This manual covers the motorcycles produced between 2007 and 2015. The Vulcan 900 Custom is a mid-size cruiser motorcycle renowned for its sleek, modern aesthetic, featuring a low seat height and a prominent V-twin engine. Powered by a liquid-cooled, 852cc SOHC V-twin engine, it delivers smooth power and torque, complemented by a reliable belt drive system for low maintenance. Its design emphasizes customization, offering riders a platform for personalization. The Vulcan 900 Custom is engineered for riders seeking a stylish, dependable cruiser suitable for both commuting and touring. This factory service manual provides comprehensive guidance for the maintenance, repair, and troubleshooting of your Vulcan 900 Custom. It covers all essential systems, including the engine mechanicals, fuel and ignition systems, transmission, electrical components, brakes, suspension, steering, and chassis. Detailed procedures for routine maintenance, major repairs, disassembly, and assembly are included, along with essential technical specifications and wiring diagrams. This manual is an indispensable resource for owners, technicians, and mechanics, ensuring the proper upkeep and longevity of the vehicle. 🏷️ Basic Information Identification Make: Kawasaki Model: Vulcan 900 Custom Product Type: Service Manual Codes Model Codes: VN900C 👋 Introduction Market Position Segment: Mid-size cruiser motorcycle. Target Audience: Riders seeking a stylish, reliable, and customizable cruiser with a V-twin engine, suitable for commuting and touring. Competitive Analysis Competitors: Honda Shadow 750, Yamaha V-Star 950, Suzuki Boulevard C50, Indian Scout (though the Scout is a more premium offering). Key Features Styling: Sleek, modern custom cruiser aesthetic with a low seat height, prominent V-twin engine, and often featuring chrome accents, custom handlebars, and unique paint schemes. Engine: Liquid-cooled, 852cc (approx. 52 cu in) SOHC V-twin engine known for its smooth power delivery and torquey feel. Drivetrain: Reliable belt drive system for low maintenance and smooth power transfer. Customization: Designed for personalization, with a wide range of genuine Kawasaki and aftermarket accessories available. 📋 Manual Details Coverage Areas Years Covered: 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015 Page Count Estimated Page Count: Approximately 300-400 pages (typical for this type of manual) Manual Type Type: Official Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, inspection, assembly, torque specifications, valve clearance, timing, cooling system, lubrication system. Fuel System: Fuel injection system, throttle body, injectors, fuel pump, fuel pressure regulation, evaporative emission control. Ignition System: Ignition timing, spark plugs, ignition coils, ECU control. Transmission Drivetrain: Clutch operation, gearbox disassembly and assembly, final drive (belt drive system), lubrication. Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starting system, lighting, indicators, horn, instrument cluster, ECU (Engine Control Unit). Brakes: Brake fluid, hydraulic system, brake calipers, master cylinders, brake pads, discs, bleeding procedures. Suspension: Front forks (telescopic), rear shock absorber, swingarm, bearing checks and replacement. Steering: Handlebar, steering stem, steering bearings, lubrication and adjustment. Chassis Frame: Frame inspection, disassembly and reassembly of frame-mounted components. Bodywork Styling: Fenders, fuel tank, seat, side covers, exhaust system, detailing of trim components. Procedures Included Routine Maintenance: Oil changes, filter replacement, chain/belt adjustment (as applicable), spark plug replacement, air filter cleaning/replacement, brake inspection. Troubleshooting: Diagnostic flowcharts, symptom-based problem identification, common fault correction for engine, electrical, and mechanical systems. Major Repairs: Engine rebuild, transmission overhaul, suspension fork service, brake system overhauls. Diagnostics: Fault code reading (if applicable via diagnostic tool), electrical testing, fuel system pressure testing. Disassembly Assembly: Step-by-step instructions for component removal and installation. Technical Depth Depth: Comprehensive. Covers everything from basic maintenance to full engine and transmission rebuilds, including detailed electrical schematics and troubleshooting. 📊 Manual Specifications File Format Quality: High-resolution PDF, typically searchable text and clear diagrams. Print Quality Printability: Designed to be printed, with clear layout and legible text/diagrams. 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 Displacement: 852 cc (52.0 cu in) Bore X Stroke: 88.0 x 72.0 mm (3.46 x 2.83 in) Cooling System: Liquid-cooled Valve Train: SOHC, 4 valves per cylinder (Desmodromic valve actuation is NOT used) Compression Ratio: 9.5:1 Performance Horsepower Est: Approx. 50-55 HP (actual figures vary by tuning and measurement) Torque Est: Approx. 50-55 lb-ft (actual figures vary by tuning and measurement) Fuel System Fuel Delivery: Fuel Injection with Dual 34mm Throttle Bodies (Dual throttle valves control intake air flow for precise response) Fuel Type: Unleaded gasoline, 87 octane minimum (91 AKI recommended) Lubrication Oil Capacity W Filter: 3.1 US qt. (2.9 L) Ignition Ignition System: Digital CDI with electronic ignition advance Spark Plug Type: NGK CR9EK, DENSO U27FER9 (Verify with manual for exact spec) 🔧 Transmission Standard Type: Constant-mesh, 5-speed Clutch Type: Wet, multi-disc Features Final Drive: Sealed belt drive Gear Ratios: Specific gear ratios provided in the manual for diagnosis and performance analysis. Fluid Specifications Transmission Oil Type: Kawasaki Motorcycle Gear Oil...