostic procedures for common issues, fault finding by symptom.
Repair:
Detailed step-by-step repair instructions for all major components and systems.
Disassembly Assembly:
Complete guidance on disassembling and reassembling all mechanical and electrical components.
Torquing Specifications:
Precise torque values for all critical fasteners.
Depth:
Comprehensive; covers everything from routine maintenance to complete engine rebuilds and advanced electrical diagnostics.
Searchability:
Searchable text content for efficient information retrieval.
Print Quality:
High-resolution scans, suitable for printing.
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Engine Type:
Four-stroke, SOHC, V-twin
Displacement:
892 cc (54.5 cubic inches)
Bore X Stroke:
88.0 x 74.3 mm
Cooling System:
Liquid-cooled
Horsepower:
Approx. 57 hp @ 6,000 rpm (manufacturer claim, subject to regional variation)
Torque:
Approx. 53 lb-ft @ 3,500 rpm (manufacturer claim, subject to regional variation)
Fuel Delivery:
Fuel Injection (DFI) with dual 34mm throttle bodies
Fuel Type:
Unleaded gasoline, 87 octane or higher
Ignition System:
Digital CDI with electronic ignition timing
Exhaust System:
Dual exhaust, often with chrome finish
Overall Length:
Approx. 2,405 mm (94.7 in)
Overall Width:
Approx. 930 mm (36.6 in)
Overall Height:
Approx. 1,135 mm (44.7 in)
Wheelbase:
Approx. 1,635 mm (64.4 in)
Ground Clearance:
Approx. 140 mm (5.5 in)
Seat Height:
Approx. 686 mm (27.0 in)
Dry Weight:
Approx. 252 kg (555.6 lbs)
Curb Weight:
Approx. 260 kg (573.2 lbs) with all necessary fluids and a full tank of fuel.
Fuel Capacity:
20.0 liters (5.3 US gal)
Crash Test Ratings:
Not Applicable (Motorcycle)
Braking System:
Hydraulic disc brakes front and rear. ABS was an optional feature on some models/markets during this period.
Lighting:
Halogen headlamp, LED taillight and brake light, standard turn signals.
Oil Change:
Every 4,000 miles or 6 months (refer to manual for specific conditions).
Air Filter Cleaning:
Inspect every 4,000 miles, clean/replace as needed.
Spark Plug Replacement:
Every 8,000 miles or 12 months.
Coolant Check:
Check level every 2,000 miles or monthly.
Brake Fluid Change:
Every 24,000 miles or 24 months.
Engine Oil Type:
SAE 10W-40 API SG, SH, SJ, SL or JASO MA/MA2 certified motorcycle oil.
Engine Oil Capacity:
3.2 liters (3.4 US qt) without filter change; 3.5 liters (3.7 US qt) with filter change.
Coolant Type:
Kawasaki Genuine Coolant or equivalent mixture of ethylene glycol and distilled water (50/50 ratio).
Common Wear Items:
Tires, brake pads, clutch plates, drive chain and sprockets (if applicable, though this model has shaft drive which is generally lower maintenance). Clutch cable adjustment may be needed over time.
Potential Electrical:
Occasional reports of regulator/rectifier issues or battery charging system problems, common to many motorcycles of this era. The manual provides diagnostic steps.
Fuel System Maintenance:
Regular injector cleaning or fuel system additive use can help maintain optimal performance, especially with modern fuel formulations.
Parts Identification:
This service manual often references genuine Kawasaki part numbers for common replacement items (e.g., oil filters, spark plugs, brake pads) for accurate part ordering.
Heritage:
Kawasaki has a long and rich history in motorcycle manufacturing, particularly known for its performance and innovative designs across various categories, including cruisers.
Vulcan Lineage:
The Vulcan line has been a cornerstone of Kawasaki's cruiser offerings since its inception. The VN900 Custom represents a modern take on classic cruiser aesthetics, building upon the success of previous Vulcan models.
Production Period:
The VN900 Custom was introduced in 2006 and received updates throughout its production run up to 2013, with variations and successors continuing the lineage.
Manufacturing Location:
Primarily manufactured in Japan.
Motorcycle Reviews:
The Vulcan 900 series consistently received positive reviews for its styling, comfortable ride, and value proposition, making it a popular choice in the mid-size cruiser segment.
Reliability:
Generally considered reliable with proper maintenance, aligning with Kawasaki's reputation for robust engineering.
Emissions Standards:
Meets relevant emissions standards for the model years and regions of sale.
