2012 Kawasaki Vulcan 900 Custom Owners Manual
2012 Kawasaki Vulcan 900 Custom Manual
2012 Kawasaki Vulcan 900 Custom manual content summary:
- 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 1
- 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 2
- 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 3
Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION HOW TO RIDE THE MOTORCYCLE SAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE j j j j j j A Table of Contents is included after the - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 4
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, - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 5
. This manual offers many safe riding tips, but its purpose is not to provide instruction in all 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 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 6
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 © 2011 Kawasaki Heavy - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 7
TABLE OF CONTENTS SPECIFICATIONS...SERIAL NUMBER LOCATIONS ...LOCATION OF PARTS ...LOCATION OF LABELS...LOADING INFORMATION ...GENERAL INFORMATION ...Meter Instruments ...Speedometer: ...Digital Display ...Fuel Gauge: ...RESET Button/MODE button: ...Warning/Indicator Lights: ...Keys ...Ignition - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 8
Tires -...Battery...Headlight Beam...Fuses ...General Lubrication...Cleaning Your Motorcycle ...Bolt and Nut Tightening...STORAGE ...TROUBLESHOOTING GUIDE...YOUR WARRANTY/OWNER SATISFACTION ...Reporting Safety Defects ...ENVIRONMENTAL PROTECTION ...MAINTENANCE RECORD ...LABEL INFORMATION ... 113 116 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 9
SPECIFICATIONS 7 SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System Cylinder Numbering Method Firing Order SOHC, V-type 2-cylinder, 4-stroke, liquid-cooled 903 cm³ (55.1 cu - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 10
8 SPECIFICATIONS Fuel System Ignition System Ignition Timing (Electronically advanced) Spark Plugs Lubrication System Engine Oil: Type Viscosity Capacity Coolant Capacity TRANSMISSION Transmission Type Clutch Type Driving System Primary Reduction Ratio Final Reduction Ratio 5-speed, return shift Wet - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 11
SPECIFICATIONS 9 Overall Drive Ratio Gear Ratio 1st 2nd 3rd 4th 5th FRAME Castor Trail Tire Size: Rim Size: Fuel Tank Capacity ELECTRICAL EQUIPMENT Battery Front Rear Front Rear 4.338 (Top gear) 2.786 (39/14) 1.889 (34/18) 1.360 (34/25) 1.107 (31/28) 0.963 (26/27) 33° 182 mm (7.2 in.) 80/90-21 M/C - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 12
10 SPECIFICATIONS Headlight Tail/Brake Light 12 V 60/55 W 12 V 5/21 W Specifications subject to change without notice. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 13
SERIAL NUMBER LOCATIONS 11 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 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 14
12 LOCATION OF PARTS LOCATION OF PARTS 1. 2. 3. 4. 5. 6. Clutch Lever Clutch Lever Adjuster Meter Instruments Brake Fluid Reservoir (Front) Brake Lever Adjuster Front Brake Lever 7. 8. 9. 10. 11. Left Handlebar Switches Indicator Lights Fuel Tank Cap Right Handlebar Switches Throttle Grip - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 15
LOCATION OF PARTS 13 12. 13. 14. 15. 16. 17. 18. Front Fork Headlight Turn Signal Light Horn Spark Plugs Battery Brake Disc 19. 20. 21. 22. 23. 24. 25. Brake Caliper Wheel Radiator Shift Pedal Oil Level Gauge Side Stand Switch Side Stand 26. 27. 28. 29. 30. Fuse Box Coolant Reserve Tank Rear - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 16
14 LOCATION OF PARTS 31. 32. 33. 34. 35. Tail/Brake Light Seat Tool Kit Case/Tool Kit Air Cleaner Element Fuel Tank 36. Steering Lock 37. Mufflers 38. Idle Speed Adjusting Screw 39. Rear Brake Pedal 40. Rear Brake Light Switch 41. Brake Fluid Reservoir (Rear) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 17
LOCATION OF LABELS 15 LOCATION OF LABELS 1. *2. 3. 4. Daily Safety Checks Fuel Level Brake Fluid (Front) Brake Fluid (Rear) (For further information of label, refer to the "LABEL INFORMATION" chapter.) *: only on California model - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 18
16 LOCATION OF LABELS 5. 6. *7. 8. Tire and Load Data Battery Position/Danger Vacuum Hose Routing Diagram Vehicle Emission Control Information (For further information of label, refer to the "LABEL INFORMATION" chapter.) *: only on California model - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 19
LOCATION OF LABELS 17 9. Weight and Manufacture 10. Noise Emission Control Information (For further information of label, refer to the "LABEL INFORMATION" chapter.) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 20
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 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 21
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 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 22
20 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 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 23
GENERAL INFORMATION 21 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 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 24
22 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 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 25
GENERAL INFORMATION 23 display starts flashing. Push the MODE button to advance the minutes. NOTE żPushing the MODE button momen- the RESET button. Both the • Push hour and minute displays start flashthe MODE button. • Push plays stop flashing and starts working. ing again. The disthe clock - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 26
24 GENERAL INFORMATION Odometer The odometer shows the total distance in kilometers (miles) that the vehicle has been ridden. This meter cannot be reset. NOTE żThe data is maintained even if the battery is disconnected. żWhen the figures come to 999999, they are stopped and locked. Trip Meters - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 27
GENERAL INFORMATION 25 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 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 28
