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: 2007 Year End: 2015 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: PDF 📖 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...