Kawasaki Vulcan 900 Custom 2013 Owner's manual

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GENERAL INFORMATION

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HOW TO RIDE THE MOTORCYCLE

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SAFE OPERATION

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MAINTENANCE AND ADJUSTMENT

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STORAGE

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TROUBLESHOOTING GUIDE

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A Table of Contents is included after the Foreword.

Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE

NOTICE is used to address practices not related to personal injury.

NOTE

NOTE indicates information that may help or guide you in the operation or service of the vehicle.

WARNING

Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

NOTICE

THIS PRODUCT HAS BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OPERATOR AND AS A VEHICLE ONLY.

FOREWORD

Congratulations on your purchase of a new Kawasaki Motorcycle. Your new motorcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance.

Please read this Owner’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its features, capabilities, and limitations. This manual 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 vehicle enroll in a motorcycle rider training program to attain awareness of the mental and physical requirements necessary for safe motorcycle 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 information on their Kawasaki Motorcycle, a Service Manual is available for purchase from any authorized Kawasaki motorcycle dealer. The Service Manual contains detailed 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 between the actual product and illustrations and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

© 2013 Kawasaki Heavy Industries, Ltd.

Mar. 15, 2013. (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 Switches................

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 High

 

Speed Operation ..........................

74

MAINTENANCE AND 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..............................................

118

Brake Light Switches........................

122

Rear Shock Absorber.......................

124

Wheels .............................................

127

Tires -............................................

128

Battery..............................................

133

Headlight Beam................................

140

Fuses ...............................................

141

General Lubrication..........................

145

Cleaning Your Motorcycle ................

146

Bolt and Nut Tightening....................

153

STORAGE...........................................

155

TROUBLESHOOTING GUIDE............

158

YOUR WARRANTY/OWNER

 

SATISFACTION ..............................

159

Reporting Safety Defects..................

165

ENVIRONMENTAL PROTECTION.....

166

MAINTENANCE RECORD .................

167

LABEL INFORMATION ......................

173

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

1 645 mm (64.8 in.)

Road Clearance

140 mm (5.5 in.)

Curb Mass

277 kg (611 lb)

ENGINE

 

 

Type

SOHC, V-type 2-cylinder, 4-stroke, liquid-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

Cylinder Numbering Method

Firing Order

 

Fuel System

 

Ignition System

 

Ignition Timing

 

(Electronically advanced)

Spark Plugs

 

Lubrication System

 

Engine Oil:

Type

 

 

Viscosity

 

Capacity

Coolant Capacity

 

TRANSMISSION

 

SPECIFICATIONS 9

Front to rear, 1-2 1-2

Digital fuel injection system (DFI) Battery and coil (transistorized ignition) 3° BTDC @1 000 r/min (rpm)

39° BTDC @5 400 r/min (rpm) NGK CPR7EA-9

Forced lubrication (wet sump)

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

3.7L (3.9 US qt)

2.2L (2.3 US qt)

Transmission Type

5-speed, constant mesh, return shift

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

 

 

 

Castor

 

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

Headlight

12

V 60/55 W

Tail/Brake Light

12 V 5/21 W

Specifications are subject to change without notice.

12 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer 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.

 

Engine No.

 

 

 

 

 

 

A. Frame Number

A. Engine Number

LOCATION OF PARTS 13

LOCATION OF PARTS

1.

Clutch Lever

7.

Left Handlebar Switches

2.

Clutch Lever Adjuster

8.

Indicator Lights

3.

Meter Instruments

9.

Fuel Tank Cap

4.

Brake Fluid Reservoir (Front)

10.

Right Handlebar Switches

5.

Brake Lever Adjuster

11.

Throttle Grip

6.

Front Brake Lever

 

 

Kawasaki Vulcan 900 Custom 2013 Owner's manual

14 LOCATION OF PARTS

 

 

 

 

 

 

 

 

12.

Front Fork

22.

Shift Pedal

13.

Headlight

23.

Oil Level Inspection Window

14.

Turn Signal Light

24.

Side Stand Switch

15.

Horn

25.

Side Stand

16.

Spark Plugs

26.

Fuse Box

17.

Battery

27.

Coolant Reserve Tank

18.

Brake Disc

28.

Rear Shock Absorber

19.

Brake Caliper

29.

Belt

20.

Wheel

30.

Belt Pulley

21.