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 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 29
GENERAL INFORMATION 27 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. Keys This motorcycle has a - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 30
28 GENERAL INFORMATION A. Ignition Key B. Tag C. Key Number Write your key number here. In the event you lose your keys, you will need the key number to have a duplicate made. If you cannot locate your key number, contact the dealer where you purchased your Kawasaki motorcycle. It's possible the - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 31
GENERAL INFORMATION 29 Ignition Switch The ignition switch is located at the left side behind the rear cylinder. This is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF or P (Park) position. OFF ON Engine off. All electrical circuits off. Engine - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 32
the enposition. gine stop switch to the Refer to the Starting the Engine section of the "How to Ride the Motorcycle" chapter for starting instructions. NOTE żAlthough the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 33
GENERAL INFORMATION 31 Left Handlebar Switches Dimmer Switch: High or low beam can be selected with the dimmer switch. When the ), the headlight is on high beam ( high beam indicator light is lit. ) High beam...( ) Low beam...( Turn Signal Switch: When the turn signal switch is turned ) or right ( - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 34
32 GENERAL INFORMATION Brake Lever Adjusters There is an adjuster on the brake lever. The adjuster has 5 positions so that the released lever position can be adjusted to suit the operator's hands. Push the lever forward and turn the adjuster to align the number with the arrow mark on the lever - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 35
GENERAL INFORMATION 33 Fuel Tank Cap To open the fuel tank cap, insert the ignition key into the fuel tank cap and turn the key to the right. To close the cap, push it down into place with the key inserted. The key can be removed by turning it to the left to the original position. Close the key - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 36
34 GENERAL INFORMATION Fuel Tank Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition switch - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 37
regulation. Fuel Requirement: Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock Index of 87. The Antiknock Index is posted on service station pumps. The octane rating of a gasoline is a measure of its resistance to detonation or "knocking". The Antiknock Index is an average - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 38
. Gasoline quality is important. Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended fuel may not be covered under your warranty. Fuels Containing Oxygenates - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 39
unleaded gasoline and methanol (wood alcohol) whenever possible, and never use "gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTBE). You may use gasoline containing up - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 40
gasohol" in the fuel system. Before storage it is recommended that you drain all fuel from the fuel system. See the Storage section in this manual. Side Stand The motorcycle is equipped with a side stand. A. Side Stand NOTE żWhen using the side stand, turn the handlebar to the left. Whenever the - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 41
GENERAL INFORMATION 39 NOTE Seat Seat Removal To remove the seat, insert the ignition key into the seat lock, and turn the key to the right. żThe motorcycle is equipped with a side stand switch. This switch is designed so that the engine does not start if the transmission is in gear and the side - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 42
40 GENERAL INFORMATION Seat Installation To install the seat, insert the projection of the front on the seat into the receptacle on the frame. Insert the hook of the middle on the seat into the holes on the frame. Push down the middle on the seat. • • • the front and rear ends of the • Pull seat - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 43
is located under the seat. The kit contains tools that can be helpful in making roadside repairs, adjustments, and some maintenance procedures explained in this manual. Keep the tool kit in this case. Remove the seat. Open the tool kit case cover by pulling the knob. • • A. Tool Kit Case B. Tool - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 44
42 GENERAL INFORMATION Helmet-Hook Helmet can be secured to the motorcycle using the helmet-hook. The helmet hook is located under the seat. WARNING Riding with helmet attached to the hook could cause an accident by distracting the operator or interfering with normal vehicle operation. Do not ride - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 45
GENERAL INFORMATION 43 Steering Lock The motorcycle is equipped with the steering lock at the right side of the head pipe. To lock the steering: 1. Turn the handlebar to the left. 2. Insert the ignition key. 3. Turn the key half a turn to the left. 4. Pull the key out. WARNING Attempting to ride - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 46
44 GENERAL INFORMATION Electric Accessory Connectors The electric power of the battery can be used through the electric accessory connectors regardless of ignition switch position. Observe and follow the notes listed below. Electric Accessory Connectors Location Under Rider's Seat Under Fuel Tank - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 47
GENERAL INFORMATION 45 NOTICE The vehicle has an electrical accessory circuit (10 A fuse) for the socket and connectors. Always install a fuse 10 A or less in the electrical accessory circuit. Do not connect more than 70 W of total load to the vehicle's electrical system or the battery may become - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 48
46 BREAK-IN BREAK-IN The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a "broken down" instead of a "broken in" motorcycle after a few thousand kilometers. The - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 49
