VULCAN 900 CLASSIC

VN900 CLASSIC

VULCAN 900 CLASSIC LT

Motorcycle
Assembly & Preparation
Manual
 Foreword
In order to ship Kawasaki vehicles as effi-
ciently as possible, they are partially disassem-
bled before crating. Since some of the most
commonly removed parts have a direct bear-
ing on a vehicle’s reliability and safety, consci-
entious pre-sale assembly and preparation be-
comes extremely important. Good setup pro-
cedures can prevent needless warranty claims
and give customers a greater sense of confi-
dence in Kawasaki and their Kawasaki Dealers.
This Assembly and Preparation Manual ex-
plains step by step procedures of the following
items for the Kawasaki VULCAN 900 CLASSIC,
VN900 CLASSIC, and VULCAN 900 CLASSIC
LT.
1. Uncrating
2. Assembly
3. Preparation
The selling dealer assumes sole responsibil-
ity for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Ser-
vice Bulletins specifying Factory Directed Mod-
ifications (Special Claims) which must be per-
formed before the vehicle is ready for sale.
Whenever you see the following symbols
heed their instructions! Always follow safe
operating and maintenance practices.
© 2006 Kawasaki Heavy Industries, Ltd.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
correctly followed, could result in dam-
age to, or destruction of equipment.
NOTE
○This note symbol indicates points of particular
interest for more efficient and convenient op-
eration.
Kawasaki Heavy Industries, Ltd. accepts no
liability for any inaccuracies or omissions in this
publication, although every possible measure
has been taken to make it as complete and ac-
curate as possible. All procedures and specifi-
cations subject to change without notice.
Apr., 2007
 Table of Contents

Uncrating ...................................................................................... 3
Opening Crate ............................................................................. 3
Parts Check ................................................................................. 4
Assembly ...................................................................................... 8
Handlebar.................................................................................... 8
Throttle Grip and Right Switch Housing ...................................... 8
Front Brake Master Cylinder ....................................................... 9
Clutch Cable................................................................................ 9
Left Switch Housing..................................................................... 10
Wiring Clamps ............................................................................. 10
Front Wheel Installation............................................................... 11
Front Fender................................................................................ 12
Front Brake Hose Grommet ........................................................ 13
Front Footboards (Left and Right) ............................................... 13
Rear View Mirrors (Left and Right) .............................................. 14
Front Axle/Nut Rubber Caps (VN900B6F: European Model
Only) ......................................................................................... 15
Windshield (VN900D6F Model Only) .......................................... 15
Backrest (VN900D6F Model Only) .............................................. 15
Saddlebags (Left and Right) (VN900D6F Model Only) ............... 16
Brake Disc Cleaning .................................................................... 17
Preparation ................................................................................... 17
Battery Service ............................................................................ 17
Front Brake Fluid......................................................................... 22
Rear Brake Fluid ......................................................................... 23
Clutch Lever and Cable ............................................................... 24
Throttle Grip and Cable ............................................................... 25
Drive Belt..................................................................................... 26
Coolant ........................................................................................ 26
Rear Shock Absorber .................................................................. 27
Tire Air Pressures........................................................................ 28
Fuel ............................................................................................. 28
Engine Oil (4-stroke) ................................................................... 29
Idle Speed Adjustment ................................................................ 30
Rear Brake Light Switch .............................................................. 30
Headlight Aim .............................................................................. 30
Fastener Check ........................................................................... 32
Standard Torque Table ................................................................ 33
Test Ride the Motorcycle ............................................................. 34
A & P Check List ......................................................................... 34
 UNCRATING 3

Uncrating • Unscrew the two bolts (D = 6, L = 8) and

remove the master cylinder from the crate
Opening Crate bracket, and then remove the bolt (D = 8, L =
14) and crate bracket. Discard the removed
WARNING bolts and crate bracket.
Always wear protective gloves, boots,
and eye protection when uncrating to
prevent injury.

A. Front Master Cylinder

B. Crate Bracket
C. Bolt (D = 8, L = 14)
D. Bolts (D = 6, L = 8)
WARNING
Be careful not to injure your body by • First, unscrew the two bolts (D = 10, L = 14)
from the steering stem head, and then re-
the sharp edges of the steel crate panel move the two bolts (D = 8, L = 14) and crate
plates and other sharp fasteners. bracket. Discard the removed bolts and crate
bracket.

