Kawasaki Vulcan 900 VN 900 2006-2013 Workshop Service Repair Manual
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The Kawasaki Vulcan 900 VN900, available in Classic, Custom, and LT variants, is a cruiser motorcycle renowned for its blend of classic styling and modern engineering. Produced from 2006 to 2013, this model features a robust 805 cc V-twin, air-cooled engine delivering approximately 50-52 HP and 50-53 lb-ft of torque, coupled with a 5-speed transmission and reliable belt drive. Its comfortable riding position and dependable performance have established it as a strong contender in the mid-size cruiser market, often compared favorably to models from Honda, Yamaha, and Suzuki. The Vulcan 900 is appreciated for its value proposition, offering comprehensive diagnostic and repair guidance that empowers owners to maintain their machines effectively. This workshop service repair manual provides extensive coverage for the Kawasaki Vulcan 900 VN900 models from 2006 through 2013. It details essential maintenance procedures, from routine oil changes and filter replacements to more involved tasks like engine overhauls and transmission servicing. The manual includes in-depth troubleshooting guides, technical specifications, wiring diagrams, and information on special tools, making it an invaluable resource for owners, mechanics, and technicians. With a focus on clear, step-by-step instructions and high-resolution diagrams, this approximately 600+ page English manual ensures that all aspects of the motorcycle's engine, drivetrain, chassis, brakes, and electrical systems can be understood, maintained, and repaired with confidence. 🏷️ Basic Information Identification Make: Kawasaki Model: Vulcan 900 VN900 Model Variants: Classic, Custom, LT Product Name: Kawasaki Vulcan 900 VN 900 2006-2013 Workshop Service Repair Manual PDF Download Codes Chassis Codes: VN900B, VN900C, VN900D 👋 Introduction Market Position Segment: Cruiser Motorcycle Target Audience: Hobbyists, independent repair shops, professional mechanics, owners seeking in-depth maintenance knowledge Competitive Analysis Competitors: Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series Key Features Value Proposition: Comprehensive diagnostic and repair guidance for a popular cruiser model, enabling owners to perform maintenance and repairs effectively. 📋 Manual Details Coverage Areas Covered Years: 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 Geographic Coverage: Global (primarily North America and Europe) Page Count Estimated Page Count: Approximately 600+ Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, top end, bottom end, cooling system, lubrication system, fuel system (carburetion/injection), ignition system, starting system, exhaust system Transmission Drivetrain: Clutch, gearbox, final drive (belt drive system), internal transmission components Chassis Suspension: Frame, front suspension (forks), rear suspension (shock absorbers), wheels, tires, steering system Brakes: Front and rear brake systems (hydraulic, caliper, rotor, master cylinder), brake fluid specifications Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, ignition switches, starter motor, fuses, relays, instrumentation Fuel System: Fuel tank, fuel pump, fuel injectors (if applicable), fuel lines, fuel filter, carburetor specifications and tuning (for relevant models) Bodywork Fittings: Body panels, fenders, seat, handlebars, footpegs, mirrors, luggage (if applicable to LT model) Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment (if applicable, though VN900 uses belt drive), spark plug replacement, air filter cleaning/replacement, brake inspection, tire pressure checks Troubleshooting: Diagnostic procedures for common and uncommon issues, fault codes (if applicable to EFI models), symptom-based troubleshooting guides Major Repairs: Engine disassembly and reassembly, transmission overhaul, suspension fork servicing, brake caliper rebuild, fuel system component replacement Special Tools: Identification and usage of specialized tools required for specific procedures Technical Depth Diagnostic Capabilities: Detailed step-by-step diagnostics, electrical testing procedures, component testing specifications Rebuild Procedures: Comprehensive instructions for complete engine and component rebuilds, including torque specifications and clearances Specification Data: All critical technical specifications, torque values, fluid capacities, tolerances, and measurements 📊 Manual Specifications File Format File Format: PDF Searchability: Text-searchable PDF (allows keyword searching within the document) Print Quality Print Quality: High-resolution scans, clear diagrams and text, suitable for printing Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, four-stroke Displacement: 805 cc (49.1 cu in) Bore X Stroke: 88.0 x 66.0 mm (3.46 x 2.60 in) Cooling System: Air-cooled Valvetrain: SOHC, 4 valves per cylinder Performance Horsepower: Approx. 50-52 HP (at crankshaft, depending on specific model variant and tuning) Torque: Approx. 50-53 lb-ft (at crankshaft, depending on specific model variant and tuning) Fuel System Fuel Delivery: Fuel Injection (EFI) on most models, some earlier models may have carburetor; check specific VIN. Fuel Type: Unleaded gasoline, 87 octane or higher recommended Lubrication Oil Type: SAE 10W-40 API SG or higher, JASO MA Oil Capacity: 3.4 US qt (3.2 L) with filter change 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Final Drive: Belt drive Features Clutch Type: Wet, multi-disc Gear Ratios: Detailed ratios provided within the manual for each gear. Transmission Fluid: Refer to engine oil specifications; transmission is lubricated by engine oil. 📐 Dimensions Exterior Overall Length: Approx. 92.5 in (2350 mm) Overall Width: Approx. 36.0 in (915 mm) Overall Height:...
