Kawasaki VN900CA 2010 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: VN900CA Year: 2010 Motorcycle Type: Cruiser Codes Model Code: VN900CA 👋 Introduction Market Position Segment: Mid-size cruiser motorcycle segment Target Audience: Riders seeking classic styling with modern reliability and performance, suitable for cruising and commuting. Competitive Analysis Key Competitors: Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series. Key Features Styling: Classic cruiser aesthetics with flowing lines, spoke wheels, and ample chrome accents. Engine Type: V-twin, liquid-cooled, SOHC, 8-valve engine. Fueling: Electronic fuel injection for smooth throttle response and efficient operation. 📋 Manual Details Coverage Areas General Coverage: All VN900CA models Engine Coverage: VN900 engine variants Transmission Coverage: VN900 transmission variants Trim Coverage: All trim levels Page Count Estimated Page Count: Approximately 600-800 pages (typical for a comprehensive workshop manual) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, cylinder head, pistons, crankshaft, valve train, timing Fuel System: Fuel injection system, throttle body, injectors, fuel pump, fuel pressure regulator, fuel tank Ignition System: Ignition coils, spark plugs, ignition control module (ICM), timing Cooling System: Radiator, coolant, thermostat, water pump, fan Transmission And Drivetrain: Clutch, gearbox, final drive, drive shaft, bearings Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, rotors, pads, bleeding procedures Suspension: Front fork assembly, rear shock absorber, linkages, spring rates, damping adjustments Steering: Handlebars, triple clamps, steering head bearings, alignment Electrical System: Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), starter motor, lighting, switches, fuses, relays Wheels And Tires: Wheel bearings, tire sizes, inflation pressures, wheel balancing Chassis And Frame: Frame inspection, alignment, body panels, mounting hardware Instrumentation: Speedometer, tachometer, indicators, diagnostics Exhaust System: Mufflers, pipes, gaskets, emissions components Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, brake inspections, fluid checks, lubrication points Troubleshooting: Diagnostic procedures for common and uncommon problems, fault codes, electrical diagnostic charts Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment for all major systems Overhaul Instructions: Detailed procedures for complete engine and transmission rebuilds Wiring Diagrams: Comprehensive electrical system schematics for accurate diagnosis and repair Specification Charts: Torque specifications, clearances, fluid capacities, electrical values Technical Depth Depth Level: Comprehensive (covers basic maintenance to full engine rebuilds) Diagnostic Capability: Advanced diagnostics for fuel injection, ignition, and electrical systems Special Tools: Identification of required special tools and their usage 📊 Manual Specifications File Format File Type: PDF Searchability: Typically searchable text within the PDF Print Quality Print Readability: High resolution, suitable for printing section by section Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, 4-stroke Displacement: 892 cc (54.5 cubic inches) Bore X Stroke: 92.0 x 68.0 mm Valvetrain: SOHC, 2 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower: Approximately 50-55 HP (at crankshaft, depending on region) Torque: Approximately 76 Nm (56 lb-ft) @ 3,500 rpm Fuel System Fuel Delivery: Digital Fuel Injection with dual 36mm throttle bodies Fuel Type: Unleaded gasoline 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Optional Optional Transmission: N/A (Only one transmission offered) Features Clutch Type: Wet, multiple-disc, cable-actuated Final Drive: Belt drive 📐 Dimensions Exterior Length: 2,400 mm (94.5 in) Width: 990 mm (39.0 in) Height: 1,135 mm (44.7 in) Wheelbase: 1,605 mm (63.2 in) Ground Clearance: 140 mm (5.5 in) Seat Height: 705 mm (27.8 in) Weights Curb Weight: 260 kg (573.2 lbs) Fuel Capacity: 20 Liters (5.3 US gal) 🛡️ Safety Features Ratings Safety Ratings: Motorcycles are not typically rated by organizations like NHTSA or Euro NCAP in the same way as cars. Safety is primarily determined by rider skill and adherence to traffic laws. Active Features Braking System: Dual front disc brakes, single rear disc brake. Lighting: Halogen headlight, LED taillight, standard turn signals. Passive Features Frame Construction: Steel double-cradle frame for stability. Ergonomics: Low seat height and relaxed rider triangle contribute to rider control and comfort. 💡 Technology Features Infotainment Infotainment System: N/A (Does not feature an infotainment system like modern cars; basic analogue and digital instrumentation.) Driver Assistance Driver Assistance Features: N/A Connectivity Connectivity Features: N/A Instrumentation Dashboard Features: Analogue speedometer, digital odometer, trip meter, clock, fuel gauge, and indicator lights. 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or 6 months Air Filter Inspection: Every 6,000 km (3,700 miles) Spark Plug Replacement: Every 12,000 km (7,500 miles) Brake Fluid Change: Every 24,000 km (15,000 miles) or 2 years Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or higher (JASO MA recommended) Engine Oil Capacity: Approx. 3.4 Liters (3.6 US qt) with filter change Coolant Type: Permanent antifreeze (ethylene glycol base) with demineralized water (50:50 mixture) Brake Fluid Type: DOT 4 Known Issues Common Wear Items: Brake pads, tires, clutch friction plates, drive belt wear. Potential Electronic...