Radiator

 

 

LOCATION OF PARTS 15

 

 

 

 

 

 

 

 

 

 

 

 

 

 

31.

Tail/Brake Light

36.

Steering Lock

40.

Rear Brake Light

32.

Seat

37.

Mufflers

41.

Switch

33.

Tool Kit Case/Tool Kit

38.

Idle Speed Adjusting

Brake Fluid Reservoir

34.

Air Cleaner Element

39.

Screw

 

(Rear)

35.

Fuel Tank

Rear Brake Pedal

 

 

 

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 operate your vehicle. Therefore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct position.

NOTE

The sample warning labels in this section have part numbers to help you and your dealer obtain the correct 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 Position/Danger

(For further information of label, refer to the “LABEL INFORMATION” chapter.)

18 LOCATION OF LABELS

6. Vacuum Hose Routing Diagram

*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.) *: only on California model

20 LOADING INFORMATION

LOADING INFORMATION

WARNING

Incorrect loading, improper installation or use of accessories, or modification of your motorcycle may result in an unsafe riding condition. Before you ride the motorcycle, make sure it is not overloaded and that you have followed these instructions.

With the exception of genuine Kawasaki Parts and Accessories, Kawasaki has no control over the design or application of accessories. In some cases, improper installation or use of accessories, or motorcycle modification, will void the motorcycle warranty. In selecting and using accessories, and in loading the motorcycle,

you are personally responsible for your own safety and the safety of other persons involved.

NOTE

Kawasaki Parts and Accessories have been specially designed for use on Kawasaki motorcycles. We strongly recommend that all parts and accessories you add to your motorcycle be genuine Kawasaki components.

Because a motorcycle is sensitive to changes in weight and aerodynamic forces, you must take extreme care in carrying cargo, passengers and/or in the fitting of additional accessories. The following general guidelines have

been prepared to assist you in making your determinations.

1.Any passenger should be thoroughly familiar with motorcycle operation. The passenger can affect control of the motorcycle by improper positioning during cornering and sudden movements. It is important that the passenger sit still while the motorcycle is in motion and not interfere with the operation of the motorcycle. Do not carry animals on your motorcycle.

2.You should instruct any passenger before riding to keep his feet on the passenger footpegs and hold on to the operator or seat strap. Do not carry a passenger unless he or she is tall enough to reach the footpegs and footpegs are provided.

3.All baggage should be carried as low as possible to reduce the effect on the motorcycle center of gravity.

LOADING INFORMATION 21

Baggage weight should also be distributed equally on both sides of the motorcycle. Avoid carrying baggage that extends beyond the rear of the motorcycle.

4.Baggage should be securely attached. Make sure that the baggage will not move around while you are riding. Recheck baggage security as often as possible (not while the motorcycle is in motion) and adjust as necessary.

5.Do not carry heavy or bulky items on a luggage rack. They are designed for light items, and overloading can affect handling due to changes in weight distribution and aerodynamic forces.

6.Do not install accessories or carry baggage that impairs the performance of the motorcycle. Make sure that you have not adversely affected any lighting components,

22 LOADING INFORMATION

road clearance, banking capability (i.e., lean angle), control operation, wheel travel, front fork movement, or any other aspect of the motorcycle’s operation.

7.Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can result in an unsafe riding condition.

8.Fairings, windshields, backrests, and other large items have the capability of adversely affecting stability and handling of the motorcycle, not only because of their weight, but also due to the aerodynamic forces acting on these surfaces while the motorcycle is in operation. Poorly designed or installed items can result in an unsafe riding condition.

9.This motorcycle was not intended to be equipped with a sidecar or to

be used to tow any trailer or other vehicle. Kawasaki does not manufacture sidecars or trailers for motorcycles and cannot predict the effects of such accessories on handling or stability, but can only warn that the effects can be adverse and that Kawasaki cannot assume responsibility for the results of such unintended use of the motorcycle. Furthermore, any adverse effects on motorcycle components caused by the use of such accessories will not be remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage, and accessories must not exceed 180 kg (397 lb).

GENERAL INFORMATION 23

GENERAL INFORMATION

Meter Instruments

A.Speedometer

B.Digital Display

C.Fuel Level Warning Indicator Light

D.Coolant Temperature Warning Indicator Light

E.Fuel Gauge

F.Oil Pressure Warning Indicator Light

G.Fuel Injection Warning Indicator Light

H.MODE Button

I.RESET Button

J.Neutral Indicator Light

K.Turn Signal Indicator Light

L.High Beam Indicator Light

24 GENERAL INFORMATION

Speedometer:

The speedometer shows the speed of the vehicle.