The Kawasaki Vulcan 900 VN900, available in Classic, Custom, and LT variants, is a cruiser motorcycle renowned for its blend of classic styling and modern engineering. Produced from 2006 to 2013, this model features a robust 805 cc V-twin, air-cooled engine delivering approximately 50-52 HP and 50-53 lb-ft of torque, coupled with a 5-speed transmission and reliable belt drive. Its comfortable riding position and dependable performance have established it as a strong contender in the mid-size cruiser market, often compared favorably to models from Honda, Yamaha, and Suzuki. The Vulcan 900 is appreciated for its value proposition, offering comprehensive diagnostic and repair guidance that empowers owners to maintain their machines effectively.
This workshop service repair manual provides extensive coverage for the Kawasaki Vulcan 900 VN900 models from 2006 through 2013. It details essential maintenance procedures, from routine oil changes and filter replacements to more involved tasks like engine overhauls and transmission servicing. The manual includes in-depth troubleshooting guides, technical specifications, wiring diagrams, and information on special tools, making it an invaluable resource for owners, mechanics, and technicians. With a focus on clear, step-by-step instructions and high-resolution diagrams, this approximately 600+ page English manual ensures that all aspects of the motorcycle's engine, drivetrain, chassis, brakes, and electrical systems can be understood, maintained, and repaired with confidence.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Vulcan 900 VN900
Model Variants:
Classic, Custom, LT
Product Name:
Kawasaki Vulcan 900 VN 900 2006-2013 Workshop Service Repair Manual PDF Download
Comprehensive instructions for complete engine and component rebuilds, including torque specifications and clearances
Specification Data:
All critical technical specifications, torque values, fluid capacities, tolerances, and measurements
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Text-searchable PDF (allows keyword searching within the document)
Print Quality
Print Quality:
High-resolution scans, clear diagrams and text, suitable for printing
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, four-stroke
Displacement:
805 cc (49.1 cu in)
Bore X Stroke:
88.0 x 66.0 mm (3.46 x 2.60 in)
Cooling System:
Air-cooled
Valvetrain:
SOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 50-52 HP (at crankshaft, depending on specific model variant and tuning)
Torque:
Approx. 50-53 lb-ft (at crankshaft, depending on specific model variant and tuning)
Fuel System
Fuel Delivery:
Fuel Injection (EFI) on most models, some earlier models may have carburetor; check specific VIN.
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended
Lubrication
Oil Type:
SAE 10W-40 API SG or higher, JASO MA
Oil Capacity:
3.4 US qt (3.2 L) with filter change
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Final Drive:
Belt drive
Features
Clutch Type:
Wet, multi-disc
Gear Ratios:
Detailed ratios provided within the manual for each gear.
Transmission Fluid:
Refer to engine oil specifications; transmission is lubricated by engine oil.
📐 Dimensions
Exterior
Overall Length:
Approx. 92.5 in (2350 mm)
Overall Width:
Approx. 36.0 in (915 mm)
Overall Height:
Approx. 43.1 in (1095 mm)
Wheelbase:
Approx. 64.8 in (1645 mm)
Weights
Dry Weight:
Approx. 573 lbs (260 kg)
Curb Weight:
Approx. 597 lbs (271 kg)
Fuel Capacity:
5.5 US qt (5.2 L)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycle safety is primarily determined by rider skill and adherence to traffic laws. Specific crash test ratings are not typically applicable in the same way as automobiles.
Active Features
Braking System:
Hydraulic disc brakes front and rear.
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable to this model's primary design intent (basic cruiser).
Driver Assistance
ABS:
ABS was an optional feature on some models during this production run, not standard on all.
Connectivity
Connectivity Features:
Not applicable.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,700 miles (6,000 km) or 6 months, whichever comes first.
Air Filter Inspection:
Every 3,700 miles (6,000 km)
Spark Plug Replacement:
Every 7,500 miles (12,000 km)
Belt Drive Inspection:
Every 7,500 miles (12,000 km) for tension and condition
Brake Fluid Flush:
Every 2 years or 15,000 miles (24,000 km)
Fluid Specifications
Engine Oil:
SAE 10W-40 API SG or higher, JASO MA
Brake Fluid:
DOT 4
Coolant:
N/A (Air-cooled engine)
Known Issues
Common Wear Items:
Belt drive wear, clutch plates, brake pads, tires, fork seals.
Potential Complaints:
Occasional throttle response issues (related to fuel delivery tuning), starter motor solenoid issues (rare).
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycle Division:
Kawasaki Heavy Industries' motorcycle division boasts a long history of innovation and performance, from early Z models to modern Ninja and cruisers.
Model Evolution
Vulcan Lineage:
The Vulcan 900 builds upon Kawasaki's cruiser heritage, offering a balance of classic styling and modern engineering.
Production
Production Period:
2006-Present (with minor updates)
Manufacturing Location:
Japan and various international assembly plants.
🏆 Awards & Recognition
Recognitions
Market Reception:
Consistently praised for its comfortable riding position, reliable V-twin engine, and classic styling, making it a popular choice in the mid-size cruiser segment.
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