Kawasaki Vulcan 900 Custom 2013 Owner's manual

Quick Reference Guide

This Quick Reference Guide will
assist you in finding the information
you’re looking for.

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 and main­tenance practices.

NOTICE

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

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 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, c apabilities, and limita tio ns. 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 p ro gram 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 th e motorcycle whe n 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 I ndustries, Ltd. Mar. 15, 2013. (1)

TABLE OF CO NTE NTS

SPECIFICATIONS............................... 8

SERIAL NUMBER L OCATIONS......... 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.................. 1 65

ENVIRONMENTAL PROTECTION ..... 166

MAINTENANCE RECORD ................. 167

LABEL INFORMATION ...................... 173

8 SPECIFICATIONS

SPECIFICATIONS

PERFORMANCE

Minimum Turing Radius

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

Road Clearance 140 mm (5.5 in.)

Curb Mass 277 kg (611 lb)

ENGINE

Type

Displacement

Bore × S troke 88.0 × 74.2 mm (3.5 × 2.9 in.)

Compression Ratio

Starting System

3.1 m (122 in.)

1645mm(64.8in.)

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

903 cm³ (55.1 cu in.)

9.5 : 1

Electric starter

SPECIFICATIONS 9

Cylinder Numbering Method

Firing Order

Front to rear, 1-2

1-2

Fuel System Digital fuel injection system (DFI)

Ignition System Battery and coil (transistorized ignition)

Ignition Timing

3° BTDC @1 000 r/min (rpm) ∼

(Electronically advanced) 39° BTDC @5 400 r/min (rpm)

Spark Plugs NGK CPR7EA-9

Lubrication System Forced lubrication (wet sump)

Engine Oil:

Type

Viscosity

Capacity

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

SAE 10W-40

3.7 L (3.9 US qt)

Coolant Capacity 2.2 L (2.3 US qt)

TRANSMISSION

Transmission Type

Clutch Type

Driving System

5-speed, con s tant mesh, return shift

Wet, multi disc

Belt drive

10 SPECIFICATIONS

Primary Reduction Ratio

Final Reduction Ratio

Overall Dri ve Ratio 4.338 (Top gea r )

Gear Ratio

FRAME

Castor 33°

Trail

Tire Size:

Rim S ize:

Fuel Tank Capacity 20 L (5.3 US gal)

1st

2nd

3rd

4th

5th

Front

Rear

Front

Rear

2.184 (83/38)

2.063 (66/32)

2.786 (39/14)

1.889 (34/18)

1.360 (34/25)

1.107 (31/28)

0.963 (26/27)

182 mm (7.2 in.)

80/90-21 M/C 48H

180/70-15 M/C 76H

J21M/C × MT2.15

J15M/C × MT4.50

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.

SPECIFICATIONS 11

12 SERIAL NUMBER LOCATIONS

SERIAL NUMBER LOCATIONS

The engine and frame serial numbe rs are u se d t o re g ister the motorcycle. T he y
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 m odel type and any peculiar features of your machine that can help
them id entify it.

Frame No.

A. Frame Number

Engine No.

A. Engine Number

LOCATION OF PARTS

LOCATION OF PARTS 13

1. Clutch Lever

2. Clutch Lever Adjuster

3. Meter Instruments

4. Brake Fluid Reservoir (Front)

5. Brake Lever Adjuster

6. Front Brake Lever

7. L e ft Handlebar Switches

8. In dicator Lights

9. Fuel Tank Cap

10. Right Handlebar S witches

11. Throttle Grip

14 LOCATION OF PARTS

12. Front Fork

13. Headlight

14. Turn Sign a l Light

15. H o rn

16. Spark Plugs

17. B attery

18. B rake Disc

19. Brake Caliper

20. Wheel

21. Radiator

22. Shift Pedal

23. Oil Level Inspection Window

24. Side Stand Switch

25. Side Stand

26. Fuse Box

27. C oo lant Reserve Tank

28. R ear Shock Absorber

29. B elt

30. B elt Pulley

LOCATION OF PARTS 15

31. Tail/Brake Light

32. Seat

33. Tool Kit Case/Tool Kit

34. Air Cleaner Element

35. Fuel Tank

36. Steering Lock

37. M ufflers

38. Idle Speed Adjusting
Screw

39. R ear Brake Pedal

40. Rear Brake 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 a nd understand them
thoroughly. They contain information
which is important for your safety a nd
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. 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 warnin g 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. B rake Fluid (Front)

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

*: only on California model

LOCATION OF LABELS 17

3. Brak e Fluid (Rear)

4. Tire and Load Data

5. Ba ttery 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 Informatio n

8. Weight and Manufacture

9. N oise 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 in-

stallation or use of accessories,

or modification of your motorcy-

cle may result in an unsafe riding

condition. Before you ride the

motorcycle,makesureitisnot

overloaded and that you have

followed these instructions.

With the exception of genuine
Kawasaki Parts and Accessories,
Kawasaki has no control o ver the
design or application of accessories.
In some cases, improper ins tallation
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
andaccessoriesyouaddtoyour
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

LOADING INFORMATION 21

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 o f 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
thesteeringassemblyandcanre­sult 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 motorcy cle 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
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).

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 Lig ht
L. High Beam Indicator Light

GENERAL INFORMATION 23

GENERAL INFORMATION

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 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

GENERAL INFORMATION 25

display starts flashing. Push the
MODEbuttontoadvancethemin­utes.

Push the RESE T 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 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.PushtheMODEbuttontodisplay

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 m eter 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. TheMODEbuttonisusedto
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 th e 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 ope ra tion. If it
stays on, stop the engine and ch eck 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 us able fuel remains. Re­fuel at the earliest opportunity when the

GENERAL INFORMATION 29

fuel level warning indicator light comes
on with the engine run ning. When ve­hicle s tands 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.

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.