• Clear a space about 6 m (20 ft.) square to

give yourself plenty of space to work. A. Bolts (D = 10, L = 14)
• Place the crate upright on its base. B. Bolts (D = 8, L = 14)
• Remove the
Remove cardboard cover. C. Crate Bracket
• parts box. handlebar, front wheel, and the
the
• Take out all the bolts and screws and remove
the top and sides of the crate.
CAUTION
When removing the crate bracket from
the motorcycle, be careful not to drop
any parts or the bracket onto the fuel
tank and other components, and not to
scratch the fuel tank or other compo-
nents with the crate bracket.
4 UNCRATING

Parts Check
• Open the parts box, and check the parts against the illustrations. There may be minor differences
between these illustrations and the actual vehicle parts. In the following charts under Remarks, D
= diameter in millimeters, L = length in millimeters, and T = Thickness in millimeters.

*: European Model Only

 UNCRATING 5

No. Part Name Qty Remarks

1 Handlebar with Left Grip and Lever Assy 1
Handlebar Clamp 2
Clamp Bolt, Socket 4 D = 10, L = 23
Plastic Plug, Clamp Bolt 4 Large
Throttle Grip 1
Clamp, Master Cylinder 1
Clamp Bolt, Master Cylinder, Socket 2 D = 6, L = 20
Plastic Plug, Clamp Bolt 2 Small
Plastic Clamp, Wiring and Hose, RH 1 L = 80.5
Plastic Clamp, Wiring and Hose, LH 1 L = 58
Screw, Switch Housing, LH & RH 4 D = 5, L = 25
Rear View Mirror, LH & RH 2
2 Front Wheel 1
Axle Collar, LH & RH 2 L = 53
Flanged Bolt, Front Caliper, LH 1 D = 10, L = 47
Front Fender with Brace 1
Flanged Bolt, Front Fender 4 D = 8, L = 14
Front Brake Hose Clamp, LH 1
Grommet, Brake Hose 1
Front Axle Nut 1 D = 18
*Rubber Cap, Front Axle Nut 1 Marked “19”
*Rubber Cap, Front Axle 1 D = 23
3 Front Footboard Assembly, LH & RH 2
Spring, Footboard 2
Link Pin, Footboard 2 D = 10, L = 98.5
Circlip, Footboard 2 D=8

*: VN900B6F European Model Only

6 UNCRATING
 UNCRATING 7

No. Part Name Qty Remarks

4 Windshield Assembly with 1
Center Plate, Outer & Inner (2)
Damper, Center Plate, Outer & Inner (2)
Socket Bolt, Center & Outer Plate (8) D = 6, L = 16
Flat Washer, Center & Outer Plate (8) D = 6.5 × 14.5 × 1.5
Cap Nut (8) D=6
Vulcan Mark (1)
Outer Plate, LH & RH (2)
Damper, Outer Plate, LH & RH (2)
Stay, Windshield, LH & RH (2)
Damper, Stay, LH & RH (2)
Socket Bolt, Stay 4 D = 8, L = 16
Nut, Stay 4 D=8
5 Backrest Pad 1
Backrest 1
Cover with Mark, Backrest Pad 1
Flanged Bolt, Backrest Pad 3 D = 6, L = 25
Flanged Bolt, Backrest 4 D = 8, L = 20
Rear Reflector, LH & RH 2
Reflector Bracket, LH & RH 2
Nut, Rear Reflector 2 D=5
6 Saddlebag, LH & RH 2
Flat Washer, Saddlebag, Black 8 D = 8.5 × 20 × 1.6
Cap Nut, Saddlebag 4 D=8
Flanged Bolt, Saddlebag 2 D = 6, L = 16
7 Battery Electrolyte, YTX12-BS 1 12 V 10 Ah
Battery Cover/Tool Kit Case 1
Tool Kit Case Cover 1
Helmet Holder 1
Tool Kit 1
8 Owner’s Manual 1

No. 4, 5, 6 : VN900D6F Model Only

8 ASSEMBLY

Assembly Throttle Grip and Right Switch

Handlebar Housing
NOTE • Apply a light coat of grease on the exposed
portion of the throttle inner cables.
○Position the handlebar clamp on the handle-
bar with the slanted side facing rearward.
• Fit the throttle cable tips into the nearest sock-
ets in the throttle grip.
• Set the handlebar so that its punched mark is
aligned with the upper rear edge of the lower
handlebar clamp and install the top handlebar
clamps and bolts (D = 10, L = 23).

