2015 Kawasaki Vulcan 900 Custom Owners Manual

2015 Kawasaki Vulcan 900 Custom Manual

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  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 1
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 2
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 3
    you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. or serious injury. ○NOTE indicates information that may NOTE help or guide you in the operation or service of the vehicle. WARNING WARNING indicates a hazardous situation which, if
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 4
    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
  • 2015 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
  • 2015 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 © 2014 Kawasaki Heavy
  • 2015 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
  • 2015 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 ... 115 117
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 9
    8 SPECIFICATIONS SPECIFICATIONS PERFORMANCE Minimum Turing Radius DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass ENGINE Type Displacement Bore × Stroke Compression Ratio Starting System SOHC, V-type 2-cylinder, 4-stroke, liquid-cooled 903 cm³ (55.1 cu in.)
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 10
    SPECIFICATIONS 9 Cylinder Numbering Method Firing Order Fuel System Ignition System Ignition Timing (Electronically advanced) Spark Plugs Lubrication System Engine Oil: Type Viscosity Capacity Coolant Capacity TRANSMISSION Transmission Type Clutch Type Driving System Front to rear, 1-2 1-2 Digital
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 11
    10 SPECIFICATIONS Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Gear Ratio 1st 2nd 3rd 4th 5th FRAME Caster Trail Tire Size: Rim Size: Fuel Tank Capacity Front Rear Front Rear 33° 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 20 L (5.3 US gal
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 12
    SPECIFICATIONS 11 ELECTRICAL EQUIPMENT Battery Headlight Brake/Tail Light 12 V 10 Ah (10 HR) 12 V 60/55 W 12 V 21/5 W Specifications are subject to change without notice.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 13
    12 SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATIONS The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. In
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 14
    LOCATION OF PARTS 13 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 15
    14 LOCATION OF PARTS 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Front Fork Headlight Turn Signal Light Horn Spark Plugs Battery Brake Disc Brake Caliper Wheel Radiator 22. 23. 24. 25. 26. 27. 28. 29. 30. Shift Pedal Oil Level Inspection Window Side Stand Switch Side Stand Fuse Box Coolant Reserve
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 16
    LOCATION OF PARTS 15 31. 32. 33. 34. 35. 36. Tail/Brake Light Seat Tool Kit Case/Tool Kit Air Cleaner Element Fuel Tank Steering Lock 37. 38. 39. 40. 41. Mufflers Idle Speed Adjusting Screw Rear Brake Pedal Rear Brake Light Switch Brake Fluid Reservoir (Rear)
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 17
    16 LOCATION OF LABELS LOCATION OF LABELS All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your vehicle. Therefore, it
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 18
    LOCATION OF LABELS 17 3. Brake Fluid (Rear) 4. Tire and Load Data 5. Battery Position/Danger (For further information of label, refer to the "LABEL INFORMATION" chapter.)
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 19
    18 LOCATION OF LABELS *6. 7. 8. 9. Vacuum Hose Routing Diagram Vehicle Emission Control Information Weight and Manufacture Noise Emission Control Information (For further information of label, refer to the "LABEL INFORMATION" chapter.) *: only on California model
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 20
    LOCATION OF LABELS 19 10. Radiator Cap Danger (For further information of label, refer to the "LABEL INFORMATION" chapter.)
