Kawasaki Vulcan 900 Custom Owner's manual

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Quick Reference Guide
GENERAL INFORMATION j
HOW TO RIDE THE MOTORCYCLE j
SAFE OPERATION j
MAINTENANCE AND ADJUSTMENT j
STORAGE j
TROUBLESHOOTING GUIDE j
This Quick Reference Guide will
assist you in finding the information
you’re looking for.
A Table of Contents is included after
the Foreword.
Whenever you see the symbols
shown below, heed their instructions!
Always follow safe operating and main-
tenance practices.
DANGER
DANGER indicates a hazardous
situation which, if not avoided,
will result in death or serious in-
jury.
WARNING
WARNING indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
NOTICE
NOTICE is used to address prac-
tices not related to personal in-
jury.
NOTE
NOTE ind icates informat ion that may
help or guide you in the operation or
service of the vehicle.
WARNING
Engine exhaust, some of its
constituents, and certain vehi-
cle components contain or emit
chemicals known to the State of
California to cause cancer and
birth defects or other reproduc-
tive harm.
NOTICE
THIS PRODUCT HAS BEEN
MANUFACTURED FOR USE IN A
REASONABLE AND PRUDENT
MANNER BY A QUALIFIED OP-
ERATOR AND AS A VEHICLE
ONLY.
FOREWORD
Congratulations on your purchase of a new Kawasaki Motorcycle. Your new mo-
torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,
and continuous striving for superior re liability, safety and performance .
Please read this Owners Manual carefully before riding so that you will be
thoroughly familiar with the proper operatio n of your motorcyc le’s controls, its fea-
tures, capabilities, and limitations. T his ma n ua l offers many safe riding tips , but its
purpose is not to provide instruction in all the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi-
cle enroll in a motorcycle rider training program to a ttain awareness of the m ental
and physical requirements necessary for safe m otorcycle operation.
To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in-
formation on their Kawasaki Motorcycle, a Service M an ual is a va ilable for purchase
from any authorized Kawasaki motorcycle dealer. The Service Manual contains de-
tailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the Service Manual.
Keep this Owner’s Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.
This manual should be considered a permanent part of the motorcycle and should
remain with the motorcycle when it is sold.
All rights reserved. No part of this publication may be reproduced without our
prior written permission.
This publication includes the latest information available at the time of printing.
However, there may be minor differences betwe e n the actual produ ct and illustra-
tions and text in this manual.
All products are subject to change without prior notice or obligation.
KAWASAKI HEAVY INDUSTRIES, LTD.
Motorcycle & Engine Company
© 2014 Kawasaki Heavy Industries, Ltd. May 16, 2014. (1)
TABLE OF CONTENTS
SPECIFICATIONS............................... 8
SERIAL NUMBER LOCATIONS......... 12
LOCATION OF PARTS ....................... 13
LOCATION OF LABELS ..................... 16
LOADING INFORMATION.................. 20
GENERAL INFORMATION................. 23
Meter Instruments ............................ 23
Speedometer: ............................... 24
Digital Display............................... 24
Fuel Gauge:.................................. 27
RESET Button/MODE button: ...... 27
Warning/Indicator Lights: .............. 28
Keys ................................................. 29
Ignition Switch.................................. 31
Right Handlebar Sw itches................ 32
Engine Stop Switch: ..................... 32
Starter Button: .............................. 32
Left Handlebar Switches .................. 33
Dimmer Switch: ............................ 33
Turn Signal Switch:....................... 33
Horn Button: ................................. 33
Brake Lever Adjusters...................... 34
Fuel Tank Cap.................................. 35
Fuel Tank ......................................... 36
Side Stand ....................................... 40
Seat.................................................. 41
Tool Kit Case.................................... 43
Helmet-Hook .................................... 44
Steering Lock ................................... 45
Electric Accessory Connectors ........ 46
BREAK-IN ........................................... 49
HOW TO RIDE THE MOTORCYCLE .51
Starting the Engine .......................... 51
Jump Starting................................... 54
Moving Off........................................ 58
Shifting Gears .................................. 59
Braking............................................. 61
Stopping the Engine......................... 62
Stopping the Motorcycle in an
Emergency ................................... 63
Parking............................................. 64
Catalytic Converter........................... 66
SAFE OPERATION............................. 68
Safe Riding Technique ..................... 68
Daily Checks .................................... 71
Additional Considerations for Hi gh
Speed Operation .......................... 74
MAINTENANCE A ND ADJUSTMENT 76
Periodic Maintenance Chart............. 81
Engine Oil ........................................ 92
Cooling System................................ 99
Drive Belt.......................................... 106
Spark Plugs...................................... 106
Evaporative Emission Control
System (California model only) .... 107
Valve Clearance ............................... 108
Kawasaki Clean Air System............. 109
Air Cleaner ....................................... 110
Throttle Control System ................... 112
Idle Speed........................................ 114
Clutch............................................... 115
Brakes.............................................. 117
Brake Light Switches........................ 121
Rear Shock Absorber....................... 123
Wheels ............................................. 126
Tires -............................................ 128
Battery.............................................. 132
Headlight Beam................................ 139
Fuses ............................................... 140
General Lubrication.......................... 144
Cleaning Your Motorcycle ................ 145
Bolt and N ut Tightening.................... 152
STORAGE........................................... 154
TROUBLESHOOTING GUIDE............ 157
YOUR WARRANTY/OWNER
SATISFACTION .............................. 158
Reporting Safety Defects.................. 164
ENVIRONMENTAL PROTECTION..... 165
MAINTENANCE RECORD ................. 166
LABEL INFORMATION ...................... 172
8 SPECIFICATIONS
SPECIFICATIONS
PERFORMANCE
Minimum Turing Radius
3.1 m (122 in.)
