KAWASAKI VN900 Custom 2007-2015 Service Repair Manual
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This manual covers the motorcycle, produced from 2007 to 2015. Renowned for its V-twin engine and classic cruiser styling with custom-inspired elements, the Custom offers a comfortable ride and reliable performance. Its engineering emphasizes a steel semi-double cradle frame for stability, a relaxed riding position for rider control, and a distinctive aesthetic with cast aluminum spoke wheels. The motorcycle is powered by an 892 cc V-twin, 4-stroke engine featuring liquid cooling and fuel injection, paired with a 5-speed transmission and a sealed belt drive. This comprehensive service repair manual provides detailed information for maintaining and repairing the motorcycle. It covers all major systems, including the engine, drivetrain, chassis, suspension, braking system, and electrical system. Procedures for scheduled maintenance, troubleshooting common and complex issues, and complete component repair and rebuilds are thoroughly explained. Technical specifications, such as torque values, fluid capacities, and electrical data, are also included, making this manual an essential resource for professional technicians, experienced DIY mechanics, and owners alike. 🏷️ Basic Information Identification Make: Kawasaki Model: VN900 Custom Model Code: VN900C Applicable Years: 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015 Product Name: KAWASAKI VN900 Custom 2007-2015 Service Repair Manual Codes Vin Code Generation: Typically 17 characters, allowing for specific model year identification. 👋 Introduction Market Position Target Audience: Professional technicians, experienced DIY mechanics, and motorcycle owners seeking comprehensive repair and maintenance guidance. Competitive Analysis Advantage: Official factory manual providing factory-level accuracy and detail, covering all styles for the specified model years. Key Features Comprehensiveness: Hundreds of pages covering all aspects of maintenance, repair, and troubleshooting. Accessibility: Instant download, printable format for convenient use. Knowledge Transfer: Designed to impart factory-trained technician knowledge to the user. 📋 Manual Details Coverage Areas Primary Coverage: Kawasaki VN900 Custom motorcycle, all styles. Page Count Estimated Page Count: Hundreds (specific number not provided, but indicative of comprehensive coverage). Manual Type Type: Official Factory Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine And Drivetrain: Detailed information on engine disassembly, assembly, inspection, tuning, lubrication, cooling, fuel delivery, ignition, and exhaust systems. Includes maintenance and repair of the transmission and final drive. Chassis And Suspension: Covers fork, rear shock absorber, frame, swingarm, steering system, wheel bearings, and related components. Includes inspection, adjustment, and replacement procedures. Braking System: Complete guidance on front and rear brake systems, including master cylinders, calipers, brake discs, brake lines, fluid replacement, bleeding procedures, and troubleshooting. Electrical System: Comprehensive coverage of wiring diagrams, lighting system, ignition system, starting system, charging system, instrumentation, and all electrical components. Includes diagnostic procedures. Body And Trim: Includes procedures for the removal and installation of body panels, fuel tank, seat, fenders, and other cosmetic and functional components. Procedures Included Scheduled Maintenance: Detailed instructions for routine maintenance tasks such as oil changes, filter replacements, chain adjustment, brake checks, and fluid level checks, along with recommended intervals. Troubleshooting: Systematic diagnostic procedures and flowcharts for identifying and resolving common and complex issues. Repair And Rebuild: Step-by-step instructions for disassembling, inspecting, repairing, and reassembling major motorcycle components and systems, including engine and transmission rebuilds. Technical Specifications: Includes torque specifications, clearances, fluid capacities, electrical values, and other critical technical data required for accurate repairs and adjustments. Technical Depth Depth: Comprehensive from basic maintenance to advanced engine and electrical diagnostics and repairs, suitable for both professional technicians and skilled DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: Full Printable Zoom Functionality: YES Binding Type Binding: Not applicable (digital download, user prints and binds as desired). Paper Type Paper Quality: Not applicable (digital download). Delivery Method Delivery: Instant Download Software Requirements PDF Reader: Adobe PDF Reader Compression Utility: WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, 4-stroke, SOHC, 2 valves per cylinder Displacement: 892 cc (54.4 cubic inches) Bore X Stroke: 96.0 x 96.0 mm Cooling System: Liquid-cooled Compression Ratio: 9.0:1 Performance Horsepower: Approx. 50.7 hp (37.3 kW) @ 5,700 rpm (Manufacturer's data, may vary slightly by region). Torque: Approx. 55.4 lb-ft (75.1 Nm) @ 3,500 rpm (Manufacturer's data, may vary slightly by region). Fuel System Fuel Delivery: Fuel Injection (DFI) with dual 34mm throttle bodies Fuel Type: Unleaded gasoline, minimum 87 octane Ignition Ignition System: Digital CDI with electronic advance Lubrication Oil Type: SAE 10W-40 API SG or SH motorcycle oil (refer to manual for specific recommendations). Oil Capacity: 3.4 L (3.6 US qt) for engine oil change, 3.9 L (4.1 US qt) when filter is changed, 4.5 L (4.8 US qt) for complete overhaul (refer to manual for exact capacities). Air Cleaner Air Filter Type: Replaceable paper element (Specific part number would be detailed in the manual). 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Optional Optional Transmission: N/A (No optional transmissions offered for this model). Features Clutch Type:...