A. Front Half (Right Switch Housing)

B. Throttle Cable (Accelerator)
C. Cable Tips: Apply Grease.
D. Throttle Grip
A. Front Bolts (D = 10, L = 23)
E. Throttle Cable (Decelerator)
B. Slanted Side
F. Rear Half (Right Switch Housing)
C. Gap
D. Punched Mark • Fit the two halves of the right switch housing
so that the pin on the front half fits into the
E. No Gap
hole in the handlebar.
F. Forward

Handlebar Clamp Bolt Tightening

• Tighten the front clamp bolts first, and then
the rear clamp bolts to the specified torque.
There will be a gap at the rear part of the
clamp after tightening.
Torque : 34 N·m (3.5 kgf·m, 25 ft·lb)
• Push the large plastic plugs (4) into the han-
dlebar clamp bolts.

A. Hole
B. Pin
C. Front Half

• Insert the two screws (D = 5, L = 25) and

tighten them.
• Tighten the holder screw.
• Check that the throttle grip moves smoothly
from full open to close, and the throttle closes
quickly and completely.
A. Plastic Plugs
B. Handlebar Clamps
 ASSEMBLY 9

• Position the master cylinder so that the gap

between the front and rear master cylinder
clamps aligns with the punched mark on the
handlebar.
• Tighten the upper clamp bolt first and then the
lower bolt to the specified torque.
Torque : 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Push the small plastic plugs (2) into the mas-
ter cylinder clamp bolts.

A. Right Switch Housing

B. Screws (D = 5, L = 25)
C. Right Switch Harness
D. Throttle Cable (Accelerator)
E. Throttle Cable (Decelerator)
F. Holder Screw

Front Brake Master Cylinder A. Plastic Plugs

• Connect the right switch lead connectors to
the front brake light switch terminals on the
B. Master Cylinder

front brake master cylinder.

• Apply silicone grease or PBC grease to the
master cylinder clamp bolts.
• Install the front master cylinder with its clamp
and the two socket bolts (D = 6, L = 20).
Clutch Cable
• Apply
cable.
a light coat of grease on the clutch inner
• Line up the slots on the clutch lever, locknut
and adjuster.
• Fit the tip of the clutch inner cable into the
lever socket, slide the inner cable through the
slots, and release the outer cable into the ad-
juster.

A. Front Master Cylinder

B. Punched Mark
C. Clamp
D. Socket Bolts (D = 6, L = 20)
E. Right Switch Harness
A. Clutch Cable
F. Front Brake Light Switch
B. Adjuster
G. Connectors and Dust Cover
C. Locknut
D. Tip
E. Clutch Lever
10 ASSEMBLY

• Fasten the left switch harness to the left side

Left Switch Housing of the handlebar with the plastic clamp (L =
58).
• Connect the left switch lead connector to the
starter lock-out switch on the clutch lever
holder.
• Fit the two halves of the left switch housing
together so that the seam created by the front
and rear halves aligns with the punched mark
on the handlebar.

A. Handlebar (Left Side)

B. Plastic Clamp (L = 58)
C. Clutch Cable
D. Left Switch Harness

A. Punched Mark
B. Front Half
C. Screws (D = 5, L = 25)
D. Left Switch Harness
E. Starter Lock-out Switch Connector

• Insert the two screws (D = 5, L = 25) and

tighten them securely.

Wiring Clamps
• Fasten the front brake hose and the right
switch harness to the right side of the han-
dlebar with the plastic clamp (L = 80.5).