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 21
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 22
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 23
    22 LOADING INFORMATION road clearance, banking capability (i.e., lean angle), control operation, wheel travel, front fork movement, or any other aspect of the motorcycle's operation. 7. Weight attached to the handlebar or front fork will increase the mass of the steering assembly and can result in
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 24
    GENERAL INFORMATION 23 GENERAL INFORMATION Meter Instruments A. Speedometer B. Digital Display C. Fuel Level Warning Indicator Light D. Coolant Temperature Warning Indicator Light E. Fuel Gauge F. Oil Pressure Warning Indicator Light G. Fuel Injection Warning Indicator Light H. MODE Button I. RESET
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 25
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 26
    GENERAL INFORMATION 25 the RESET button. The hour • Push display stops flashing and the minute display starts flashing. Push the MODE button to advance the minutes. ○Pushing the MODE button momen- NOTE the RESET button. Both the • Push hour and minute displays start flash- • ing again. Push
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 27
    26 GENERAL INFORMATION Odometer The odometer shows the total distance in kilometers (miles) that the vehicle has been ridden. This meter cannot be reset. ○The data is maintained even if the battery is disconnected. ○When the figures come to 999999, they are stopped and locked. NOTE Trip Meters
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 28
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 29
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 30
    GENERAL INFORMATION 29 : 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 31
    30 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 32
    GENERAL INFORMATION 31 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. Ignition Switch OFF ON Engine off. All electrical circuits off.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 33
    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. ○Although NOTE the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 34
    GENERAL INFORMATION 33 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 ( ), the to the left (
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 35
    34 GENERAL INFORMATION 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 holder. The distance from
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 36
    GENERAL INFORMATION 35 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 hole cover. Fuel
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 37
    36 GENERAL INFORMATION Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. Fuel Tank WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition switch
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 38
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 39
    . 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 40
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 41
    "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. The motorcycle is equipped with a side stand. Side Stand A. Side Stand ○When using the side stand, turn the handlebar to the left. Do not sit
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 42
    GENERAL INFORMATION 41 ○The NOTE Seat Seat Removal To remove the seat, insert the ignition key into the seat lock, and turn the key to the right. 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 43
    42 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 44
    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. Tool Kit Case • • A. Tool Kit
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 45
    44 GENERAL INFORMATION Helmet can be secured to the motorcycle using the helmet-hook. The helmet hook is located under the seat. Helmet-Hook WARNING Riding with helmet attached to the hook could cause an accident by distracting the operator or interfering with normal vehicle operation. Do not
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 46
    GENERAL INFORMATION 45 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. Steering Lock WARNING Attempting to ride
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 47
    46 GENERAL INFORMATION 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 Maximum Current: Polarity Wire
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 48
    GENERAL INFORMATION 47 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 49
    48 GENERAL INFORMATION A. Stay B. Rear View Mirror A. Lower Hexagonal Area for Tightening B. Upper Hexagonal Area C. Rear View Mirror D. Rubber Boots ○If a torque wrench is not available, this item should be serviced by a Kawasaki dealer. NOTE
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 50
    BREAK-IN 49 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 51
    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.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 52
    HOW TO RIDE THE MOTORCYCLE 51 HOW TO RIDE THE MOTORCYCLE Starting the Engine • Check that the engine stop switch is position. in the • Turn the ignition key to ON. A. Ignition Switch B. ON Position A. Engine Stop Switch B. Starter Button
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 53
    52 HOW TO RIDE THE MOTORCYCLE sure the transmission is in neu• Make tral. ○The motorcycle is equipped with a vehicle-down sensor, which causes the engine to stop automatically when the motorcycle falls down. After righting the motorcycle, first turn the ignition key to "OFF" and then back to "ON"
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 54
    HOW TO RIDE THE MOTORCYCLE 53 ○The NOTE NOTICE Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 55
    54 HOW TO RIDE THE MOTORCYCLE 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 56
    HOW TO RIDE THE MOTORCYCLE 55 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 (+)
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 57
    56 HOW TO RIDE THE MOTORCYCLE shift pedal or other unpainted metal surface. Do not use the negative (−) terminal of the battery. the standard engine starting • Follow procedure. DANGER Batteries contain sulfuric acid that can cause burns and produce hydrogen gas which is highly explosive. Do not
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 58
    or wires should be routed as shown in the figure. ○After 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 59
    58 HOW TO RIDE THE MOTORCYCLE 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 60
    HOW TO RIDE THE MOTORCYCLE 59 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 61
    60 HOW TO RIDE THE MOTORCYCLE Vehicle speed when shifting Shifting up 1st → 2nd 2nd → 3rd 3rd → 4th 4th → 5th km/h (mph) 20 (12) 30 (19) 40 (25) 50 (31) Shifting down 5th → 4th 4th → 3rd 3rd → 2nd 2nd → 1st km/h (mph) 40 (25) 30 (19) 20 (12) 15 (9)
