Kawasaki Vulcan 900 Classic LT 2013 Owner's manual

Quick Reference Guide
A Table of Contents is included after the Foreword.
GENERAL INFORMATION j
HOW TO RIDE THE MOTORCYCLE j
SAFE OPERATION j
MAINTENANCE AND ADJUSTMENT j
STORAGE j
TROUBLESHOOTING GUIDE j
Whenever you see the symbols shown below, heed their instructions! Always follow safe operating a nd main­tenance practices.
NOTICE
NOTICE is used to address prac­ticesnotrelatedtopersonalin­jury.
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.
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 a nd 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, cap ab ilitie s, and limitations. This manual offers many safe rid ing 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 Mot orcycle, a Service Manual is a va ilable 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 p ublication includes the la te st information available at the time of pr inting . 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. May. 15, 2013. (1)
TABLE OF CONTENTS
SPECIFICATIONS............................... 9
SERIAL NUMBER L OCATIONS......... 13
LOCATION OF PARTS....................... 14
LOCATION OF LABELS..................... 17
LOADING INFORMATION.................. 21
GENERAL INFORMATION................. 24
Meter Instruments ............................ 24
Speedometer: ............................... 25
Digital Display ............................... 25
Fuel Gauge: .................................. 28
RESET Button/MODE Button: ...... 28
Warning/Indicator Lights: .............. 28
Keys ................................................. 30
Ignition Switch .................................. 31
Right Handlebar Switches ................ 33
Engine Stop Switch: ..................... 33
Starter Button: .............................. 33
Left Handlebar Switches .................. 34
Dimmer Switch: ............................ 34
Turn Signal Switch: ....................... 34
Horn Button: ................................. 34
Brake Lever Adjusters...................... 35
Fuel Tank Cap .................................. 36
Fuel Tank ......................................... 37
Side Stand ....................................... 41
Seat.................................................. 42
Tool Kit Case .................................... 44
Helmet-Hook .................................... 44
Windshield........................................ 45
Special Warning on the Use of
Saddlebags................................... 46
Saddlebags ...................................... 48
Steering Lock ................................... 50
Electric Accessory Connectors ........ 51
Rear View Mirror .............................. 53
BREAK-IN ........................................... 55
HOW TO RIDE THE MOTORCYCLE .57
Starting the Engine .......................... 57
Jump Starting ................................... 60
Moving Off........................................ 64
Shifting Gears .................................. 65
Braking............................................. 68
Stopping the Engine ......................... 69
Stopping the Motorcycle in an
Emergency ................................... 70
Parking............................................. 71
Catalytic Converter........................... 73
SAFE OPERATION............................. 75
Safe Riding Technique ..................... 75
Daily Checks .................................... 78
Additional Considerations for High
Speed Operation .......................... 81
MAINTENANCE AND ADJUSTMENT 83
Periodic Maintenance Chart............. 88
Engine Oil ........................................ 100
Cooling System ................................ 107
Drive Belt.......................................... 113
Spark Plugs...................................... 114
Evaporative Emission Control
System (California model only) .... 115
Valve Clearance ............................... 116
Kawasaki Clean Air System ............. 117
Air Cleaner ....................................... 118
Throttle Control System ................... 120
Idle Speed ........................................ 122
Clutch............................................... 123
Brakes.............................................. 125
Brake Light Switches........................ 129
Rear Shock Absorber....................... 131
Wheels ............................................. 134
Battery.............................................. 138
Headlight Beam................................ 145
Fuses ............................................... 146
General Lubrication.......................... 150
Cleaning Your Motorcycle ................ 151
Bolt and Nut Tightening.................... 158
STORAGE........................................... 160
TROUBLESHOOTING GUIDE............ 163
YOUR WARRANTY/OWNER
SATISFACTION .............................. 164
Reporting Safety Defects.................. 170
ENVIRONMENTAL PROTECTION..... 171
MAINTENANCE RECORD ................. 172
LABEL INFORMATION ...................... 178

