Market Segment:
Cruiser Motorcycle
Key Competitors Era:
Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series, Harley-Davidson Sportster models
Vehicle Design Philosophy:
Classic cruiser styling with modern V-twin performance and reliability
Target Audience:
Riders seeking a comfortable, stylish, and capable cruiser for touring and everyday riding
Manual Benefit:
Enables owners and technicians to perform maintenance, diagnostics, and repairs efficiently and accurately, reducing reliance on costly dealer services.
Model Years Covered:
2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Estimated Page Count:
Approx. 400-500 pages (typical for this class of service manual)
Manual Type:
Factory Repair Service Manual
Engine Mechanical:
Engine overhaul, disassembly, assembly, inspection, specifications, tuning
Fuel System:
Fuel injection system, fuel pump, injectors, fuel tank, lines, troubleshooting
Cooling System:
Radiator, fan, coolant, thermostat, troubleshooting
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, final drive, internal inspection
Brakes:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, pad replacement, bleeding procedures
Suspension:
Front fork (telescopic), rear shock absorber, linkage, adjustments, overhaul
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), starter motor, lighting, horn, instrumentation
Chassis Frame:
Frame inspection, component removal/installation (handlebars, footpegs, seat)
Bodywork Trim:
Fenders, fuel tank, side covers, seat removal/installation
Ignition System:
Ignition coils, spark plugs, ECU control, timing specifications
Preventive Maintenance:
Scheduled maintenance, lubrication, adjustments, fluid changes
Troubleshooting:
Diagnostic charts, common problems, symptom-based repair guidance
Disassembly Assembly:
Detailed step-by-step procedures for component removal and reinstallation
Engine Rebuild:
Complete engine teardown and rebuild procedures, including top-end and bottom-end work
Electrical Diagnostics:
Fault finding for electrical circuits, use of multimeters, sensor testing
Diagnostic Capabilities:
In-depth diagnostic procedures for engine, electrical, and mechanical systems
Repair Scope:
Covers routine maintenance to complete engine and component overhauls
Data Accuracy:
Factory-level torque specifications, clearances, and tolerances
Engine Type:
Air-cooled, V-twin, SOHC, 4-stroke
Displacement:
892 cc (54.4 cu in)
Bore X Stroke:
92.0 x 81.0 mm
Valvetrain:
2 valves per cylinder, SOHC (Single Overhead Camshaft)
Horsepower Rating:
Approx. 57 hp @ 6,000 rpm (manufacturer estimate)
Torque Rating:
Approx. 77 Nm (57 lb-ft) @ 3,500 rpm (manufacturer estimate)
Fuel Delivery:
Fuel injection, Dual throttle body (40mm x 2)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Type Capacity:
Kawasaki Genuine 10W-40 Motorcycle Oil, 3.5 L (3.7 US qt) with filter change
Instrumentation:
Analog speedometer, digital odometer, trip meter, clock, fuel gauge, and indicator lights.
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature on certain VN900 models and model years. The service manual would cover ABS system diagnostics and maintenance if equipped.
Electronics Complexity:
Relatively straightforward electronics focused on core motorcycle functions, making diagnostics and repairs manageable with the service manual.
First Service:
1000 km or 6 months
Subsequent Service Interval:
6000 km or 12 months (whichever comes first)
Engine Oil Change Interval:
Every 6000 km or 12 months
Spark Plug Replacement:
Refer to manual, typically around 12,000-24,000 km depending on plug type
Coolant Type:
Kawasaki Coolant Type 2 (Ethylene Glycol based, 50/50 mix with distilled water)
Common Wear Items:
Brake pads, tires, clutch friction plates (depending on riding style)
Potential Electrical:
While generally reliable, like any motorcycle, issues with charging systems or switches can arise with age and mileage. The manual provides diagnostics.
Engine Reliability:
The VN900 engine is known for its robust construction and reliability when properly maintained. Key areas to monitor include oil levels and regular filter changes.
Kawasaki Motorcycle Legacy:
Kawasaki has a long and storied history in motorcycle manufacturing, known for performance and innovation across various segments, including cruisers.
Vulcan Lineage:
The Vulcan line has been a staple of Kawasaki's cruiser offerings since the late 1980s, evolving through various displacements and styles. The VN900 introduced a modern V-twin platform to the mid-size cruiser segment.
Manufacturing Location:
Japan