Comprehensive (covers basic maintenance to full engine rebuilds)
Diagnostic Capability:
Advanced diagnostics for fuel injection, ignition, and electrical systems
Special Tools:
Identification of required special tools and their usage
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Typically searchable text within the PDF
Print Quality
Print Readability:
High resolution, suitable for printing section by section
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, 4-stroke
Displacement:
892 cc (54.5 cubic inches)
Bore X Stroke:
92.0 x 68.0 mm
Valvetrain:
SOHC, 2 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approximately 50-55 HP (at crankshaft, depending on region)
Torque:
Approximately 76 Nm (56 lb-ft) @ 3,500 rpm
Fuel System
Fuel Delivery:
Digital Fuel Injection with dual 36mm throttle bodies
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Optional
Optional Transmission:
N/A (Only one transmission offered)
Features
Clutch Type:
Wet, multiple-disc, cable-actuated
Final Drive:
Belt drive
📐 Dimensions
Exterior
Length:
2,400 mm (94.5 in)
Width:
990 mm (39.0 in)
Height:
1,135 mm (44.7 in)
Wheelbase:
1,605 mm (63.2 in)
Ground Clearance:
140 mm (5.5 in)
Seat Height:
705 mm (27.8 in)
Weights
Curb Weight:
260 kg (573.2 lbs)
Fuel Capacity:
20 Liters (5.3 US gal)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles are not typically rated by organizations like NHTSA or Euro NCAP in the same way as cars. Safety is primarily determined by rider skill and adherence to traffic laws.
Active Features
Braking System:
Dual front disc brakes, single rear disc brake.
Lighting:
Halogen headlight, LED taillight, standard turn signals.
Passive Features
Frame Construction:
Steel double-cradle frame for stability.
Ergonomics:
Low seat height and relaxed rider triangle contribute to rider control and comfort.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Does not feature an infotainment system like modern cars; basic analogue and digital instrumentation.)
Driver Assistance
Driver Assistance Features:
N/A
Connectivity
Connectivity Features:
N/A
Instrumentation
Dashboard Features:
Analogue speedometer, digital odometer, trip meter, clock, fuel gauge, and indicator lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months
Air Filter Inspection:
Every 6,000 km (3,700 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Brake Fluid Change:
Every 24,000 km (15,000 miles) or 2 years
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher (JASO MA recommended)
Engine Oil Capacity:
Approx. 3.4 Liters (3.6 US qt) with filter change
Coolant Type:
Permanent antifreeze (ethylene glycol base) with demineralized water (50:50 mixture)
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Brake pads, tires, clutch friction plates, drive belt wear.
Potential Electronic Issues:
While generally reliable, some units might experience issues with voltage regulators or stators over extended periods, especially if maintenance is neglected.
Fuel System Maintenance:
Regular use of quality fuel and occasional injector cleaning can prevent performance issues.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long-standing reputation for building reliable and performance-oriented motorcycles across various segments, including cruisers.
Model Evolution
Vn900 Lineage:
The VN900 series, including the VN900CA, builds upon Kawasaki's V-twin cruiser heritage, offering a blend of classic styling and modern technology.
Production
Production Years:
The VN900 series was introduced in 2006 and has seen continuous production with minor updates. The 2010 model is part of this established lineage.
🏆 Awards & Recognition
Recognitions
Awards Received:
The VN900 platform has generally received positive reviews from motorcycle publications for its styling, ride comfort, and value for money in the cruiser segment. Specific awards are not widely documented as for major automotive models.
Ratings
Customer Satisfaction:
Often cited for reliable performance and enjoyable riding experience, contributing to good owner satisfaction.
Certifications
Emissions Certification:
Meets relevant emissions standards for its model year and region of sale.
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