SPECIFICATIONS

PERFORMANCE
Minimum Turning Radius
DIMENSIONS
Overall Length 2 465 mm (97.0 in.)
Overall W idth 1 005 mm (39.6 in.)
Overall Height 1 480 mm (58.3 in.)
Wheelbase
Road Clearance 135 mm (5.31 in.)
Curb Mass 298 kg (657 lb)
ENGINE
Type
Displacement
Bore × Stroke 88.0 × 74.2 mm (3.5 × 2.9 in.)
Compression Ratio
Starting System
2.9 m (114 in.)
1645mm(64.8in.)
SOHC, V-type 2-cylinder, 4-stroke, liquid -cooled
903cm³(55.1cuin.)
9.5 : 1
Electric starter
SPECIFICATIONS 9
10 SPECIFICATIONS
Cylinder Numbering Method
Firing Order
Fuel System Digital fuel injection system (DFI)
Ignition System Battery and coil (transistorized ignition)
Ignition Timing
(Electronically advan ced) 39° BTDC @5 400 r/min (rpm)
Spark Plu gs NGK CPR7EA-9
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Coolant Capacity 2.2 L (2.3 US qt)
TRANSMISSION
Transmission Type
Clutch Type
Driving System
Type
Viscosity
Capacity
Front to rear, 1-2
1-2
3° BTDC @1 000 r/min (rpm)
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
3.7L(3.9USqt)
5-speed, constant mesh, return shift
Wet, mu lti d isc
Belt drive
SPECIFICATIONS 11
Primary Reduction Ratio
Final Reduction Ratio
2.184 (83/38)
2.063 (66/32)
Overall Drive Ratio 4.338 (Top gear)
Gear Ratio
1st
2nd
3rd
4th
5th
2.786 (39/14)
1.889 (34/18)
1.360 (34/25)
1.107 (31/28)
0.963 (26/27)
FRAME
Castor 32°
Trail
Tire Size:
Rim S ize:
Front
Rear
Front
Rear
160 mm (6.3 in.)
130/90-16 M/C 67H
180/70-15 M/C 76H
J16 M /C × MT3.00
J15 M /C × MT4.50
Fuel Tank Capacity 20 L (5.3 US gal)
12 SPECIFICATIONS
ELECTRICAL EQUIPMENT
Battery 12 V 10 Ah
Headlight
Tail/Brake Light 12 V 5/21 W
12 V 60/55 W
Specifications are subject to change without notice.
SERIAL NUMBER LOCATIONS 13

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 id entify it.
Frame No.
A. Frame Number
Engine N o.
A. Engine Number
14 LOCATION OF PARTS

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 Lever
7. Left Handlebar Switches
8. Indicator Lights
9. Fuel Tank C ap
10. R igh t Handlebar Switches
11. Throttle G rip
LOCATION OF PARTS 15
12. Front Fork
13. Headlight
14. Turn Signal Light
15. Ho rn
16. Windshield
17. Spark Plugs
18. Battery
19. Saddlebag
20. B rake Disc
21. B rake Caliper
22. Wh eel
23. R adiator
24. Shift Pedal
25. Oil Level Inspection Window
26. Side Stand Switch
27. Side Stand
28. Fuse Box
29. Coolant Reserve Tank
30. Rear Shock Absorber
31. Belt
32. Belt Pulley
16 LOCATION OF PARTS
33. Tail/Brake Light
34. S eat
35. Tool Kit Case/Tool Kit
36. Air Cleaner Element
37. Fu el Tank
38. Steering Lock
39. Mufflers
40. Idle Speed Adjusting Screw
41. Rear Brake Pedal
42. R ear Brake Light Switch
43. B rake Fluid Reservoir (Rear)

LOCATION OF LABELS

LOCATION OF LABELS 17
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 you r vehicle. Therefore, it is very important that all warning labels be on your vehicle in the locations shown. I f 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 th e illustration.
1. Radiator Cap Danger
(For further information of label, refer to the “LABEL INFORMATION” chapter.)
18 LOCATION OF LABELS
*2. Fuel Level
3. Brake Fluid (Front)
4. Brake Fluid (Rear)
6. Battery Position/Danger
(For further information of label, refer to the “LABEL INFORMATION” chapter.)
*: only on California model
LOCATION OF LABELS 19
*5. Vacuum Hose Routing Diagram
7. Tire and Load Data
8. Vehicle Emission Control Information
9. No ise Emission Control Information
(For further information of label, refer to the “LABEL INFORMATION” chapter.)
*: only on California model
20 LOCATION OF LABELS
10. Weight and Manufacture
(For further information of label, refer to the “LABEL INFORMATION” chapter.)

LOADING INFORMATION

LOADING INFORMATION 21
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 s en sitive 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
22 LOADING INFORMATION
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. 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
LOADING INFORMATION 23
affected any lighting components, 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 r e­sult 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 n ot 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 thattheeffectscanbeadverseand 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).
24 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 Injectio n Warning
Indicator Light H. MODE Button I. RESET Button J. Neutral Indicator Light K. Turn Signal Indicator Light L. High Beam Indicator Light

GENERAL INFORMATION

GENERAL INFORMATION 25
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 ig nition key to “ON”.
PushtheMODEbuttontodisplaythe
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
26 GENERAL INFORMATION
display starts flashing. Push the MODEbuttontoadvancethemin­utes.
Push the RES ET button. Both the
hour and minute displays start flash­ing again. Push the MODE button. The dis-
plays stop flashing and the clock starts working.
NOTE
Pushing the MODE button momen-
tarily advances the hour or minute step by step. Pushing and hold­ing the button advance the hour or minute continuously. The clock works normally fro m 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.
GENERAL INFORMATION 27
Odometer -
The odo meter sh ows 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:
Push the MODE b utton to display the
trip meter. Push the RESET button and hold it
in. After two seconds, the figure display
turns to 0.0, and then starts cou nting when the vehicle is operated. The meter counts until it is next reset.
28 GENERAL INFORMATION
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 m eter display resets to 0.0.
Fuel Gauge:
The fuel gauge shows the amount of fuel in the fuel tank. When the needle comes near the E (empty) po sition, re­fuel at the earliest opportunity.
Whenvehiclestandswithsidestand, 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 But to n :
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 m odes and to adjust the clock.
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.
GENERAL INFORMATION 29
: 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 m otorcycle 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 w arn ing indicator light comes on, have the DFI system checked by a n 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.
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