acceleration, and hard cornering. In addition to the above, at 1 000 km (600 mi) it is extremely important that the owner has the initial maintenance service performed by a competent mechanic following the procedures in the Service Manual. give the oil a chance to work up into all the engine parts. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 50
48 HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Starting the Engine in the position. • Check that the engine stop switch is • Turn the ignition key to ON. A. Ignition Switch B. ON Position A. Engine Stop Switch B. Starter Button - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 51
HOW TO RIDE THE MOTORCYCLE 49 sure the transmission is in neu• Make tral. when the motorcycle falls down. After righting the motorcycle, first turn the ignition key to "OFF" and then back to "ON" before starting the engine. the throttle grip completely • Leaving closed, push the starter button. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 52
50 HOW TO RIDE THE MOTORCYCLE NOTE NOTICE Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. żThe motorcycle is equipped with a starter lockout switch. This switch is designed so that the engine does not start if the transmission is in gear and the - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 53
HOW TO RIDE THE MOTORCYCLE 51 Jump Starting If your motorcycle battery is "run down", it should be removed and charged. If this is not practical, a 12 volt booster battery and jumper cables may be used to start the engine. DANGER Battery acid generates hydrogen gas which is flammable and explosive - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 54
52 HOW TO RIDE THE MOTORCYCLE Connecting Jumper Cables Make sure the ignition key is turned to "OFF". Remove the seat. • • the tool kit case by un• Remove screwing the helmet-hook mounting screws. a jumper cable from the • Connect positive (+) terminal of the booster battery to the positive (+) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 55
HOW TO RIDE THE MOTORCYCLE 53 shift pedal or other unpainted metal surface. Do not use the negative (í) terminal of the battery. the standard engine starting • Follow procedure. NOTICE DANGER Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 56
54 HOW TO RIDE THE MOTORCYCLE or wires. The hose or wires should be routed as shown in the figure. żAfter installing the tool kit case, run the seat lock cable and wires along the guide and put the connectors into the original place. A. Wires B. Guide C. Connectors A. Seat Lock Cable B. Guide - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 57
HOW TO RIDE THE MOTORCYCLE 55 Moving Off that the side stand is up. • Check Pull in the clutch lever. • Shift into 1st gear. • Open the throttle a little, and start to • let out the clutch lever very slowly. As the clutch starts to engage, open • the throttle a little more, giving the engine just - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 58
56 HOW TO RIDE THE MOTORCYCLE Shifting Gears • • Close the throttle while pulling in the clutch lever. Shift into the next higher or lower gear. For smooth riding, shift up or down when the motorcycle is operated the speeds shown in the table below. the throttle part way, while re• Open leasing - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 59
HOW TO RIDE THE MOTORCYCLE 57 Vehicle speed when shifting Shifting up 1st ĺ 2nd 2nd ĺ 3rd 3rd ĺ 4th 4th ĺ 5th km/h (mph) 20 (12) 30 (19) 40 (25) 50 (31) Shifting down 5th ĺ 4th 4th ĺ 3rd 3rd ĺ 2nd 2nd ĺ 1st km/h (mph) 40 (25) 30 (19) 20 (12) 15 (9) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 60
58 HOW TO RIDE THE MOTORCYCLE Braking • • • • Close the throttle completely, leaving the clutch engaged (except when shifting gears) so that the engine will help slow down the motorcycle. Shift down one gear at a time so that you are in 1st gear when you come to a complete stop. When stopping, - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 61
TO RIDE THE MOTORCYCLE 59 Stopping the Engine the throttle completely. • Close Shift the into neutral. • Turn the transmission key to "OFF". • Support ignition the motorcycle on a firm, • level surface with the side stand. Lock the steering. • NOTE A. Rear Brake Pedal żThe motorcycle is equipped - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 62
. Improper maintenance can create a dangerous situation known as throttle failure. Two of the most common causes of throttle failure are: 1. An improperly serviced or clogged air cleaner may allow dirt and dust to enter the throttle body and stick the throttle open. 2. During removal of the air - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 63
operation or after stopping the engine. the transmission into neutral • Shift and turn the ignition key to "OFF". the motorcycle on a firm, • Support level surface with the side stand. Operating or parking the vehicle near flammable materials can cause a fire, and can result in property damage or - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 64
62 HOW TO RIDE THE MOTORCYCLE and the motorcycle is not close to any source of flame or sparks; this includes any appliance with a pilot light. NOTE żWhen stopping near traffic at night, WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 65
HOW TO RIDE THE MOTORCYCLE 63 Catalytic Converter This motorcycle is equipped with a catalytic converter in the exhaust system. The converter reacts with carbon monoxide, hydorocarbons and nitrogen oxides to convert them into carbon dioxide, water, nitrogen and oxygen resulting in much cleaner - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 66
64 HOW TO RIDE THE MOTORCYCLE only unleaded gasoline. Never • Use use leaded gasoline. Leaded gaso- • line significantly reduces the capability of the catalytic converter. Do not operate the vehicle with the engine or any one cylinder misfiring. Under these conditions unburned air/fuel mixture - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 67
