Description
This 405 page, 2006-2019 Kawasaki Vulcan 900 Classic, Classic LT & Custom Clymer Manual provides service, repair and maintenance information for the following motorcycles:
VN900B, BC Classic (2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019)
VN900D, DC Classic LT (2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019)
VN900C, CC Custom (2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019)
Quick Reference Data
Chapter One, General Information
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, 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, Wheel, 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