Digital Display

The digital display located in the speedometer face is used to display the odometer, trip meter, and clock. Pushing the MODE button shifts the display through the following three modes: ODO, TRIP and CLOCK. When the ignition key is turned to “ON”, all the segments are displayed for a few seconds, then the clock or meters operates normally depending on the mode selected.

Clock -

To adjust hours and minutes:

Turn the ignition key to “ON”.

Push the MODE button to display the clock.

Push the RESET button for more than two seconds. Both the hour and minute displays start flashing.

Again push the RESET button. When only the hour display flashes, push the MODE button to advance the hours.

Push the RESET button. The hour display stops flashing and the minute

display starts flashing. Push the MODE button to advance the minutes.

Push the RESET button. Both the hour and minute displays start flashing again.

Push the MODE button. The displays stop flashing and the clock starts working.

GENERAL INFORMATION 25

NOTE

Pushing the MODE button momentarily advances the hour or minute step by step. Pushing and holding the button advance the hour or minute continuously.

The clock works normally from the back-up power while the ignition switch is turned off.

When the battery is disconnected, the clock resets to 1:00, and starts working again when the battery is connected.

26 GENERAL INFORMATION

Odometer -

The odometer shows the total distance in kilometers (miles) that the vehicle has been ridden. This meter cannot be reset.

NOTE

The data is maintained even if the battery is disconnected.

When the figures come to 999999, they are stopped and locked.

Trip Meters -

The trip meter shows the distance in kilometers (miles) traveled since it was last reset to zero.

To reset a trip meter:

1.Push the MODE button to display the trip meter.

2.Push the RESET button and hold it in.

3.After two seconds, the figure display turns to 0.0, and then starts counting when the vehicle is operated. The meter counts until it is next reset.

NOTE

The data is maintained by the back -up power if the ignition key is turned to “OFF”.

When the trip meter reaches 999.9 while riding, the meter resets to 0.0 and continue counting.

When the battery is disconnected, the meter display resets to 0.0.

GENERAL INFORMATION 27

Fuel Gauge:

The fuel gauge shows the amount of fuel in the fuel tank. When the needle comes near the E (empty) position, refuel at the earliest opportunity. When vehicle stands with side stand, fuel gauge cannot show the amount of fuel in the fuel tank exactly. Stand upright the vehicle to check the fuel level.

RESET Button/MODE button:

The RESET button is used to reset the trip meter and to adjust the clock. The MODE button is used to shift through the digital display modes and to adjust the clock.

28 GENERAL INFORMATION

Warning/Indicator Lights:

N: When the transmission is in neutral, the neutral indicator light is lit.

: When the headlight is on high beam, the high beam indicator light is lit.

: When the turn signal switch is pushed to left or right, the turn signal indicator light flashes on and off.

: The oil pressure warning indicator light goes on whenever the oil pressure is dangerously low or the ignition switch is in the ON position with the engine not running, and goes off when the engine oil pressure is high enough. Refer to the Maintenance and Adjustment chapter for more detailed engine oil information.

: The warning indicator light goes on whenever the coolant temperature rises to 120°C (248°F) or higher when the motorcycle is in operation. If it stays on, stop the engine and check the coolant level in the reserve tank after the engine cools down.

FI: The fuel injection (FI) warning indicator light goes on when the ignition key is turned to “ON” and goes off soon after ensuring that its circuit functions properly. The warning indicator light also goes on whenever the troubles occur in digital fuel injection system (DFI). If the warning indicator light comes on, have the DFI system checked by an authorized Kawasaki dealer.

: The fuel level warning indicator light goes on when approximately 4.0 L (1.0 US gal) of usable fuel remains. Refuel at the earliest opportunity when the

fuel level warning indicator light comes on with the engine running. When vehicle stands with side stand, fuel level warning indicator light cannot show the amount of fuel in the fuel tank exactly. Stand upright the vehicle to check the fuel level.

GENERAL INFORMATION 29

Keys

This motorcycle has a combination key, which is used for the ignition switch, steering lock, and fuel tank cap. Included with the key is a key number, which is stamped on the separate plate. Record the key number in the space provided and store the number in a safe place. If your keys came with a plate, store it in a safe place as well.

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