The Vulcan 900 Custom, produced from 2006 to 2013, is a mid-size cruiser motorcycle celebrated for its classic styling and comfortable ride. Featuring spoke wheels, a teardrop fuel tank, and abundant chrome, this model offers an ergonomic seating position and compliant suspension ideal for extended journeys. Powered by a 892 cc, air-cooled V-twin engine, it delivers approximately 46 horsepower and 76 Nm of torque, paired with a 5-speed transmission and belt drive. Its engineering quality and reliability, hallmarks of the Vulcan lineage, position it as a strong contender in the cruiser market, comparable to models from Honda, Yamaha, and Suzuki. This comprehensive English-language service manual provides detailed information for the maintenance and repair of the Vulcan 900 Custom (VN900B) from 2006 to 2013. It covers all major systems, including the engine, transmission, frame, bodywork, and electrical components, offering step-by-step instructions for disassembly, assembly, and repair. The manual also includes scheduled maintenance procedures, troubleshooting guides for common issues, and essential technical specifications. This resource is designed to assist owners, mechanics, and technicians in ensuring the optimal performance, longevity, and safety of their Vulcan 900 Custom. 🏷️ Basic Information Identification Make: Kawasaki Model: Vulcan 900 Custom Model Variant: VN900B Product Name: Kawasaki Vulcan 900 VN 900 2006-2013 Full Service Repair Manual Generation Model Generation: First Generation (VN900) Codes Chassis Code: VN900B 👋 Introduction Market Position Market Segment: Mid-size cruiser motorcycle, known for its classic styling and comfortable ride. Competitive Analysis Competitors: Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series. Key Features Styling: Classic cruiser aesthetic with spoke wheels, teardrop fuel tank, and ample chrome accents. Ride Comfort: Ergonomic seating position, compliant suspension, and low seat height contribute to comfortable long-distance riding. 📋 Manual Details Coverage Areas Years Covered: 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 Page Count Estimated Page Count: ~600-800 (typical for full service manuals) Manual Type Type: Full Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnosis, carburetor/fuel injection systems, ignition system, lubrication system, cooling system. Transmission: Gearbox disassembly, inspection, repair, clutch operation, lubrication, shift mechanism. Frame And Bodywork: Chassis inspection, front fork assembly, rear suspension, wheels, tires, brakes (front and rear), steering system, body panels, seats, fuel tank. Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), ignition system, lighting system, starter motor, instrumentation, switches, fuses. Fuel System: Fuel tank, fuel lines, fuel pump (if applicable), fuel filter, fuel injection (EFI) system components, throttle body, injectors, ECU operation. Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, chain adjustments, spark plug replacement), pre-ride checks, periodic inspections. Troubleshooting: Diagnostic procedures for common issues, fault finding, symptom-based troubleshooting charts. Repair: Step-by-step repair instructions for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, and electrical system repairs. Disassembly And Assembly: Detailed instructions for component removal, disassembly, inspection, cleaning, reassembly, and installation with torque specifications. Technical Depth Depth: Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including electrical system diagnostics and repair. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text (OCR processed if scanned). Print Quality Quality: High resolution for clear diagrams and text. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, V-twin, SOHC, 8-valve Displacement: 892 cc (54.5 cubic inches) Bore X Stroke: 88.0 x 74.0 mm Cooling System: Air-cooled Performance Horsepower: Approx. 46 hp @ 5500 rpm (claimed) Torque: Approx. 76 Nm (56 lb-ft) @ 3500 rpm (claimed) Fuel System Fuel Induction: Fuel Injection (DFI) with dual 34mm throttle bodies, sub-throttle valves. Fuel Type: Unleaded gasoline, minimum 87 octane Fuel Tank Capacity: 20 liters (5.3 US gal) 🔧 Transmission Standard Type: 5-speed constant mesh Clutch: Wet, multi-disc Final Drive: Belt Drive Features Gear Ratios: Refer to manual for specific ratios (1st-5th). 📐 Dimensions Exterior Overall Length: 2405 mm (94.7 in) Overall Width: 965 mm (38.0 in) Overall Height: 1135 mm (44.7 in) Wheelbase: 1640 mm (64.6 in) Ground Clearance: 140 mm (5.5 in) Seat Height: 705 mm (27.8 in) Weights Curb Weight: Approx. 260 kg (573 lbs) Gross Vehicle Weight Rating: Refer to manual for specific GVWR. 🛡️ Safety Features Ratings Crash Test Ratings: Not applicable for motorcycles in the same way as cars. Active Features Brakes Front: 270 mm disc with 2-piston caliper Brakes Rear: 270 mm disc with 2-piston caliper ABS: Optional on some later models, not standard on all VN900B variants. Passive Features Lighting: Halogen headlight, LED taillight and brake light. 💡 Technology Features Infotainment Instrumentation: Analog speedometer, digital tachometer, fuel gauge, clock, trip meter, gear position indicator (on some models). Driver Assistance ABS: As mentioned, optional on certain model years/trims. Connectivity Connectivity Features: None (no Bluetooth or smartphone integration). 🔧 Maintenance Service Intervals Engine Oil Change: Every 6,000 km (3,700 miles)...