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Kawasaki Vulcan 900 Classic, Classic LT & Custom 2006-2013 Online Manual (ECM246)

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Kawasaki Vulcan 900 Classic, Classic LT & Custom Service and Repair Manual (2006-2013) M246

Includes Color Wiring Diagrams.

This service manual provides specific, detailed instructions for performing everything from basic maintenance and troubleshooting to a complete overhaul of the Kawasaki Vulcan 900 Series motorcycle. Do-it-yourselfers will find this service and repair manual more comprehensive than the factory manual, making it an indispensable part of your tool box.

Model:
Kawasaki Vulcan 900 Classic VN900B VN900BC (2006-2013)
Kawasaki Vulcan 900 Classic LT VN900D VN900DC (2006-2013)
Kawasaki Vulcan 900 Custom VN900C VN900CC (2007-2013)

QUICK REFERENCE DATA

CHAPTER ONE/GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING

Starting the engine / Starting procedures / Engine performance / Engine / Engine exhaust / Engine noises / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Electronic diagnostic system / Electrical testing / Electrical troubleshooting / Suspension and steering / Brake system / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP

Cylinder numbering and firing order / Tune-up / Air filter / Engine compression test / Spark plugs / Ignition timing / Valve clearance / Engine oil / Engine oil pressure test / Fuel line inspection / Clean air system / Evaporative emissions control system (California models) / Idle speed adjustment / Throttle cable / Control cable lubrication / Clutch cable / Shift rod length / Headlight adjustment / Cooling system / Tires and wheels / Front suspension inspection / Rear suspension inspection / Steering inspection / Drive belt / Brake system / General lubrication / Fasteners / Specifications

CHAPTER FOUR / ENGINE TOP END

Cylinder head cover / Camshaft / Rocker arm and shaft / Cam chain and guides / Cam chain tensioner / Cylinder head / Valves and valve components / Cylinder / Piston and piston rings / Specifications

CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine removal and installation / Balancer and starter clutch assembly / Primary drive gear / Balancer shaft / Oil pump / Oil pipes / Oil pressure relief valve / Oil screen / Crankcase / Crankshaft and connecting rods / Engine break-in / Specifications

CHAPTER SIX / CLUTCH
Clutch cable / Clutch lever assembly / Clutch cover / Clutch release lever / Clutch / Specifications

CHAPTER SEVEN / TRANSMISSION AND SHIFT MECHANISM
Shift pedal / External shift mechanism / Engine pulley cover / Engine pulley / Transmission / Internal shift mechanism / Specifications

CHAPTER EIGHT / FUEL INJECTION, EMISSIONS AND EXHAUST SYSTEMS

Air filter housing / Fuel tank / Fuel level sensor / Fuel gauge / Fuel pump / Fuel reserve switch / Fuel pump relay / Digital fuel injection (DFI) / Electronic control unit (ECU) / ECU main relay / Fuel injectors and fuel rail / Throttle body / Intake manifold / Throttle sensor / Subthrottle (ST) sensor / Subthrottle valve (STV) actuator / Intake air pressure (IAP) sensor / Intake air temperature (IAT) sensor / Vehicle down sensor / FI indicator / Throttle cable replacement / Exhaust system / Oxygen sensor / Evaporative emissions control (EVAP) system (California models) / Clean air system / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Electrical component replacement / Electrical connectors / Battery / Charging system / Alternator / Regulator/rectifier / Ignition system / Peak voltage testing / Ignition coil cover / Ignition coil / Crankshaft sensor / Starting system / Starter / Starter relay / Starter circuit relay / Interlock system / Lighting system / Front turn signal housing / Meter assembly / Speed sensor / Horn / Switch continuity test / Left handlebar switch / Clutch switch / Right handlebar switch / Engine stop switch / Front brake light switch / Rear brake light switch / Ignition switch / Oil pressure switch / Neutral switch / Sidestand switch / Relay box / Turn signal relay / Fuses / Wiring diagrams / Specifications

CHAPTER TEN / COOLING SYSTEM
Cooling system inspection / Coolant reservoir cover / Coolant reservoir / Radiator / Radiator fan / Fan relay / Coolant temperature sensor / Thermostat / Coolant return pipe / Water pump / Specifications

CHAPTER ELEVEN / WHEELS, TIRES AND DRIVE BELT
Motorcycle lift / Front wheel / Rear wheel / Wheel and axle inspection / Front and rear hub / Rear coupling / Rear pulley / Drive belt / Drive belt adjuster / Laced wheels (B and D models) / Cast wheels (C models) / Wheel balance / Tires / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Handlebar grip / Steering head and stem / Steering bearing preload / Steering head bearing race / Steering stem bearing / Front fork / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION
Shock absorber / Suspension lever / Tie rod / Swing arm / Bearing replacement / Specifications

CHAPTER FOURTEEN / BRAKES
Brake service / Brake bleeding tips / Bleeding the brakes / Brake fluid draining / Brake pads / Brake caliper / Front master cylinder / Rear master cylinder / Brake pedal / Brake disc / Brake hose / Specifications

CHAPTER FIFTEEN / BODY AND FRAME
Seat / Side covers / Front footrest / Rear footpeg (all models) / Frame downtube / Front fender / Rear fender / Tool box / Battery box / Sidestand / Windshield (D models) / Saddlebags (D models) / Saddlebag brackets (D models) / Backrest (D models) / Specifications

INDEX

COLOR WIRING DIAGRAMS

More details
Part number: ECM246
Language: English

With a Haynes Online Manual in an online format you get all the trusted content of a printed manual, with additional features to help you get the job done. Take your entire manual with you on every journey.

Key features:

  • All colour step-by-step guides for over 200 jobs with 700+ photos
  • Image zoom feature for close-up view of jobs
  • Brand-new “how to” video tutorials covering key repair tasks
  • Print complete sections to take with you into the workshop
  • Troubleshooting section – quickly find the cause of a problem
  • Colour wiring diagrams help track problems quickly and easily
  • Easy search feature – find your job fast
  • Dictionary of automotive terms
  • Quick links to popular DIY tasks and other jobs linked to your task
  • Conversion calculator – imperial and metric units
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