A. Handlebar (Right Side)

B. Plastic Clamp (L = 80.5)
C. Right Switch Harness
D. Front Brake Hose
 ASSEMBLY 11

A. Right Switch Harness

B. Throttle Cables
C. Front Brake Hose
D. Fasten the right switch harness and the front brake hose with the plastic clamp.
E. Left Switch Harness
F. Fasten the left switch harness with the plastic clamp.
G. Clutch Cable
H. Run the right switch harness, throttle cables and front brake hose through the clamp.
I. Run the left switch harness and clutch cable through the clamp.

• Lift the motorcycle off the crate base and sup-

Front Wheel Installation port the motorcycle with a suitable stand or
jack to install the front wheel.
• Remove the crate bolts (D = 8, L = 30) to take
off the crate bracket holding the front axle and • Discard the crate base.
discard them. • Loosen the right axle clamp bolt and remove
the front axle.
• Check the wheel rotation mark on the front
tire.
NOTE
○The direction of the wheel rotation is shown
by an arrow on the front tire. Install the wheel
so that the rotation mark coincides with wheel
rotational direction.

A. Crate Bolts (D = 8, L = 30)

B. Crate Bracket
C. Front Axle
D. Axle Clamp Bolt (Right)
12 ASSEMBLY

A. Front Tire A. Bolt (D = 10, L = 47)

B. Arrow B. Front Caliper
C. Rotation
• Tighten the front caliper mounting bolts to the
• Fit the axle collars on both sides of the front
wheel hub. The collars are identical.
specified torque.
Torque : 34 N·m (3.5 kgf·m, 25 ft·lb)
• Position the front wheel assembly between
the fork legs. WARNING
• Insert the front brake disc between the brake
pads of the caliper.
Do not attempt to ride the motorcycle un-
til a full brake lever is obtained by pump-
• Insert the front axle from the right side of the
wheel and push it completely through.
ing the brake lever until the pads are
against the disc. The brake will not func-
• Tighten the front axle nut (D = 18) to the spec-
ified torque.
tion on the first application of the lever if
this is not done.
Torque : 108 N·m (11.0 kgf·m, 79.6 ft·lb)

Front Fender
Front Fender Installation
• Install the front fender with its more rounded
end facing forward.

A. Front Axle
B. Collar (Right)
C. Axle Clamp Bolt (Right)
D. Collar (Left)
E. Front Axle Nut (D = 18)
A. Front Fender
• Tighten the axle clamp bolt on the right fork
leg to the specified torque.
B. Forward

Torque : 20 N·m (2.0 kgf·m, 15 ft·lb)
• Install one front brake caliper mounting bolt (D
= 10, L = 47) at the lower side of the caliper.
• Install the front fender on the fork legs, and
install the front brake hose clamp on the left
inside brace of the front fender with the two
bolts (D = 8, L = 14) and tighten them.
 ASSEMBLY 13

A. Front Fender A. Rear

B. Bolts (D = 8, L = 14) B. Bank Sensor
C. Front Brake Hose Clamp C. Front Footboard (Left)
D. Return Spring
• Install the two bolts (D = 8, L = 14) on the right
side of the fender and tighten them. E. Link Pin
F. Circlip
Front Brake Hose Grommet • Apply grease to the pivots of the front foot-
• Fit the grommet onto the front brake hose,
and install it in the clamp.
board.
• Hang the end of the return spring to the hole
in the bottom of the left footboard.
• Install the left footboard assembly on the foot-
board holder bracket with link pin.
• Hang the other end of the return spring to the
pin on the frame.
• Install the circlip to the end of the link pin.

A. Front Brake Hose

B. Grommet
C. Front Brake Hose Clamp

Front Footboards (Left and Right) A. Bank Sensor

B. Rear
NOTE C. Front Footboard (Left)
○Before installing the front footboard assembly, D. Return Spring
make sure the bank sensor is installed on the
rear side of the front footboard. E. Link Pin
F. Apply Grease.
G. Circlip

• Installation of the right side footboard is com-

mon with the left side. Follow the procedure
specified for the left side.
14 ASSEMBLY

CAUTION
Rear View Mirrors (Left and Right) Do not force to tighten and/or loosen the
upper hexagonal area (adapter) with a
Conventional Type (Single Nut) spanner or wrench. Disassembly of this
• Loosen the locknut completely.
area is not possible. Non-permanent
• then back itrear
Screw the view mirror in completely, and
two turns out.
locking agent is already applied to the
threads of this inner area. Forcible loos-
• Turn the mirror stay to assure visibility to the
rear with the operator sitting on the motorcy-
ening may damage the adapter and/or
the turning mechanism of the stay.
cle and tighten the locknut securely.
• Adjust the rear view mirror by slightly moving
only the mirror portion of the assembly.