SAFE OPERATION 65 SAFE OPERATION Safe Riding Technique The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a helmet are strongly recommended. You should be aware of and verify the - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 68
66 SAFE OPERATION In general your actions should be smooth as sudden acceleration, braking or turning may cause loss of control, especially when riding in wet conditions or on loose roadway surfaces, when the ability to maneuver will be reduced. When going up steep slopes, shift to a lower gear so - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 69
SAFE OPERATION 67 Do not downshift at too high an r/min (rpm) to avoid damage to the engine from overrevving. Avoiding unnecessary weaving is important to the safety of both the rider and other motorists. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 70
68 SAFE OPERATION Daily Safety Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the Maintenance and Adjustment - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 71
SAFE OPERATION 69 Front Rear Up to 180 kg (397 lb) 280 kPa (2.80 kgf/cm², 40 psi) Load Up to 97.5 kg (215 lb) 200 kPa (2.00 kgf/cm², 28 psi) Load 97.5 ∼ 180 kg (215 ∼ 397 lb) Load 225 kPa (2.25 kgf/cm², 32 psi) Install the air valve cap. Nuts, bolts, fasteners .. Check that steering and - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 72
70 SAFE OPERATION Side stand ...Returns to its fully up position by spring tension. Return spring not weak or not damaged. Refer to the "Daily Safety Checks" caution label attached to the back of seat. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 73
SAFE OPERATION 71 Additional Considerations for High Speed Operation WARNING Handling characteristics of a motorcycle at high speeds may vary from those you are familiar with at legal highway speeds. Do not attempt high speed operation unless you have received sufficient training and have the - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 74
72 SAFE OPERATION Coolant:To avoid overheating, check that the coolant level is at the upper level line. Electrical Equipment: Make sure that the headlight, tail/brake light, turn signals, horn, etc., all work properly. Miscellaneous: Make sure that all nuts and bolts are tight and that all safety - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 75
MAINTENANCE AND ADJUSTMENT 73 MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 76
74 MAINTENANCE AND ADJUSTMENT EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 77
MAINTENANCE AND ADJUSTMENT 75 3. Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel tank. 3. Evaporative Emission Control System (California) Vapors caused by fuel evaporation in the fuel system are not - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 78
owner of this motorcycle, you have the responsibility to make sure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. The Kawasaki Limited Emission Control System Warranty requires that you return your motorcycle to an authorized - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 79
MAINTENANCE AND ADJUSTMENT 77 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 80
an authorized Kawasaki dealer. * : For higher odometer readings, repeat at the frequency interval established here. # : Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping. 1. Periodic Inspection (Engine Related Items) Frequency - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 81
MAINTENANCE AND ADJUSTMENT 79 Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Engine Items) K K Fuel leak (fuel hose and pipe) - inspect Fuel hoses damage - inspect Every year year year 1 6 12 18 24 30 36 (0.6) (3.75) (7.5) (11.25) (15) (18.75) ( - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 82
80 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Engine Items) Radiator hoses installation condition - inspect Air suction system damage - inspect Evaporative emission control system - function (California model only) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 83
MAINTENANCE AND ADJUSTMENT 81 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Clutch and drive train: Clutch operation (play, engagement, disengagement) inspect K K Drive belt deflection - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 84
82 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Wheels/tires damage - inspect Tire tread wear, abnormal wear inspect K Wheel bearings damage - inspect Brake fluid leak inspect K Brake hoses damage - inspect - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 85
MAINTENANCE AND ADJUSTMENT 83 Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Brake hose K installation condition - inspect Brake fluid level inspect Brake operation (effectiveness, play, drag) - inspect Brake light switch operation - - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 86
84 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Suspensions: Front forks/rear shock absorber K operation (damping and smooth stroke) - inspect Front forks/rear K shock absorber oil leak - inspect K K K - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 87
MAINTENANCE AND ADJUSTMENT 85 Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) K K Uni-trak rocker arm bearings - lubricate Uni-trak tie rods bearings - lubricate Steering play inspect Steering stem bearings - lubricate Lights and - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 88
86 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) See Page Operation (Chassis Items) Side stand switch operation - inspect Engine stop switch operation - inspect Chassis: Chassis parts lubricate Bolts and nuts tightness - inspect Every year - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 89
MAINTENANCE AND ADJUSTMENT 87 3. Periodic Replacement Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) 1 12 24 36 48 (0.6) (7.5) (15) (22.5) (30) See Page Change/Replacement Items K Air cleaner element # - replace Engine oil # - change Oil filter - replace K Fuel hoses - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 90
88 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first *Odometer Reading km × 1 000 (mile × 1 000) 1 12 24 36 48 (0.6) (7.5) (15) (22.5) (30) See Page Change/Replacement Items K Rubber parts of master cylinder and caliper - replace Every 4 years K Spark plug - replace • • • • • - 102 - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 91
