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Kawasaki VN900 Custom User Manual

Kawasaki VN900 Custom
617 pages
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VULCAN 900 Custom
VN900 Custom
Downloaded for free, http://VulcanRider.se/

Table of Contents

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Kawasaki VN900 Custom Specifications

General IconGeneral
Displacement903 cc
Bore x Stroke88.0 x 74.2 mm
Compression Ratio9.5:1
IgnitionTCBI with electronic advance
Final DriveBelt
Frame TypeDouble-cradle, high-tensile steel
Front Suspension41 mm telescopic fork
Wheelbase1, 645 mm
Engine Type4-stroke, V-twin, SOHC, 4 valves per cylinder
Fuel SystemFuel injection: ø34 mm x 2
Transmission5-speed
Rear SuspensionUni-Trak swingarm
Front BrakesSingle 300mm hydraulic disc
Rear BrakesSingle 270 mm disc with two-piston caliper
Rear Tire180/70-15
Ground Clearance140mm
Seat Height685 mm
Fuel Capacity20 liters

Summary

Emission Control Information

Crankcase Emission Control System

System to prevent crankcase vapors from entering the atmosphere.

Exhaust Emission Control System

System to reduce atmospheric pollutants from exhaust.

Evaporative Emission Control System

System to manage fuel vapors from the fuel system.

Tampering With Noise Control System Prohibited

Foreword

How to Use This Manual

Explains manual symbols and how to navigate procedures.

DANGER

Indicates a critical hazard resulting in death or serious injury if not avoided.

WARNING

Indicates a hazardous situation that could result in death or serious injury if not avoided.

List of Abbreviations

Country and Area Codes

General Information

Before Servicing

Precautions and guidelines before starting inspection or disassembly.

Model Identification

Information for identifying the motorcycle model.

General Specifications

Key technical specifications for the motorcycle.

Periodic Maintenance

Periodic Maintenance Chart

Schedule of inspections and replacements based on mileage and time.

Torque and Locking Agent

Lists tightening torques and locking agents for fasteners.

Periodic Maintenance Procedures

Step-by-step instructions for various maintenance tasks.

Fuel System (DFI)

Specifications

Technical specifications for the fuel system.

DFI Parts Location

Identifies the location of DFI system components on the motorcycle.

DFI Servicing Precautions

Important precautions for servicing the DFI system.

Troubleshooting the DFI System

Guide for diagnosing and resolving DFI system issues.

Clutch

Exploded View

Illustrated breakdown of clutch components.

Specifications

Specifications for clutch components.

Clutch Lever and Cable

Procedures for clutch lever and cable service.

Clutch

Procedures for clutch removal, installation, and inspection.

Engine Lubrication System

Specifications

Specifications for engine lubrication system components.

Engine Oil and Oil Filter

Procedures for inspecting and changing engine oil and oil filter.

Oil Pressure Measurement

Procedure for measuring oil pressure.

Engine Removal/Installation

Exploded View

Illustrated breakdown of engine removal and installation components.

Engine Removal

Step-by-step instructions for removing the engine.

Engine Installation

Step-by-step instructions for installing the engine.

Crankshaft/Transmission

Exploded View

Illustrated breakdown of crankshaft and transmission components.

Specifications

Specifications for crankshaft and transmission parts.

Crankcase Splitting

Procedures for splitting the crankcase.

Crankshaft, Connecting Rods

Details on crankshaft, connecting rods, their removal, installation, and inspection.

Transmission

Maintenance procedures for the transmission system.

Wheels/Tires

Exploded View

Illustrated breakdown of wheel and tire components.

Specifications

Specifications for wheels and tires.

Wheels (Rims)

Procedures for wheel removal, installation, inspection, and balancing.

Tires

Procedures for tire inspection, removal, installation, and repair.

Hub Bearing

Procedures for hub bearing removal, installation, inspection, and lubrication.

Final Drive

Exploded View

Illustrated breakdown of final drive components.

Specifications

Specifications for the drive belt.

Drive Belt

Procedures for handling, inspecting, adjusting, removing, and installing the drive belt.

Pulley and Coupling

Procedures for servicing pulleys, couplings, and bearings.

Suspension

Exploded View

Illustrated breakdown of suspension components.

Specifications

Specifications for front fork and rear shock absorber.

Front Fork

Procedures for front fork removal, installation, oil change, disassembly, and assembly.

Rear Shock Absorber

Procedures for rear shock absorber adjustment, removal, installation, and inspection.

Swingarm

Procedures for swingarm removal, installation, and bearing service.

Tie-Rod, Rocker Arm

Procedures for tie-rod and rocker arm removal, installation, and bearing service.

Steering

Exploded View

Illustrated breakdown of steering components.

Special Tools

Lists special tools for steering service.

Steering

Procedures for steering inspection and adjustment.

Steering Stem

Procedures for steering stem and bearing service.

Handlebar

Procedures for handlebar removal and installation.

Frame

Exploded View

Illustrated breakdown of frame components.

Special Tool

Lists special tools for frame service.

Seat

Procedures for seat removal and installation.

Side Covers

Procedures for side cover removal and installation.

Fenders

Procedures for fender removal and installation.

Battery Case

Procedures for battery case removal and installation.

Footpeg

Procedures for footpeg removal and installation.

Sidestand

Procedures for sidestand removal, installation, and inspection.

Rear View Mirrors

Procedures for rear view mirror removal and installation.

Downtube

Procedures for downtube removal and installation.

Frame

Procedure for frame inspection.

Electrical System

Exploded View

Illustrated breakdown of electrical system components.

Specifications

Specifications for electrical system components.

Parts Location

Identifies the location of electrical system parts.

Wiring Diagram (VN900C7 ~ C8)

Electrical wiring diagram for VN900C7 to C8 models.

Wiring Diagram (VN900C9 ~)

Electrical wiring diagram for VN900C9 and later models.

Precautions

Important precautions for servicing electrical systems.

Battery

Procedures for battery removal, installation, activation, and charging.

Charging System

Procedures for inspecting and servicing the charging system.

Ignition System

Procedures related to the ignition system.

Electric Starter System

Procedures for the electric starter system.

Lighting System

Procedures for headlight, taillight, and turn signal maintenance.

Meter Unit

Procedures for meter unit service and inspection.

Switches and Sensors

Procedures for inspecting and testing various switches and sensors.

Appendix

Cable, Wire, and Hose Routing

Diagrams and instructions for routing cables, wires, and hoses.

Troubleshooting Guide

Guide for diagnosing and resolving common motorcycle issues.

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