The Vulcan 900 Custom (VN900B) is a cruiser motorcycle designed to offer a blend of classic aesthetics and modern engineering. Produced for the model years 2007 through 2013, this model is characterized by its stripped-down appearance, featuring spoke wheels, custom-style handlebars, and a low-slung profile, making it an attractive option for riders seeking personalization. Built upon a long-standing heritage in motorcycle manufacturing, the Vulcan 900 Custom emphasizes accessible performance and a comfortable riding experience, positioning it as a strong contender in the cruiser market. Its 892 cc V-twin engine, coupled with a belt drive system, contributes to its smooth operation and characteristic cruiser feel. This comprehensive workshop service manual provides in-depth guidance for the maintenance, repair, and troubleshooting of the Vulcan 900 Custom. It covers all essential systems, including detailed procedures for the engine, fuel system, transmission, drivetrain, electrical components, chassis, braking, and suspension. The manual is structured to assist owners, mechanics, and technicians by offering clear instructions, diagnostic flowcharts, and precise technical specifications. From routine maintenance tasks such as oil changes and filter replacements to complex engine overhauls and electrical diagnostics, this resource ensures the longevity and optimal performance of the vehicle. 🏷️ Basic Information Identification Make: Kawasaki Model: Vulcan 900 Custom Model Variant: VN900B Model Years Covered: 2007, 2008, 2009, 2010, 2011, 2012, 2013 Codes Chassis Code: VN900B 👋 Introduction Market Position Vehicle Segment: Cruiser motorcycle, known for its comfortable riding position and custom styling. Competitive Analysis Key Competitors: Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series. Key Features Design Philosophy: Combines classic cruiser aesthetics with modern engineering for accessible performance and style. Custom Appeal: Features a stripped-down look with spoke wheels, custom-style handlebars, and a low-slung profile, appealing to riders seeking personalization. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual Language: English Format: PDF Download Page Count Estimated Page Count: Refer to specific product listing for exact page count, typically 500+ pages for a comprehensive workshop manual. 📖 Manual Coverage Systems Covered Engine Mechanics: Detailed instructions for engine overhaul, piston, cylinder, crankshaft, valve train, timing, lubrication, and cooling systems. Fuel System: Comprehensive coverage of fuel injection system (EFI), fuel pump, injectors, sensors, and throttle body. Transmission Drivetrain: In-depth information on clutch operation, gearbox disassembly and reassembly, final drive belt maintenance, and related components. Electrical System: Wiring diagrams, starter system, charging system (alternator/stator, regulator/rectifier), ignition system, lighting, and instrument cluster. Chassis Frame: Frame inspection, front fork disassembly and assembly, rear shock absorber service, steering system. Braking System: Front and rear brake caliper service, master cylinder repair, brake fluid bleeding, disc and pad replacement. Suspension: Front fork specifications, seal replacement, oil levels, and rear suspension shock absorber servicing. Wheels Tires: Wheel bearing service, tire mounting and balancing, spoke tension adjustment (if applicable). Bodywork Trim: Fender, tank, seat, and other body panel removal and installation procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment (if applicable, though belt drive). Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common issues. Engine Rebuild: Complete engine disassembly, inspection, measurement, and reassembly with torque specifications. Electrical Diagnostics: Step-by-step procedures for diagnosing electrical faults using multimeters and wiring diagrams. Suspension Overhaul: Front fork seal replacement, rear shock absorber servicing. Brake System Overhaul: Caliper rebuilds, master cylinder replacement, line bleeding. Efi System Service: Throttle body synchronization, sensor testing, injector cleaning. Technical Depth Diagnostic Level: Advanced diagnostics with component testing procedures and expected values. Repair Level: Comprehensive repair procedures, from minor adjustments to complete component overhauls. Specification Detail: Includes detailed torque specifications, clearances, fluid capacities, and electrical resistance values. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Typically yes, allowing for quick navigation of topics. Printable: Yes, PDF format allows for printing specific sections or the entire manual. Print Quality Image Resolution: High-resolution diagrams and illustrations for clarity. Binding Type Binding: Not applicable (PDF format). Paper Type Paper Quality: Not applicable (PDF format). ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, SOHC, V-twin Displacement: 892 cc (54.5 cu. in.) Bore X Stroke: 92.0 x 68.0 mm (3.62 x 2.68 in.) Compression Ratio: 9.5:1 Performance Horsepower: Approx. 50-55 HP (at crankshaft, subject to specific market tuning) Torque: Approx. 50-55 lb-ft (at crankshaft, subject to specific market tuning) Fuel System Fuel Delivery: Fuel Injection (EFI) with dual 34mm throttle bodies Fuel Tank Capacity: 20.0 L (5.3 gal) Lubrication Oil Type: SAE 10W-40 API SG or SH, JASO MA Oil Capacity: 3.8 L (4.0 US qt) with filter change Ignition Ignition System: Digital CDI Cooling Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Final Drive: Belt drive Features Clutch: Wet, multi-disc 📐 Dimensions Exterior Overall Length: 2,415 mm (95.1 in.) Overall Width: 930 mm (36.6 in.) Overall Height: 1,110 mm (43.7 in.) Wheelbase: 1,635 mm (64.4 in.) Weights Curb Weight: Approx. 260 kg (573.2...