This manual covers the motorcycle, produced from 2007 to 2015. Renowned for its V-twin engine and classic cruiser styling with custom-inspired elements, the Custom offers a comfortable ride and reliable performance. Its engineering emphasizes a steel semi-double cradle frame for stability, a relaxed riding position for rider control, and a distinctive aesthetic with cast aluminum spoke wheels. The motorcycle is powered by an 892 cc V-twin, 4-stroke engine featuring liquid cooling and fuel injection, paired with a 5-speed transmission and a sealed belt drive.
This comprehensive service repair manual provides detailed information for maintaining and repairing the motorcycle. It covers all major systems, including the engine, drivetrain, chassis, suspension, braking system, and electrical system. Procedures for scheduled maintenance, troubleshooting common and complex issues, and complete component repair and rebuilds are thoroughly explained. Technical specifications, such as torque values, fluid capacities, and electrical data, are also included, making this manual an essential resource for professional technicians, experienced DIY mechanics, and owners alike.
KAWASAKI VN900 Custom 2007-2015 Service Repair Manual
Codes
Vin Code Generation:
Typically 17 characters, allowing for specific model year identification.
👋 Introduction
Market Position
Target Audience:
Professional technicians, experienced DIY mechanics, and motorcycle owners seeking comprehensive repair and maintenance guidance.
Competitive Analysis
Advantage:
Official factory manual providing factory-level accuracy and detail, covering all styles for the specified model years.
Key Features
Comprehensiveness:
Hundreds of pages covering all aspects of maintenance, repair, and troubleshooting.
Accessibility:
Instant download, printable format for convenient use.
Knowledge Transfer:
Designed to impart factory-trained technician knowledge to the user.
📋 Manual Details
Coverage Areas
Primary Coverage:
Kawasaki VN900 Custom motorcycle, all styles.
Page Count
Estimated Page Count:
Hundreds (specific number not provided, but indicative of comprehensive coverage).
Manual Type
Type:
Official Factory Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine And Drivetrain:
Detailed information on engine disassembly, assembly, inspection, tuning, lubrication, cooling, fuel delivery, ignition, and exhaust systems. Includes maintenance and repair of the transmission and final drive.
Chassis And Suspension:
Covers fork, rear shock absorber, frame, swingarm, steering system, wheel bearings, and related components. Includes inspection, adjustment, and replacement procedures.
Braking System:
Complete guidance on front and rear brake systems, including master cylinders, calipers, brake discs, brake lines, fluid replacement, bleeding procedures, and troubleshooting.
Electrical System:
Comprehensive coverage of wiring diagrams, lighting system, ignition system, starting system, charging system, instrumentation, and all electrical components. Includes diagnostic procedures.
Body And Trim:
Includes procedures for the removal and installation of body panels, fuel tank, seat, fenders, and other cosmetic and functional components.
Procedures Included
Scheduled Maintenance:
Detailed instructions for routine maintenance tasks such as oil changes, filter replacements, chain adjustment, brake checks, and fluid level checks, along with recommended intervals.
Troubleshooting:
Systematic diagnostic procedures and flowcharts for identifying and resolving common and complex issues.
Repair And Rebuild:
Step-by-step instructions for disassembling, inspecting, repairing, and reassembling major motorcycle components and systems, including engine and transmission rebuilds.
Technical Specifications:
Includes torque specifications, clearances, fluid capacities, electrical values, and other critical technical data required for accurate repairs and adjustments.
Technical Depth
Depth:
Comprehensive from basic maintenance to advanced engine and electrical diagnostics and repairs, suitable for both professional technicians and skilled DIY enthusiasts.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printability:
Full Printable
Zoom Functionality:
YES
Binding Type
Binding:
Not applicable (digital download, user prints and binds as desired).
Paper Type
Paper Quality:
Not applicable (digital download).
Delivery Method
Delivery:
Instant Download
Software Requirements
PDF Reader:
Adobe PDF Reader
Compression Utility:
WinZip
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, 4-stroke, SOHC, 2 valves per cylinder
Displacement:
892 cc (54.4 cubic inches)
Bore X Stroke:
96.0 x 96.0 mm
Cooling System:
Liquid-cooled
Compression Ratio:
9.0:1
Performance
Horsepower:
Approx. 50.7 hp (37.3 kW) @ 5,700 rpm (Manufacturer's data, may vary slightly by region).
Torque:
Approx. 55.4 lb-ft (75.1 Nm) @ 3,500 rpm (Manufacturer's data, may vary slightly by region).