DIMENSIONS
Overall Length 2 405 mm (94.7 in.)
Overall Width 895 mm (35.2 in.)
Overall Height 1 120 mm (44.1 in.)
Wheelbase
1645mm(64.8in.)
Road Clearance 140 mm (5.5 in.)
Curb Mass 277 kg (611 lb)
ENGINE
Type
SOHC, V-typ e 2-cylinder, 4-stroke, liq uid-cooled
Displacement
903 cm³ (55.1 cu in.)
Bore × Stroke 88.0 × 74.2 mm (3.5 × 2.9 in.)
Compression Ratio
9.5 : 1
Starting System
Electric starter
SPECIFICAT IO NS 9
Cylinder Numbering Method
Front to rear, 1-2
Firing Order
1-2
Fuel System Digital fuel injection system (D FI)
Ignition System Battery and coil (transistorized ignition)
Ignition Timing
BTDC @1 000 r/min (rpm)
(Electronically advanced) 39° B TDC @5 400 r/mi n (rpm)
Spark Plugs NGK CPR7EA-9
Lubrication System Forced lubrication (wet su mp)
Engine Oil:
Type
API SG, SH, SJ, SL or SM with JASO MA, MA1
or MA2
Viscosity
SAE 10W-40
Capacity
3.7 L (3.9 US qt)
Coolant Capacity 2.2 L (2.3 US qt)
TRANSMISSION
Transmission Type
5-speed, constant me sh, return s hift
Clutch Type
Wet, multi disc
Driving System
Belt drive
10 SPECIFICATIONS
Primary Reduction Ratio
2.184 (83/38)
Final Reduction Ratio
2.063 (66/32)
Overall Drive Ratio 4.338 (Top gear)
Gear Ratio
1st
2.786 (39/14)
2nd
1.889 (34/18)
3rd
1.360 (34/25)
4th
1.107 (31/28)
5th
0.963 (26/27)
FRAME
Caster 33°
Trail
182 mm (7.2 in.)
Tire Size:
Front
80/90-21 M/C 48H
Rear
180/70-15 M/C 76H
Rim Size:
Front
J21M/C × MT2.15
Rear
J15M/C × MT4.50
Fuel Tank Capacity 20 L (5.3 US gal)
SPECIFICATIONS 11
ELECTRICAL EQUIPMENT
Battery
12 V 10 Ah (10 HR)
Headlight
12 V 60/55 W
Brake/Tail Light 12 V 21/5 W
Specifications are subject to change without notice.
12 SERIAL NUMBER L OCATIONS
SERIAL NUMBER LOCATIONS
The engine a nd frame serial num be rs are u sed to register the m ot orcycle. The y
are the only means of identifying your particular machine from others of the same
model type. The se serial numbers ma y b e needed by your d ea ler when ordering
parts. In the event of theft, the investigating authorities will require both numbers
as well as the model type and any peculiar features of your machine that can help
them identify it.
Frame No.
A. Frame Number
Engine No.
A. Engine Number
LOCATION OF PARTS 13
LOCATION OF PARTS
1. Clutch Lever
2. Clutch Lever Adjuster
3. Meter Instruments
4. Brake Fluid Reservoir (Front)
5. Brake Lever Adjuster
6. Front Brake L ever
7. Left Handlebar Switches
8. Indicator Lights
9. Fuel Tank Cap
10. Right Handlebar Switches
11. Throttle G rip
14 LOCATION OF PARTS
12. Front Fork
13. Headlight
14. Turn S ign al Ligh t
15. Horn
16. Spark Plugs
17. Battery
18. Brake Disc
19. Brake Caliper
20. Wheel
21. Radiator
22. Shift Pedal
23. Oil Level Inspection Wind ow
24. Side Stand Switch
25. Side Stand
26. Fuse Box
27. Coolant R ese rve Tank
28. Rear Shock Absorbe r
29. Belt
30. Belt Pulley
LOCATION OF PARTS 15
31. Tail/Brake L igh t
32. Seat
33. Tool Kit Case/Tool Kit
34. Air Cleaner Elemen t
35. Fuel Tank
36. Steering Lock
37. Mufflers
38. Idle Speed Adjusting Screw
39. Rear Brake Pedal
40. Rear B rake Light Switch
41. Brake Fluid Reservoir (Rear)
16 LOCATION OF LABELS
LOCATION OF LABELS
All warning labels which are on your
vehicle are repeated here. Read labels
on your vehicle and understand them
thoroughly. They contain information
which is important for your safety and
the safety of anyone else who may op-
erate your vehicle. Therefore, it is very
important tha t all warn ing labels be on
your vehicle in the locations show n. If
any label is missing, damaged, or worn,
get a replacement from your Kawasaki
dealer and install it in the correct posi-
tion.
NOTE
The sample warning labels in this
section have part numbers to help
you and your dealer obtain the cor-
rect replacement.
Refer to the actual vehicle label for
model specific data grayed out in the
illustration .
*1. Fuel Level
2. Brake Fluid (Front)
(For further information of label, refer to
the “LABEL INFORMATION chapter.)
*: only on California model
LOCATION OF LABELS 17
3. Brake Fluid (Rear)
4. Tire and Load Data
5. Battery Po siti on/ Danger
(For further information of label, refer to
the “LABEL INFORMATION” chapter.)
18 LOCATION OF LABELS
*6. Vacuum Ho se Routing D iagram
7. Vehicle Emission Control Information
8. Weight and Manufacture
9. Noise Emission Control Information
(For further information of label, refer to
the “LABEL INFORMATION chapter.)
*: only on California model
LOCATION OF LABELS 19
10. Radiator Cap Danger
(For further information of label, refer to
the “LABEL INFORMATION” chapter.)
/