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 62
    HOW TO RIDE THE MOTORCYCLE 61 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, always
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 63
    62 HOW TO RIDE THE MOTORCYCLE 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. • A. Rear Brake Pedal ○The motorcycle is equipped
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 64
    . 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. Stopping the Motorcycle in an
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 65
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 66
    HOW TO RIDE THE MOTORCYCLE 65 parking inside a garage or other • If structure, be sure it is well ventilated and the motorcycle is not close to any source of flame or sparks; this includes any appliance with a pilot light. the • Lock theft. steering to help prevent ○When stopping near traffic
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 67
    66 HOW TO RIDE THE MOTORCYCLE 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 exhaust gases to be
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 68
    HOW TO RIDE THE MOTORCYCLE 67 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 69
    68 SAFE OPERATION SAFE OPERATION 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 applicable safety
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 70
    SAFE OPERATION 69 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 71
    70 SAFE OPERATION 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.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 72
    SAFE OPERATION 71 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 chapter or see your
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 73
    72 SAFE OPERATION 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 suspension
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 74
    SAFE OPERATION 73 Side stand ...Returns to its fully up position by spring tension. Return spring not weak or not damaged.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 75
    74 SAFE OPERATION 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 76
    SAFE OPERATION 75 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 77
    76 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 78
    MAINTENANCE AND ADJUSTMENT 77 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 79
    78 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 80
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 81
    80 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 82
    MAINTENANCE AND ADJUSTMENT 81 Periodic Maintenance Chart K : Should be serviced by 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 83
    82 MAINTENANCE AND ADJUSTMENT 1. Periodic Inspection (Engine Related Items) Frequency Whichever comes first Operation (Engine Items) Valve clearance inspect (e) Throttle control system (play, smooth return, no drag) - inspect (e) Idle speed - inspect (e) K K K Fuel leak (fuel hose and pipe) -
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 84
    MAINTENANCE AND ADJUSTMENT 83 Frequency Whichever comes first Operation (Engine Items) Coolant level - inspect Coolant leak - inspect Radiator hose damage - inspect Radiator hoses installation condition inspect Air suction system damage - inspect (e) Evaporative emission control system function (
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 85
    84 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Items) Frequency Whichever comes first Operation (Chassis Items) Clutch and drive train: Clutch operation (play, engagement, disengagement) inspect K K Drive belt deflection - inspect Drive belt wear inspect Tire air pressure
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 86
    MAINTENANCE AND ADJUSTMENT 85 Frequency Whichever comes first 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 Brake pad wear inspect # year *Odometer Reading km
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 87
    86 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first Operation (Chassis Items) Brake hose K installation condition - inspect Brake fluid level inspect Brake operation (effectiveness, play, drag) - inspect Brake light switch operation - inspect *Odometer Reading km × 1 000 (mile × 1 000) See
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 88
    MAINTENANCE AND ADJUSTMENT 87 Frequency Whichever comes first 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 Swing arm pivot lubricate Uni-trak rocker arm operation -
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 89
    88 MAINTENANCE AND ADJUSTMENT Frequency Whichever comes first 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 switches operation - inspect Headlight aiming inspect *
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 90
    MAINTENANCE AND ADJUSTMENT 89 Frequency Whichever comes first Operation (Chassis Items) Side stand switch operation - inspect Engine stop switch operation - inspect Chassis: Chassis parts lubricate Bolts and nuts tightness - inspect year *Odometer Reading km × 1 000 (mile × 1 000) See Page Every
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 91
    90 MAINTENANCE AND ADJUSTMENT 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) 110 See Page Change/Replacement Items K Air cleaner element - replace # (e) Engine oil - change # Oil filter - replace K Fuel
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 92
    MAINTENANCE AND ADJUSTMENT 91 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 (e) • • • • •
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 93
    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.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 94
    MAINTENANCE AND ADJUSTMENT 93 the motorcycle has just been used, • If wait several minutes for all the oil to the engine oil level through • Check the oil level inspection window. With drain down. the oil level is too high, remove the • If excess oil through the oil filler open- the motorcycle
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 95
    94 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 96
    MAINTENANCE AND ADJUSTMENT 95 • Remove the cover. • Remove the regulator/rectifier. A. Cover B. Bolt A. Regulator/Rectifier B. Bolt
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 97
    96 MAINTENANCE AND ADJUSTMENT • Remove the bracket. the oil filter cartridge and re• Remove place it with a new one. A. Bracket B. Bolt A. Cartridge ○If a torque wrench or required Kawasaki special tool is not available, this item should be serviced by an authorized Kawasaki dealer. NOTE
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 98
    MAINTENANCE AND ADJUSTMENT 97 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 99
    Oil Capacity Capacity: *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 100
    MAINTENANCE AND ADJUSTMENT 99 Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. Cooling System Radiator and Cooling Fan Check the radiator fins for obstruction by insects or mud