transmission seizure, accident, and injury. Check the oil level before each ride and change the oil according to the periodic maintenance chart in the Owner's Manual. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 92
90 MAINTENANCE AND ADJUSTMENT the motorcycle has just been used, • If wait several minutes for all the oil to the engine oil level through • Check the oil level gauge. With the motorcycle held level, the oil level should come up between the upper and lower level lines next to the gauge. drain down. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 93
MAINTENANCE AND ADJUSTMENT 91 A. Oil Pressure Warning Indicator Light A. Engine Oil Drain Plug Oil and/or Oil Filter Change Warm up the engine thoroughly, and then stop it. Place an oil pan beneath the engine. Remove the engine oil drain plug. • • • the oil completely drain with • Let the - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 94
92 MAINTENANCE AND ADJUSTMENT • Remove the cover. • Remove the regulator/rectifier. A. Cover B. Bolt A. Regulator/Rectifier B. Bolt - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 95
MAINTENANCE AND ADJUSTMENT 93 • Remove the bracket. the oil filter cartridge and re• Remove place it with a new one. A. Bracket B. Bolt A. Cartridge NOTE żIf a torque wrench or required Kawasaki special tool is not available, this item should be serviced by an authorized Kawasaki dealer. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 96
94 MAINTENANCE AND ADJUSTMENT a thin film of oil to the packing • Apply and tighten the cartridge to the specified torque. the engine up to the upper level • Fill line with a good quality engine oil the engine. • Start Check • age. the oil level and for oil leak• Be sure to install the parts - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 97
MAINTENANCE AND ADJUSTMENT 95 Recommended Engine Oil Type: Kawasaki Performance 4-Stroke Motorcycle Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with API SG, SH, SJ, SL, SM and JASO MA, MA1, MA2 rating Viscosity: SAE - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 98
may need to be changed to accommodate atmospheric conditions in your riding area. use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. *Kawasaki Performance Oils and Lubricants have been specifically engineered for your - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 99
MAINTENANCE AND ADJUSTMENT 97 Cooling System Radiator and Cooling Fin Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a stream of low-pressure water. NOTICE Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 100
98 MAINTENANCE AND ADJUSTMENT Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator. If the coolant level becomes low, the engine overheats and may suffer severe damage. Check the coolant level each day before riding the motorcycle, also in accordance - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 101
properties. When it is diluted excessively, it loses its anti-corrosion property. Dilute a permanent type of antifreeze in accordance with the instructions of the manufacturer. NOTE żA permanent type of antifreeze is installed in the cooling system when shipped. It is colored green and contains - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 102
100 MAINTENANCE AND ADJUSTMENT the coolant level through the • Check coolant level gauge. The coolant level should be between the F (Full) and L (Low) marks. NOTE żSee the reserve tank at the inside of the reserve tank cover under the left side cover. żCheck the level when the engine is cold ( - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 103
MAINTENANCE AND ADJUSTMENT 101 Coolant Filling Remove the seat. Remove the left side cover by removing the screw. • • • Remove the reserve tank cover. A. Reserve Tank Cover B. Bolt A. Screw B. Left Side Cover - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 104
102 MAINTENANCE AND ADJUSTMENT the cap from the reserve tank, • Open and add coolant through the filler opening to the F (Full) mark. NOTE żWhen installing the left side cover, be sure to insert the projections of the left side cover to each holes. A. Reserve Tank B. Reserve Tank Cap • • - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 105
MAINTENANCE AND ADJUSTMENT 103 correct mixture ratio by the addition of antifreeze concentrate as soon as possible. Drive Belt In order for the belt and belt pulleys to function properly, check the drive belt in accordance with the Periodic Maintenance Chart. Belt check and adjustment should be - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 106
be replaced in accordance with the Periodic Maintenance Chart. Spark plug removal should be done by a competent mechanic following the instructions in the Service Manual. Spark Plug Standard Plug Plug Gap Tightening Torque NGK CPR7EA-9 0.8 ∼ 0.9 mm (0.032 ∼ 0.036 in.) 18 N·m (1.8 kgf·m, 13 ft·lb - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 107
MAINTENANCE AND ADJUSTMENT 105 Evaporative Emission Control System (California model only) This system routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 108
each valve should be checked and adjusted in accordance with the Periodic Maintenance Chart. Inspection and adjustment should be done by a competent mechanic following the instructions in the Service Manual. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 109
, engine power is greatly reduced, or there are abnormal engine noise. Air suction valve removal and inspection should be done by a competent mechanic following the instructions in the Service Manual. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 110
element consists of a wet paper filter, which cannot be cleaned. In dusty, rainy, or on muddy conditions, the air cleaner element should be serviced more frequently than the recommended interval. Element Removal Remove the bolts of the air cleaner cover located on the right-side of the engine - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 111
