This workshop service manual provides comprehensive guidance for the Vulcan VN900 Classic, covering production years from 2006 through 2013. This first-generation model is renowned for its retro cruiser aesthetics, featuring classic styling with chrome accents, a teardrop fuel tank, and spoked wheels, powered by a torquey, liquid-cooled, 892 cc V-twin engine. It offers a comfortable riding position and a user-friendly experience, making it a popular choice for riders seeking classic looks with modern reliability. The Vulcan VN900 Classic is positioned as an accessible mid-size cruiser, competing with models from Honda, Yamaha, and Suzuki, and is recognized for its overall value and dependable performance. This workshop service manual, presented in PDF format with searchable text and high-resolution diagrams, is designed to be an indispensable resource for owners, mechanics, and technicians. It covers all essential aspects of the vehicle, including detailed procedures for routine maintenance, comprehensive engine and transmission rebuilds, chassis and electrical system servicing, and advanced troubleshooting. The manual delves into specific systems such as the powertrain, brakes, fuel injection, cooling, and electrical components, providing the necessary technical specifications, torque values, and diagnostic guidance to ensure the Vulcan VN900 Classic remains in optimal condition throughout its service life. 🏷️ Basic Information Identification Make: Kawasaki Model: Vulcan VN900 Classic Model Variant: Classic VN900 Codes Chassis Code: VN900B Engine Code: ER650E (V-twin) Generation Generation: First Generation Production Years Covered: 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 👋 Introduction Market Position Segment: Mid-size cruiser motorcycle Target Audience: Riders seeking classic styling with modern reliability, enthusiasts, and professional mechanics Competitive Analysis Competitors: Honda Shadow, Yamaha V-Star, Suzuki Boulevard Key Features Styling: Retro cruiser aesthetics with chrome accents, teardrop fuel tank, spoked wheels Powertrain Emphasis: Torquey V-twin engine, comfortable riding position Value Proposition: Reliable and accessible cruiser offering classic looks and a user-friendly riding experience 📋 Manual Details Coverage Areas Documentation Type: Workshop Service Manual Content Scope: Comprehensive repair, maintenance, and troubleshooting Page Count Estimated Pages: Approximately 400-500 pages (typical for this model and depth) Manual Type Type: Official OEM Service Manual equivalent Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, clutch, final drive Chassis: Frame, suspension (front fork, rear shock), steering, wheels, tires Brakes: Front and rear brake system, hydraulic components, pads, rotors Electrical: Ignition system, charging system (stator, regulator/rectifier), lighting, instrumentation, battery, wiring diagrams Fuel System: Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), fuel tank, lines Exhaust System: Exhaust pipes, mufflers, catalytic converter (if applicable) Cooling System: Radiator, fan, coolant, hoses, thermostat (liquid-cooled engine) Bodywork: Fenders, fuel tank, seat, fairings, controls, accessories Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, spark plug inspection/replacement, fluid level checks Disassembly Assembly: Engine teardown and reassembly, transmission overhaul, suspension component replacement Troubleshooting: Diagnostic procedures, common problems and their solutions, fault code interpretation (if applicable) Calibration Adjustment: Throttle position sensor (TPS) adjustment, idle speed control, clutch lever free play Wiring Repair: Detailed wiring diagrams, connector identification, common wiring faults Technical Depth Depth Level: Expert (suitable for professional mechanics and experienced DIYers) Diagnostic Capability: Advanced diagnostics and troubleshooting guidance Rebuild Guidance: Complete engine and transmission rebuild procedures with torque specifications and clearances 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Resolution: High resolution, suitable for printing detailed diagrams and text Searchability: Searchable text for quick information retrieval Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) Completeness Manual Completeness: Full workshop manual covering all aspects of the specified models ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC, V-twin Displacement: 892 cc (54.4 cu in) Bore X Stroke: 88.0 x 74.8 mm (3.46 x 2.94 in) Compression Ratio: 9.5:1 Performance Horsepower Peak: Approx. 50-55 HP @ 5400 RPM (crank) Torque Peak: Approx. 76 Nm (56 lb-ft) @ 3300 RPM (crank) Fuel System Fuel Delivery: Digital Fuel Injection (DFI) with dual 36mm Keihin throttle bodies Fuel Type: Unleaded gasoline, 87 octane (minimum) Lubrication Oil Type: SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil Oil Capacity: 3.7 L (3.9 US qt) with filter change 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Primary Drive: Gear Final Drive: Belt drive Features Clutch Type: Wet, multi-disc, manual Gear Ratios: Detailed in manual, typically optimized for cruising Transmission Oil Type: API GL-4 SAE 80W-90 hypoid gear oil Transmission Oil Capacity: Approx. 0.9 L (0.95 US qt) 📐 Dimensions Exterior Overall Length: Approx. 2400 mm (94.5 in) Overall Width: Approx. 945 mm (37.2 in) Overall Height: Approx. 1030 mm (40.6 in) Wheelbase: Approx. 1600 mm (63.0 in) Ground Clearance: Approx. 140 mm (5.5 in) Seat Height: Approx. 705 mm (27.8 in) Weights Curb Weight: Approx. 265 kg (584 lbs) Fuel Tank Capacity: 20.0 L (5.3 US gal) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle, typically not rated by...