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 101
    100 MAINTENANCE AND ADJUSTMENT NOTICE Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair the radiator's effectiveness. Do not obstruct or deflect airflow through the radiator by installing unauthorized accessories in front of the radiator or behind the
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT 101 accumulates rust and scale in the water jacket and radiator. This will clog up the coolant passages, and considerably reduce the efficiency of the cooling system. NOTICE If hard water is used in the system, it causes scale accumulation in the water passages, and
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 103
    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. Coolant Level Inspection Situate the motorcycle so that it is perpendicular to the ground. Check the coolant level through
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 104
    MAINTENANCE AND ADJUSTMENT 103 Coolant Filling Remove the seat. Remove the left side cover by removing the screw. • • A. F (Full) Level Line B. L (Low) Level Line C. Reserve Tank the amount of coolant is insuffi• If cient, add coolant. A. Screw B. Left Side Cover
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 105
    104 MAINTENANCE AND ADJUSTMENT • Remove the reserve tank cover. the cap from the reserve tank, • Open and add coolant through the filler opening to the F (Full) mark. A. Reserve Tank Cover B. Bolt A. Reserve Tank B. Reserve Tank Cap the cap after filling coolant. • Install • Install the parts
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 106
    MAINTENANCE AND ADJUSTMENT 105 ○When installing the left side cover, be NOTE sure to insert the projections of the left side cover to each holes. however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible. NOTICE If coolant must be
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 107
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 108
    MAINTENANCE AND ADJUSTMENT 107 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 must be made at the intervals specified by the Periodic
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 109
    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.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 110
    , 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.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 111
    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. Air Cleaner Element Removal Remove the bolts of the air cleaner cover located on the right-side of the
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 112
    MAINTENANCE AND ADJUSTMENT 111 the air cleaner screw and • Remove the air cleaner. If any part of the ele- 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 hazardous operating condition. ment is damaged,
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 113
    112 MAINTENANCE AND ADJUSTMENT 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 to either cable stretch
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 114
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 115
    114 MAINTENANCE AND ADJUSTMENT 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. Adjust
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 116
    MAINTENANCE AND ADJUSTMENT 115 WARNING Operation with damaged cables could result in an unsafe riding condition. Replace damaged control cables before operation. Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accordance with the
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 117
    116 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 118
    MAINTENANCE AND ADJUSTMENT 117 ○After NOTE 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 119
    118 MAINTENANCE AND ADJUSTMENT Brake Fluid In accordance with the Periodic Maintenance Chart, inspect the brake fluid level in both the front and rear brake fluid reservoirs and change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water. Fluid
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 120
    MAINTENANCE AND ADJUSTMENT 119 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 121
    120 MAINTENANCE AND ADJUSTMENT WARNING Mixing brands and types of brake fluid can reduce the brake system's effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 122
    MAINTENANCE AND ADJUSTMENT 121 Front and Rear Brakes Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action. So there are no parts that require adjustment on the front and rear brakes. WARNING Air in the brake lines diminish braking performance
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 123
    122 MAINTENANCE AND ADJUSTMENT the operation of the rear brake • Check light switch by depressing the brake pedal. The brake light should go on after about 10 mm (0.4 in.) of pedal travel. Adjustment To adjust the rear brake light switch, move the switch up or down by turning the adjusting nut. •
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 124
    MAINTENANCE AND ADJUSTMENT 123 NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. The rear shock absorber can be adjusted by changing the spring preload for various riding and loading conditions. Spring Preload
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 125
    124 MAINTENANCE AND ADJUSTMENT tank to the holder of the frame as shown in the figure. A. Reserve Tank B. Bolt ○When NOTE removing the reserve tank, hook the under part of the reserve A. Under Part of Reserve Tank B. Holder
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 126
    MAINTENANCE AND ADJUSTMENT 125 accordance with the following ta• In ble, turn the preload adjuster with the wrench from the tool kit. The standard setting position for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is No. 4. ○This NOTE motorcycle has two hook
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 127
    126 MAINTENANCE AND ADJUSTMENT 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. Wheels A. Hook Wrench B. Extension Bar A. TUBELESS Mark
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 128
    MAINTENANCE AND ADJUSTMENT 127 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,
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 129
    128 MAINTENANCE AND ADJUSTMENT Tires Payload and Tire Pressure Failure to maintain proper inflation pressures or observe payload limits for your tires may adversely affect handling and performance of your motorcycle and can result in loss of control. The maximum recommended load in addition to
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 130
    MAINTENANCE AND ADJUSTMENT 129 ○Measure the tire pressure when the NOTE tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). ○Tire pressure is affected by changes in ambient temperature and altitude, and so the tire pressure should be checked
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 131