MAINTENANCE AND ADJUSTMENT 109 the air cleaner screw and • Remove the air cleaner. If any part of the element is damaged, the element must be replaced. WARNING If dirt or dust is allowed to pass through into the fuel injection system, the throttle may stick or become inoperable resulting in a - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 112
110 MAINTENANCE AND ADJUSTMENT Throttle Control System Check the throttle grip play, in accordance with the Periodic Maintenance Chart, and adjust the throttle grip play. Throttle Grip The throttle grip controls the butterfly valves in the throttle body. If the throttle grip has excessive play due - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 113
upper ends of the throttle cables, further adjustment of the throttle cables should be done by a competent mechanic following the instructions in the Service Manual. WARNING Operation with improperly adjusted, incorrectly routed, or damaged cables could result in an unsafe riding condition. Be sure - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 114
112 MAINTENANCE AND ADJUSTMENT Idle Speed The idle adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is disturbed. Adjustment Start the engine, and warm it up thoroughly. Wait until the idle speed drops before making the following adjustment - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 115
MAINTENANCE AND ADJUSTMENT 113 WARNING Operation with damaged cables could result in an unsafe riding condition. Replace damaged control cables before operation. Clutch Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accordance with the - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 116
114 MAINTENANCE AND ADJUSTMENT Inspection Check that the clutch lever has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play as shown in the figure. • Adjustment WARNING Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 117
MAINTENANCE AND ADJUSTMENT 115 the adjuster so that the clutch • Turn lever will have 2 ∼ 3 mm (0.08 ∼ 0.12 NOTE • in.) of play. If it cannot be done, use the nuts at the middle of the clutch cable. żAfter the adjustment is made, start the engine and check that the clutch does not slip and - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 118
116 MAINTENANCE AND ADJUSTMENT Brakes Brake Wear Inspection Inspect the brakes for wear. For each front and rear disc brake caliper, if the thickness of either pad is less than 1 mm (0.04 in), replace both pads in the caliper as a set. Pad replacement should be done by an authorized Kawasaki dealer - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 119
MAINTENANCE AND ADJUSTMENT 117 Fluid Level Inspection The brake fluid level in the front brake fluid reservoir must be kept above the line (lower level line) next to the gauge and that in the rear brake fluid reservoir (located near the brake pedal) must be kept between the upper and lower level - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 120
118 MAINTENANCE AND ADJUSTMENT the fluid level in either reservoir is • If lower than the lower level line, check for fluid leaks in the brake lines, and fill the reservoir to the upper level line. Inside the front brake fluid reservoir is a stepped line showing the upper level line. For the rear - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 121
MAINTENANCE AND ADJUSTMENT 119 So there are no parts that require adjustment on the front and rear brakes. WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If the brake lever or pedal feels mushy when it is applied, there might be - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 122
120 MAINTENANCE AND ADJUSTMENT Brake Light Switches When either the front or rear brake is applied, the brake light goes on. The front brake light switch requires no adjustment, but the rear brake light switch should be adjusted in accordance with the Periodic Maintenance Chart. Inspection Turn the - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 123
MAINTENANCE AND ADJUSTMENT 121 Adjustment To adjust the rear brake light switch, move the switch up or down by turning the adjusting nut. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. • A. B. C. D. Rear Brake - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 124
122 MAINTENANCE AND ADJUSTMENT Rear Shock Absorber The rear shock absorber can be adjusted by changing the spring preload for various riding and loading conditions. Spring Preload Adjustment The rear shock absorber spring preload adjuster has 7 positions. Remove the left side cover and reserve tank - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 125
MAINTENANCE AND ADJUSTMENT 123 accordance with the following ta• In ble, turn the preload adjuster with the wrench from the tool kit. A. Under Part of Reserve Tank B. Holder A. Spring Preload Adjuster B. Wrench Position Spring Action 1 2 3 4 5 6 7 -ĺ Strong The standard setting - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 126
124 MAINTENANCE AND ADJUSTMENT with no passenger and no accessories is No. 4. NOTE żThis motorcycle has two hook wrenches in the tool kit. When changing the spring preload of the rear shock absorber, turn the adjuster by using the suitable hook wrenches. A. Hook Wrench B. Extension Bar - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 127
MAINTENANCE AND ADJUSTMENT 125 Wheels Tubeless tires are installed on the wheels of this motorcycle. The indications of TUBELESS on the tire side wall and the rim show that the tire and rim are specially designed for tubeless use. A. TUBELESS Mark The tire and rim form a leakproof unit by making - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 128
126 MAINTENANCE AND ADJUSTMENT WARNING Installing a tube inside a tubeless-type tire can create excessive heat build up that can damage the tube and cause rapid deflation. The tires, rims, and air valves on this motorcycle are designed only for tubeless type wheels. The recommended standard tires, - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 129
MAINTENANCE AND ADJUSTMENT 127 the air valve cap. • Remove Check the pressure often, using • an accuratetire gauge. sure that the air valve cap is • Make securely installed. NOTE żMeasure the tire pressure when the tires are cold (that is, when the motorcycle has not been ridden more than a mile - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 130