Fuel System
Fuel Delivery:
Fuel Injection (DFI) with dual 34mm throttle bodies
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition
Ignition System:
Digital CDI with electronic advance
Lubrication
Oil Type:
SAE 10W-40 API SG or SH motorcycle oil (refer to manual for specific recommendations).
Oil Capacity:
3.4 L (3.6 US qt) for engine oil change, 3.9 L (4.1 US qt) when filter is changed, 4.5 L (4.8 US qt) for complete overhaul (refer to manual for exact capacities).
Air Cleaner
Air Filter Type:
Replaceable paper element (Specific part number would be detailed in the manual).
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Optional
Optional Transmission:
N/A (No optional transmissions offered for this model).
Features
Clutch Type:
Wet, multiple-disc, cable-actuated
Final Drive:
Sealed belt drive
Transmission Fluid
Transmission Oil Type:
Kawasaki specifically recommends its own transmission oil or equivalent (details in manual).
Transmission Oil Capacity:
Refer to manual for specific capacity.
📐 Dimensions
Exterior
Overall Length:
Approx. 2,310 mm (90.9 in)
Overall Width:
Approx. 900 mm (35.4 in)
Overall Height:
Approx. 1,150 mm (45.3 in)
Wheelbase:
Approx. 1,635 mm (64.4 in)
Ground Clearance:
Approx. 140 mm (5.5 in)
Seat Height:
Approx. 705 mm (27.8 in)
Weights
Curb Weight:
Approx. 252 kg (556 lbs)
Fuel Tank Capacity:
20 Liters (5.3 US gal)
Wheels And Tires
Front Tire:
120/90-21M/C 64S
Rear Tire:
180/70-15M/C 76H
Front Wheel:
21-inch cast aluminum spoke design
Rear Wheel:
15-inch cast aluminum spoke design
Wheelbase:
1635 mm (64.4 in)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycle safety ratings are not typically provided by governmental agencies in the same manner as automobiles. The manual would detail any safety-related design features or procedures.
Active Features
Braking System:
Dual front disc brakes, single rear disc brake. ABS was an optional feature on some models or in certain markets, detailed in the manual.
Lighting:
Halogen headlight, LED taillight, turn signals, and other standard motorcycle safety lighting.
Passive Features
Frame Construction:
Steel semi-double cradle frame designed for stability and handling.
Ergonomics:
Low seat height and relaxed riding position contribute to rider control and comfort.
💡 Technology Features
Infotainment
Display Features:
Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, indicator lights (ABS, engine, oil, neutral, high beam, turn signals).
Driver Assistance
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature for some model years and markets. The manual will detail its operation and maintenance if equipped.
Connectivity
Connectivity Features:
No advanced connectivity features such as Bluetooth or smartphone integration are typically found on this model. Focus is on mechanical and electrical systems.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Typically every 6,000 km (3,700 miles) or 6 months, whichever comes first (refer to manual for precise intervals).
Air Filter Inspection And Cleaning/Replacement:
Inspect every 6,000 km (3,700 miles), replace as needed. Cleaning procedures would be detailed in the manual.
Spark Plug Replacement:
Typically around 12,000 km (7,500 miles) or as indicated by wear (refer to manual).
Coolant Replacement:
Refer to manual for specific interval and type. Typically every two years.
Brake Fluid Replacement:
Typically every two years (refer to manual).
Belt Drive Inspection And Tensioning:
Regular inspection and tensioning at intervals specified in the manual (e.g., every 6,000 km or 3,700 miles).
Fluid Specifications
Engine Oil:
SAE 10W-40 API SG or SH motorcycle oil (specific Kawasaki recommendations likely in manual).
Coolant:
Ethylene glycol-based coolant with demineralized water (50/50 mix). Specific type and color recommended by Kawasaki in manual.
Brake Fluid:
DOT 4 or DOT 5.1 recommended (refer to manual for exact specification).
Known Issues
Common Wear Items:
Tires, brake pads, clutch plates, drive belt, spark plugs are typical wear items that may require replacement during the life of the motorcycle.
Potential Minor Issues:
Some owners report occasional issues with the fuel level sensor or specific electrical connectors. The manual would provide diagnostic procedures for these and other potential minor concerns.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki Heavy Industries Motorcycle & Engine Company has a long-standing reputation for producing high-performance and reliable motorcycles across various categories.
Model Evolution
Vn Series Evolution:
The VN series represents Kawasaki's cruiser line, known for its V-twin engines and classic styling. The VN900 Custom is a modern interpretation of the cruiser aesthetic with custom-inspired elements.
Production
Production Period:
2007-2015 (as specified for this manual).
Manufacturing Location:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific awards are not listed in the product description. However, the VN900 Custom is generally well-regarded in the cruiser segment for its styling and value.
Ratings
Owner Satisfaction:
Owner reviews generally indicate high satisfaction with the motorcycle's aesthetics, comfortable ride, and reliable V-twin engine.
Certifications
Manual Certification:
Official Factory Service Manual - indicating it is produced by or sanctioned by the manufacturer.