Kawasaki VULCAN 900 Classic 2006-2008 Service Manual

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This workshop service manual is designed for the Kawasaki VULCAN 900 CLASSIC for the years 2006, 2007, and 2008. It is intended for use by mechanical technicians familiar with service procedures for BRP products and covers repair and overhaul of the mentioned cars. The manual includes instructions on components manufactured for the Kawasaki VULCAN 900 CLASSIC and provides reliable information for routine maintenance, servicing, diagnostic, and repair procedures.

Whether you are a professional mechanic or a DIY enthusiast, this manual can help you save time and money by enabling you to perform many repair and maintenance tasks yourself. It emphasizes particular information denoted by the wording and symbols: WARNING, CAUTION, NOTE, and includes specifications and procedures available in an authorized Kawasaki VULCAN 900 CLASSIC dealer service department.

For those intending to do maintenance and repair on their Kawasaki VULCAN 900 CLASSIC, it is essential to use safety equipment and observe safety precautions. The manual also refers to special tools that are recommended or required to accomplish adjustments or repairs, often identified by their Kawasaki VULCAN 900 CLASSIC special tool number and illustrated.

Owning and referring to this manual will make it possible to be better informed and to more knowledgeably perform repairs like a professional automotive technician. It contains all necessary instructions needed for any repair your Kawasaki VULCAN 900 CLASSIC may require, including tune-ups, maintenance, removal & install procedures, assemblies & disassemblies, fuel system, ignition, lubrication system, exhaust, electrical system, body, and more extensive repairs involving engine and transmission disassembly.

This is an electronic delivery via email in English language. The content of the service manual depicts parts and/or procedures applicable to the particular product at the time of writing.

  • General Information
  • Maintenance
  • Lubrication
  • Heating
  • Ventilation
  • Air Conditioning
  • Suspension
  • Front Suspension
  • Rear Suspension
  • Wheel
  • Tire System
  • Differential
  • Driveline
  • Drive Shaft
  • Transfer Case
  • Brakes
  • Engine
  • Engine Mechanical
  • Engine Cooling
  • Engine Fuel
  • Engine Electrical
  • Ignition System
  • Starting
  • Charging System
  • Emissions
  • Engine Exhaust
  • Engine Lubrication
  • Engine Speed Control System
  • Clutch
  • Cooling
  • Electronic Control Modules
  • Engine Systems
  • Heated Systems
  • Horn
  • Ignition Control
  • Instrument Cluster
  • Lamps
  • Power Systems
  • Restraints
  • Speed Control
  • Transmission
  • Exhaust System
  • Body Structure
  • Seats
  • Security and Locks
  • Air Bag System
  • Exterior Trim
  • Interior Trim
  • Frame
  • Bumpers
  • Fuel System
  • Steering
  • Transmission and Transfer Case
  • Tires
  • Wheels
  • Body
  • Heating
  • Air Conditioning
  • Emissions Control
  • Engine Removal
  • Engine Installation
  • Final Drive
  • Electrical System
  • Air cleaner element renewal
  • Air cleaner temperature control check
  • Auxiliary drivebelt check
  • Battery electrolyte level check
  • Battery terminal check
  • Brake hydraulic fluid renewal
  • Brake hydraulic system seal and hose renewal
  • Brake pipe and hose check
  • Choke adjustment check
  • Contact breaker point renewal and distributor lubrication
  • Crankcase ventilation system check
  • Emission control filter element renewal
  • Engine coolant renewal
  • Engine idle speed check
  • Engine oil and filter renewal
  • Engine valve clearance check - OHV engines
  • Exhaust system check
  • Fluid leak check
  • Fluid level checks
  • Front and rear brake pad/shoe check
  • Front wheel alignment check
  • Gearbox oil level check
  • Handbrake check
  • Hinge and lock check and lubrication
  • HT lead, distributor cap
  • ignition circuit check
  • Ignition timing
  • contact breaker gap (dwell angle) check
  • Intensive maintenance
  • Mixture adjustment check
  • Road test
  • Roadwheel security check
  • Seat belt check
  • Spark plug check
  • Spark plug renewal
  • Steering and suspension security check
  • Throttle damper operation check
  • Timing belt renewal
  • Tyre checks
  • Underbody inspection
  • Wiper blade check
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