    130 MAINTENANCE AND ADJUSTMENT accordance with • In Maintenance Chart, the Periodic measure the depth of the tread with a depth gauge, and replace any tire that has worn down to the minimum allowable tread depth. Minimum Tread Depth Front - 1 mm (0.04 in.) Rear Under 130 km/h 2 mm (0.08 in.) (
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 132
    MAINTENANCE AND ADJUSTMENT 131 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 possible. To ensure safe handling and stability,
  • 2015 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 134
    MAINTENANCE AND ADJUSTMENT 133 the discharge rate. Every 15°C (59°F) doubles the rate. Electrical accessories, such as digital clocks and computer memory, also draw current from the battery even when the key is switched off. Combine such "key-off" draws with hot temperature, and a battery can go
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 135
    134 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 136
    the battery at an amperage that is about 1/10th of the battery capacity. • • ○If NOTE you charge the sealed battery, never fail to observe the instructions shown on the label on the battery.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 137
    136 MAINTENANCE AND ADJUSTMENT WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Battery Removal Remove the seat and tool kit case (see "Jump
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 138
    or wires should be routed as shown in the figure. ○After installing the tool kit case, run the seat lock cable or wire along the guide and put the connectors into the original place.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 139
    138 MAINTENANCE AND ADJUSTMENT A. Seat Lock Cable B. Guide A. Wires B. Guide C. Connectors
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 140
    MAINTENANCE AND ADJUSTMENT 139 Headlight Beam Horizontal Adjustment The headlight beam is adjustable horizontally. If not properly adjusted horizontally, the beam will point to one side rather than straight ahead. Turn the horizontal adjusting screw on the headlight rim in or out until the beam
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 141
    140 MAINTENANCE AND ADJUSTMENT 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 fuse of
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 142
    MAINTENANCE AND ADJUSTMENT 141 the seat. • Remove Remove left side cover (see • "Cooling the System" section in this chapter). • Remove the screw A. Screw B. Right Side Cover A. Fuse Box B. Spare Fuse
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 143
    142 MAINTENANCE AND ADJUSTMENT out the right side cover and then • Pull inspect the main fuse. installing the right side cover, • When be sure to insert the projections of the right side cover. A. Main Fuse A. Projections B. Right Side Cover
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 144
    MAINTENANCE AND ADJUSTMENT 143 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 of the correct capacity, as specified on the junction box and main fuse. A. Normal B. Failed
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 145
    144 MAINTENANCE AND ADJUSTMENT 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 spots with rust
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 146
    quality, breathable motorcycle cover will help protect its finish from harmful UV rays, pollutants, and reduce the amount of dust reaching its surfaces. • • (K): Should be serviced by an authorized Kawasaki dealer. ○After connecting the cables, adjust them. NOTE
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 147
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 148
    MAINTENANCE AND ADJUSTMENT 147 • 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 149
    148 MAINTENANCE AND ADJUSTMENT a mild neutral detergent (de• Mix signed for motorcycles or automo- biles) 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 150
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 151
    150 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 152
    MAINTENANCE AND ADJUSTMENT 151 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.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 153
    152 MAINTENANCE AND ADJUSTMENT 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 dealer for torque values.
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 154
    MAINTENANCE AND ADJUSTMENT 153 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 155
    154 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 Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 156
    STORAGE 155 WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition key to "OFF". Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 157
    156 STORAGE the motorcycle on a box or stand so that both wheels are raised off the ground. • Set (If this cannot be done, put boards under the front and rear wheels to keep dampoil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on • Spray rubber parts or in the brakes. all
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 158
    TROUBLESHOOTING GUIDE 157 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 159
    158 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 160
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 161
    . 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 162
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 163
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 164
    ? 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 165
    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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 166
    ENVIRONMENTAL PROTECTION 165 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 167
    166 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
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 168
    MAINTENANCE RECORD 167 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 169
    168 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 170
    MAINTENANCE RECORD 169 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 171
    170 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 172
    MAINTENANCE RECORD 171 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 173
    172 LABEL INFORMATION LABEL INFORMATION (1) only on California model
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 174
    LABEL INFORMATION 173 (2)/(3)
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 175
    174 LABEL INFORMATION (4)
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 176
    LABEL INFORMATION 175 (5)
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 177
    176 LABEL INFORMATION (6) only on California model (7) (7) only on California model
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 178
    LABEL INFORMATION 177 (8) (10) (9)
  • 2015 Kawasaki Vulcan 900 Custom | Owners Manual - Page 179
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