The Kawasaki Vulcan 900 Custom, produced from 2007 to 2015, represents a significant entry in the mid-size cruiser motorcycle segment. This model is renowned for its classic cruiser styling, featuring a V-twin engine, and is designed for riders seeking a blend of comfortable rideability and timeless aesthetics. Its engineering emphasizes reliability and a distinctive visual appeal, positioning it as a strong competitor within its class against other established cruiser lines. This comprehensive 617-page Workshop Service Manual provides in-depth guidance for the repair, maintenance, and troubleshooting of the Kawasaki Vulcan 900 Custom. It covers all essential systems, including the V twin engine, fuel injection, transmission, drivetrain, chassis, suspension, steering, braking, and electrical systems. Detailed procedures for routine maintenance, component disassembly and reassembly, diagnostics, and electrical system repair are included, along with critical technical specifications and wiring diagrams, making it an indispensable resource for owners and technicians alike. 🏷️ Basic Information Identification Make: Kawasaki Model: Vulcan 900 Custom Year: 2007-2015 Codes Engine Code: V twin, SOHC, 4-valve Chassis Code: VN900C 👋 Introduction Market Position Segment: Cruiser motorcycle, mid-size class Target Audience: Riders seeking a stylish, comfortable, and reliable cruiser with a classic aesthetic and modern performance Competitive Analysis Competitors: Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series Key Features Design Philosophy: Classic cruiser styling with a modern V-twin engine, focus on comfort and rideability Model Variations: Includes standard Vulcan 900 Classic and the more stylized Vulcan 900 Custom with different styling cues and features. 📋 Manual Details Coverage Areas Coverage: Repair, maintenance, troubleshooting, diagnostics, electrical systems, mechanical systems, chassis, bodywork Page Count Page Count: 617 Manual Type Manual Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Fuel injection, ignition, lubrication, cooling, internal engine components (cylinder head, piston, crankshaft, connecting rods), engine disassembly and assembly Transmission Drivetrain: Clutch operation and adjustment, gear shifting mechanisms, final drive (belt drive) inspection and maintenance Chassis Suspension Steering: Front fork service (oil change, seal replacement), rear shock absorber inspection, steering head bearing service, wheel and tire maintenance Braking System: Front and rear brake caliper service, hydraulic system bleeding, brake pad replacement, brake disc inspection Electrical System: Battery service, charging system (alternator, regulator/rectifier), lighting system, starter motor, ignition system diagnostics, wiring diagrams, ECU diagnostics Fuel System: Fuel pump, fuel injectors, throttle body, fuel lines, fuel tank maintenance and inspection Bodywork And Trim: Fairing removal and installation, seat removal, fender inspection, accessory mounting points Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, drive belt tension adjustment, brake fluid changes, coolant checks Troubleshooting: Diagnostic procedures for common starting issues, engine performance problems, electrical faults, and braking system malfunctions Repair And Rebuild: Detailed step-by-step instructions for component disassembly, repair, and reassembly for major vehicle systems Specifications And Tolerances: Torque specifications for all fasteners, engine clearances, suspension settings, and other critical measurements Wiring Diagrams: Comprehensive electrical schematics for all circuits, aiding in diagnosis and repair Technical Depth Depth: Comprehensive from basic owner maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable (allows finding information quickly by keyword) Print Quality Print Quality: High-resolution scans suitable for printing individual pages or the entire document Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, four-stroke Displacement: 892 cc (54.4 cu in) Bore X Stroke: 88.0 x 74.2 mm (3.46 x 2.92 in) Valve Train: SOHC, 8 valves (2 per cylinder) Cooling System: Liquid-cooled Performance Horsepower Est: Approx. 50 hp (at crankshaft, may vary by model year and tuning) Torque Est: Approx. 76 Nm (56 lb-ft) (at crankshaft, may vary by model year and tuning) Fuel System Fuel Delivery: Digital fuel injection (EFI) with dual 34mm throttle bodies Fuel Type: Unleaded gasoline, minimum 87 octane Fuel Tank Capacity: 20 liters (5.3 US gal) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Wet, multi-disc Features Final Drive: Sealed belt drive 📐 Dimensions Exterior Length Overall: Approx. 2400 mm (94.5 in) Width Overall: Approx. 930 mm (36.6 in) Height Overall: Approx. 1120 mm (44.1 in) Wheelbase: Approx. 1645 mm (64.8 in) Ground Clearance: Approx. 135 mm (5.3 in) Weights Dry Weight: Approx. 262 kg (578 lbs) Wet Weight: Approx. 281 kg (619 lbs) (fully fueled) Seat Height: Approx. 705 mm (27.8 in) 🛡️ Safety Features Active Features Braking System: Hydraulic disc brakes front and rear Lighting: Halogen headlight, LED taillight, incandescent turn signals Passive Features Frame Construction: Double-cradle, high-tensile steel frame 💡 Technology Features Infotainment Audio System: N/A (No factory audio system) Display: Analog speedometer with digital odometer, trip meter, clock, and indicator lights Driver Assistance ABS: ABS was an optional feature on some later models, but not standard across the entire 2007-2015 range....