128 MAINTENANCE AND ADJUSTMENT Tire Wear, Damage As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 131
MAINTENANCE AND ADJUSTMENT 129 Minimum Tread Depth Front - 1 mm (0.04 in.) WARNING Tires that have been punctured and repaired do not have the same capabilities as undamaged tires and can suddenly fail, causing an accident resulting in serious injury or death. Replace damaged tires as soon as - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 132
130 MAINTENANCE AND ADJUSTMENT żMost counters may have their own regulations requiring a minimum tire thread depth; be sure to follow them. 80/90-21 M/C48H WARNING New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to establish - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 133
sealed type, and the sealing strip should not be removed at any time after the specified electrolyte has been installed in the battery for initial service. It is not necessary to check the battery electrolyte level or add distilled water. However, in order to maximize battery life and ensure that it - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 134
132 MAINTENANCE AND ADJUSTMENT Self-discharge Approx. Number of Days From 100% Charged to 100% discharged Lead -Antimony Battery 40°C (104°F) 25°C (77°F) 0°C (32°F) 100 Days 200 Days 550 Days Lead -Calcium Battery 300 Days 600 Days 950 Days Current Drain Days from DisDays from 100% 100 % charging - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 135
MAINTENANCE AND ADJUSTMENT 133 Sulfation occurs when the battery is left in a discharged condition for an extended time. Sulfate is a normal by product of the chemical reactions within a battery. But when continuous discharge allows the sulfate to crystallize in the cells, the battery plates become - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 136
ready to reinstall the battery in the motorcycle (see Battery Installation). NOTE żIf you charge the sealed battery, never fail to observe the instructions shown on the label on the battery. WARNING Lead is a toxic substance. Battery posts, terminals and related accessories contain lead and lead - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 137
MAINTENANCE AND ADJUSTMENT 135 Battery Removal Remove the seat and tool kit case (see "Jump Starting" section in the " How to Ride the Motorcycle" chapter). Disconnect the cables from the battery, first from the (í) terminal and then the (+) terminal. • • the battery using a solution of • Clean - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 138
or wires should be routed as shown in the figure. żAfter installing the tool kit case, run the seat lock cable or wire along the guide and put the connectors into the original place. A. Seat Lock Cable - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 139
one side rather than straight ahead. Turn the horizontal adjusting screw on the headlight rim in or out until the beam points straight ahead. • A. Wires B. Guide C. Connectors A. Vertical Adjusting Screw B. Horizontal Adjusting Screw - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 140
138 MAINTENANCE AND ADJUSTMENT Vertical Adjustment The headlight beam is adjustable vertically. If adjusted too low, neither low nor high beam will illuminate the road far enough ahead. If adjusted too high, the high beam will fail to illuminate the road close ahead, and the low beam will blind - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 141
MAINTENANCE AND ADJUSTMENT 139 Fuses The fuses are arranged in the fuse box located behind left side cover. The main fuse is mounted on the starter relay behind right side cover. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 142
140 MAINTENANCE AND ADJUSTMENT • Remove the screw out the right side cover and then • Pull inspect the main fuse. A. Screw B. Right Side Cover A. Main Fuse - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 143
MAINTENANCE AND ADJUSTMENT 141 installing the right side cover, • When be sure to insert the projections of the right side cover. WARNING Substituting fuses can cause wiring to overheat, catch fire and/or fail. Do not use any substitute for the standard fuse. Replace the blown fuse with a new one - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 144
142 MAINTENANCE AND ADJUSTMENT General Lubrication Lubricate the points shown below, with either motor oil or regular grease, in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions. Before lubricating each part, clean off any rusty - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 145
ADJUSTMENT 143 Apply grease to the following points ż(K) Clutch Inner Cable Upper Ends ż(K) Throttle Inner Cable Upper Ends (K): Should be serviced by an authorized Kawasaki dealer. Cleaning Your Motorcycle General Precautions Frequent and proper care of your Kawasaki motorcycle will enhance its - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 146
MAINTENANCE AND ADJUSTMENT WARNING Build-up of debris or flammable material in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. When operating the vehicle in conditions that allow debris or flammable material to collect in and around - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 147
MAINTENANCE AND ADJUSTMENT 145 • Avoid areas • spraying water in delicate such as in air intakes, fuel system, brake components, electrical components, muffler outlets, and fuel tank openings. After cleaning your motorcycle, check the rubber boot covering the shift pedal ball joint for correct - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 148
146 MAINTENANCE AND ADJUSTMENT a mild neutral detergent (de• Mix signed for motorcycles or automobiles) and water in bucket. Use a soft cloth or sponge to wash your motorcycle. If needed, use a mild degreaser to remove any oil or grease build up. After washing, rinse your motorcycle thoroughly with - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 149
three months or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use nonabrasive products and apply them according to the instructions on the container. Plastic Parts After washing use a soft cloth to gently dry plastic parts. When dry, treat the headlight lens and non - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 150
