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Kawasaki Vulcan 900 VN 900 2006-2013 Workshop Service Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: Vulcan 900 Model Codes: VN900 Applicable Years: 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 👋 Introduction Market Position Segment: Cruiser Motorcycle Target...
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Kawasaki Vulcan 900 VN 900 2006-2013 Workshop Service ManualKawasaki Vulcan 900 VN 900 2006-2013 Workshop Service ManualKawasaki Vulcan 900 VN 900 2006-2013 Workshop Service ManualKawasaki Vulcan 900 VN 900 2006-2013 Workshop Service Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Vulcan 900
Model Codes:
VN900
Applicable Years:
2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
👋 Introduction
Market Position
Segment:
Cruiser Motorcycle
Target Audience:
Riders seeking a classic V-twin cruiser experience with modern reliability.
Competitive Analysis
Key Competitors:
Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series.
Key Features
Engine Type:
V-twin, liquid-cooled, SOHC, 8-valve
Styling:
Classic cruiser aesthetic with modern touches, comfortable ergonomics.
Drivetrain:
Belt drive for low maintenance and smooth power delivery.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Secondary Coverage:
Maintenance, Diagnostics, Troubleshooting, Overhaul
Page Count
Estimated Pages:
Hundreds (typical for comprehensive workshop manuals)
Manual Type
Type:
Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, cylinder head, pistons, crankshaft, lubrication system, cooling system (if applicable), fuel injection system
Transmission:
Gearbox disassembly, inspection, repair, clutch system, final drive
Chassis:
Frame, suspension (front fork, rear shock absorber), steering system, wheels, tires, brakes (front and rear)
Electrical System:
Wiring diagrams, lighting system, ignition system, starting system, charging system, sensors, ECUs
Fuel System:
Fuel tank, fuel pump, injectors, fuel lines, emissions control systems
Bodywork And Trim:
Body panels, fenders, seat, handlebars, exhaust system, decorative elements
Procedures Included
Maintenance:
Routine service, oil changes, filter replacements, spark plug inspection/replacement, chain adjustment, brake pad replacement
Diagnostics:
Troubleshooting guides, diagnostic fault codes (DTCs), symptom analysis
Repair:
Component-level repair procedures, part replacement guides, assembly and disassembly instructions
Technical Specifications:
Torque values, clearances, fluid capacities, electrical specifications
Technical Depth
Depth:
Comprehensive (suitable for professional technicians and advanced DIY enthusiasts)
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Yes (typically, for PDF manuals)
Print Quality
Quality:
High-resolution, printable pages with clear diagrams and text
Binding Type
Binding:
N/A (Digital PDF download)
Paper Type
Paper Type:
N/A (Digital PDF download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, V-twin, 8-valve
Displacement:
892 cc (54.5 cubic inches)
Bore X Stroke:
92.0 x 84.0 mm
Cooling System:
Liquid-cooled
Compression Ratio:
9.0:1
Performance
Horsepower Est:
Approx. 50-55 HP @ 5600 RPM (estimated, may vary by region and tuning)
Torque Est:
Approx. 57-60 lb-ft @ 3000 RPM (estimated)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual 34mm throttle bodies
Fuel Type:
Unleaded gasoline, minimum 87 octane
Emissions Control:
Catalytic converter, Evaporative Emission Control System (EVAP)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Clutch:
Wet, multi-plate, cable-actuated
Final Drive:
Belt Drive
Features
Gear Ratios:
Detailed in manual (typically 1st: ~2.667, 2nd: ~1.933, 3rd: ~1.458, 4th: ~1.174, 5th: ~0.960)
📐 Dimensions
Exterior
Length:
Approx. 2350 mm (92.5 in)
Width:
Approx. 990 mm (39.0 in)
Height:
Approx. 1125 mm (44.3 in)
Wheelbase:
Approx. 1605 mm (63.2 in)
Ground Clearance:
Approx. 140 mm (5.5 in)
Weights
Curb Weight:
Approx. 270 kg (595 lbs)
Fuel Capacity:
20 Liters (5.3 US gal)
Seat Height:
Approx. 705 mm (27.8 in)
🛡️ Safety Features
Ratings
Safety Features Overview:
Focus on rider control and stability. ABS was an optional feature on some models.
Active Features
Brakes Front:
Hydraulic disc, 300 mm rotor with dual-piston caliper
Brakes Rear:
Hydraulic disc, 270 mm rotor with single-piston caliper
ABS:
Optional on certain configurations and model years.
Passive Features
Lighting:
Halogen headlight, LED taillight and turn signals (depending on specific trim/year).
Tires Front:
Bias-ply or Radial, typically 80/90-21 or 90/90-21
Tires Rear:
Bias-ply or Radial, typically 180/70-15
💡 Technology Features
Infotainment
Dashboard:
Analog speedometer, digital tachometer, fuel gauge, clock, trip meter, indicator lights.
Audio System:
Not standard. LT models may have accessory audio systems.
Driver Assistance
Cruise Control:
Not standard.
Connectivity
Bluetooth:
Not standard.
Lighting Tech
Headlight Type:
12V 60/55W Halogen.
🔧 Maintenance
Service Intervals
Oil Change:
Every 4,000 miles or 6 months, whichever comes first (refer to manual for precise interval).
Air Filter Inspection:
Every 8,000 miles or 12 months.
Spark Plug Replacement:
Every 12,000 miles or 24 months.
Belt Drive Inspection:
Regularly, adjust tension as needed (specific interval in manual).
Valve Clearance Check:
Every 15,000 miles (refer to manual for exact interval and procedure).
Fluid Specifications
Engine Oil:
SAE 10W-40 API SG, JASO MA or MA2 Recommended. Capacity approx. 3.1L (3.3 US qt) with filter change.
Coolant:
Ethylene glycol-based coolant, 50/50 mix with distilled water. Capacity approx. 1.8 L (1.9 US qt).
Brake Fluid:
DOT 4 recommended.
Transmission Oil:
Integrated with engine oil for this model.
Known Issues
Common Wear Items:
Tires, brake pads, clutch plates (depending on riding style), drive belt wear.
Potential Issues:
Occasional issues with fuel sensor accuracy or electrical connector corrosion in harsh environments. Check for recalls.
Part Numbers Example
Oil Filter:
e.g., Kawasaki 16097-0004 or equivalent aftermarket (refer to manual for precise part number).
Air Filter:
e.g., Kawasaki 11013-0020 or equivalent aftermarket.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycles:
Kawasaki has a long and storied history in motorcycle manufacturing, known for performance and reliability across various segments.
Model Evolution
Vulcan Lineage:
The Vulcan line has been a staple in Kawasaki's cruiser lineup, with the 900cc models building upon the success of earlier displacements, offering a balance of power, comfort, and classic styling.
Production
Manufacturing Location:
Japan (primary)
Model Variants:
Includes Classic, Custom, and LT (Luxury Tourer) variants with differing features and aesthetics.
🏆 Awards & Recognition
Recognitions
Model Awards:
While specific 'awards' for this model are not widely publicized, the Vulcan 900 series has consistently received positive reviews for its value, comfort, and reliable performance within the cruiser segment.
Ratings
Customer Satisfaction:
Generally high customer satisfaction for its intended purpose as a comfortable, mid-size cruiser.
Certifications
Emissions Compliance:
Meets EPA and relevant regional emissions standards for its model years.
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