This manual covers the 2010 VN900CA Vulcan Custom, a mid-size cruiser motorcycle renowned for its classic styling and reliable performance. Engineered with a liquid-cooled, SOHC, V-twin engine featuring electronic fuel injection and a smooth belt drive, the Vulcan Custom offers an accessible and enjoyable riding experience. Its distinctive design, characterized by classic cruiser lines and a low seat height, makes it a popular choice for riders seeking both style and practicality for everyday use and touring. This comprehensive service manual provides detailed information for the maintenance, troubleshooting, and repair of your VN900CA Vulcan Custom. It includes complete procedures for engine, transmission, chassis, brakes, and electrical systems, along with diagnostic guides and technical specifications. Whether you are performing routine maintenance like oil changes and filter replacements or undertaking more complex repairs, this manual is an essential resource for owners and technicians to ensure the optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Kawasaki Model: VN900CA Vulcan Custom Year: 2010 Codes Chassis Code: VN900CA 👋 Introduction Market Position Segment: Mid-size cruiser motorcycle Target Audience: Riders seeking a stylish, accessible, and reliable cruiser for everyday riding and touring. Competitive Analysis Key Competitors: Honda Shadow series, Yamaha V-Star series, Suzuki Boulevard series. Key Features Styling: Classic cruiser lines with modern touches, distinctive front fork rake, low seat height. Powertrain: Liquid-cooled, SOHC, V-twin engine with electronic fuel injection. Drivetrain: Smooth and reliable belt drive for low maintenance. 📋 Manual Details Coverage Areas Primary Coverage: Complete service, maintenance, and repair procedures for the Kawasaki VN900CA Vulcan Custom. Secondary Coverage: Troubleshooting guides, diagnostic procedures, torque specifications, electrical diagrams. Page Count Estimated Pages: Approximately 400-500 pages (typical for this model and scope) Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, top-end and bottom-end components, lubrication system, cooling system (air-cooled), fuel injection system. Transmission: Clutch operation, gearbox inspection and repair, final drive (belt drive system). Chassis: Frame inspection, suspension (front fork and rear shock absorber), steering system. Brakes: Front and rear brake system servicing, hydraulic components, pad and rotor replacement. Electrical: Ignition system, starting system, charging system, lighting system, instrumentation, wiring diagrams, diagnostic codes. Fuel System: Fuel pump, fuel injectors, throttle body, ECU control, fuel tank and lines. Bodywork: Fender removal/installation, seat assembly, fuel tank removal/installation, minor body panel adjustments. Procedures Included Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake fluid flush, drive belt inspection and adjustment. Diagnostics: Troubleshooting common issues, identifying fault codes, systematic diagnostic approaches for engine and electrical systems. Repair: Engine component rebuilding (pistons, rings, valves), transmission overhaul, suspension fork rebuild, brake caliper servicing. Calibration: Throttle position sensor (TPS) adjustment, idle speed control. Technical Depth Depth: Comprehensive, covering everything from routine maintenance to full engine and transmission rebuilds, including detailed electrical troubleshooting. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Text-searchable (typically, depending on PDF creation) Print Quality Quality: High-resolution digital scans with clear text and images, suitable for printing. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, 4-stroke, SOHC, 2 valves per cylinder Displacement: 892 cc (54.5 cubic inches) Bore X Stroke: 92.0 mm x 84.0 mm Compression Ratio: 9.5:1 Cooling System: Liquid-cooled Performance Horsepower: Approximately 50-55 HP (estimated at crankshaft) Torque: Approximately 54-58 lb-ft (estimated at crankshaft) Fuel System Fuel Delivery: Digital Fuel Injection (DFI) with dual 32mm throttle bodies Fuel Type: Unleaded gasoline, 87-octane or higher Lubrication Oil Type: SAE 10W-40 API SG, JASO MA Oil Capacity: 3.2 L (3.4 US qt) with filter change 🔧 Transmission Standard Type: 5-speed constant mesh Clutch: Wet, multi-disc Final Drive: Belt drive, 2.75:1 (primary) / 2.73:1 (final) Features Gear Ratios: 1st: 2.750, 2nd: 1.944, 3rd: 1.409, 4th: 1.125, 5th: 0.958 (Refer to manual for exact ratios) Transmission Fluid: Refer to engine oil specifications (shared lubrication) 📐 Dimensions Exterior Length: 2405 mm (94.7 in) Width: 960 mm (37.8 in) Height: 1110 mm (43.7 in) Wheelbase: 1635 mm (64.4 in) Ground Clearance: 140 mm (5.5 in) Seat Height: 705 mm (27.8 in) Weights Curb Weight: 263 kg (580 lbs) Fuel Capacity: 20 L (5.3 US gal) Wheels Tires Front Tire: 80/90-21M/C 48H Rear Tire: 180/70-15M/C 76H Wheel Type: Cast aluminum spoke wheels 🛡️ Safety Features Ratings Crash Safety: Not typically rated by formal bodies like NHTSA for motorcycles. Active Features Braking System: Dual-piston caliper front disc brake, single-piston caliper rear disc brake. ABS: Optional (ABS variant available) Passive Features Lighting: Halogen headlight, LED taillight, standard turn signals. 💡 Technology Features Infotainment Features: Basic instrumentation: speedometer, odometer, trip meter, fuel gauge, clock, indicator lights. No advanced infotainment systems. Driver Assistance Features: Optional Anti-lock Braking System (ABS). Connectivity Features: N/A (No integrated smartphone connectivity or Bluetooth). 🔧 Maintenance Service Intervals Engine Oil...