148 MAINTENANCE AND ADJUSTMENT NOTICE Plastic parts may deteriorate and break if they come in contact with chemical substances or household cleaning products such as gasoline, brake fluid, window cleaners, thread-locking agents, or other harsh chemicals. If a plastic part comes in contact with any - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 151
MAINTENANCE AND ADJUSTMENT 149 WARNING Rubber protectants can be slippery and, if used on the tread area, cause loss of traction resulting in accident causing injury or death. Do not apply rubber protectant to any tread area. - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 152
150 MAINTENANCE AND ADJUSTMENT Bolt and Nut Tightening In accordance with the Periodic Maintenance Chart, it is very important to check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Please ask your authorized Kawasaki - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 153
MAINTENANCE AND ADJUSTMENT 151 14. Muffler Mounting Bolts 15. Brake Lever Holder Clamp Bolts 16. Pivot Shaft Bolt 17. Brake Pedal Mounting Bolts 18. Rear Shock Absorber Mounting Nuts - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 154
152 STORAGE STORAGE Preparation for Storage: Clean the entire vehicle thoroughly. Run the engine for about five minutes to warm the oil, shut it off and drain the engine oil. • • WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 155
STORAGE 153 the fuel system by running the engine at idle speed until all fuel in the fuel • Empty system is used up (If left in for a long time, the fuel will break down and clog the fuel system). WARNING An air/oil mist may be forcibly ejected from the spark plug holes and could get into your - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 156
154 STORAGE plastic bags over the mufflers to prevent moisture from entering. • Tie Put • a cover over the motorcycle to keep dust and dirt from collecting on it. Preparation after Storage: Remove the plastic bags from the mufflers. Install the battery in the motorcycle and charge the battery - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 157
TROUBLESHOOTING GUIDE 155 TROUBLESHOOTING GUIDE Engine Does Not Start: Starter Motor Won't Turn Engine stop switch off Transmission not in neutral Fuse blown Battery leads do not make good electrical - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 158
156 YOUR WARRANTY/OWNER SATISFACTION YOUR WARRANTY/OWNER SATISFACTION Welcome to the Kawasaki family! Congratulations on buying your Kawasaki vehicle. You've chosen a great, high -quality product with state-of-the-art features and built to Kawasaki's high standards. Your satisfaction is important - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 159
schedule shown in this owner's manual. You are responsible for notifying your dealer immediately if there is a problem, and you, as the owner the first scheduled service. You can have the required servicing done by your Kawasaki dealer (recommended) or an equally-qualified service facility. You - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 160
. Whether you do it yourself or take your vehicle to a Kawasaki dealer, be sure to record your service in the Maintenance Record section of this Owner's Manual. Keep all receipts for the service and/or items necessary to perform the maintenance so that in the event of a failure you can document - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 161
whether they are covered by the limited warranty or not. How Do I Get Warranty Service? If there is a problem with your vehicle within the limited warranty period, you will need to schedule a service appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 162
a Kawasaki dealer. What if I am not Satisfied With My Warranty Service? If you aren't satisfied with your dealership's repair work or operations, a review of the issue. If you are unable to resolve a problem after consulting with the dealership management and need further assistance, contact Kawasaki - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 163
? This owner's manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you. Please send your correspondence to: Consumer Services Kawasaki Motors Corp - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 164
that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Kawasaki Motors Corporation, U.S.A. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 165
ENVIRONMENTAL PROTECTION 163 ENVIRONMENTAL PROTECTION To help preserve the environment, properly discard used batteries, tires, oils and fluids, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 166
164 MAINTENANCE RECORD MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Selling Dealer Name ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Odometer Reading Maintenance Performed Dealer Name - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 167
MAINTENANCE RECORD 165 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 168
166 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 169
MAINTENANCE RECORD 167 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 170
168 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 171
MAINTENANCE RECORD 169 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 172
170 LABEL INFORMATION LABEL INFORMATION (1) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 173
LABEL INFORMATION 171 (2) only on California model (3)/(4) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 174
172 LABEL INFORMATION (5) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 175
LABEL INFORMATION 173 (6) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 176
174 LABEL INFORMATION (7) only on California model - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 177
LABEL INFORMATION 175 (8) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 178
176 LABEL INFORMATION (8) only on California model - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 179
LABEL INFORMATION 177 (9) (10) - 2012 Kawasaki Vulcan 900 Custom | Owners Manual - Page 180
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