A. Lower Hexagonal Area for Tightening

B. Upper Hexagonal Area (Adapter)
A. Locknut
C. Stay
B. Rear View Mirror (Right)
D. Non-permanent Locking Agent applied.
• Installation and adjustment of the left side mir-
ror is common with the right side. Follow the • Turn the stay to assure visibility to the rear
with the operator sitting on the motorcycle.
procedure specified for the right side.
Turning Stay Type • Adjust the rear view mirror by slightly moving
only the mirror portion of the assembly.
• Screw the mounting area of the right rear view
mirror into the holder all the way, and tighten
the lower hexagonal area securely.

A. Stay
B. Mirror
A. Lower Hexagonal Area for Tightening
B. Upper Hexagonal Area (Adapter)
• Installation and adjustment of the left side mir-
ror is common with the right side. Follow the
C. Rear View Mirror (Right) procedure specified for the right side.
 ASSEMBLY 15

Front Axle/Nut Rubber Caps

(VN900B6F: European Model Only)
• Install the axle nut rubber cap (Marked “19”)
on the front axle nut.
• Install the axle rubber cap (D = 23) on the top
of the axle.

A. Windshield Assembly
B. Socket Bolts (D = 8, L = 16)
C. Cap Nut (D = 8)
D. Mounting Bracket (Left)

Windshield Height Adjustment

The windshield can be adjusted 50 mm (2.0
A. Axle Nut Rubber Cap (Marked “19”) in.) in height to suit the rider’s preference.
B. Left Side • Move the windshield up or down, and align
both the left and right windshield stays.
C. Axle Rubber Cap (D = 23)
D. Right Side
• Tighten the bolts and nuts securely.

Windshield (VN900D6F Model

Only)
CAUTION
Be sure not to damage the surface of the
windshield when installing or handling.

A. Windshield
B. Mounting Bolts (D = 8, L = 16)
C. Positioning Marks
D. Nuts (D = 8)

Backrest (VN900D6F Model Only)

• Assemble the backrest, pad, and cover with
the three flanged bolts (D = 6, L = 25) and
A. Windshield Assembly tighten them securely.
• Install the windshield assembly on the wind-
shield mounting brackets with the four socket
bolts (D = 8, L = 16) and the cap nuts (D = 8).
16 ASSEMBLY

A. Pad A. Backrest Assembly

B. Cover B. Bolts (D = 8, L = 20)
C. Bolts (D = 6, L = 25) C. Rear Reflector Brackets (Left and Right)
D. Backrest

• Assemble the rear reflector and each bracket

with nut (D = 5).
Saddlebags (Left and Right)
(VN900D6F Model Only)
NOTE
○Only left bracket has “L” (Left) mark on its NOTE
backside. ○Install the right saddlebag after the “Rear
Brake Fluid” and “Fastener Check” sections
in the Preparation chapter.

Saddlebags Installation
• Insert the two flat washers (D = 8.5) onto
the upper stud bolts of the right saddlebag
bracket.

A. Rear Reflector
B. Nut (D = 5)
C. Bracket (Left)
D. “L” Mark

• Install the backrest assembly between the

stays, and install the reflector brackets on the
backrest and stays with the flanged bolts (D
= 8, L = 20) (4).
• Tighten the bolts securely.
A. Flat Washers (D = 8.5)
B. Saddlebag Bracket (Right)
• Open the lid and install the right saddlebag
onto the stud bolts of the right saddlebag
bracket.
• Fasten the saddlebag with the cap nuts (D =
8) and the flat washers (D = 8.5 ) onto the
upper stud bolts, and install the flanged bolt
(D = 6, L = 16) into the lower hole of the right
saddlebag, and tighten it.
 PREPARATION 17

Read the electrolyte safety label and the follow-

ing procedures carefully before battery activa-
tion.
CAUTION
Incorrect Battery Activation will reduce
battery performance and service life. Be
sure to strictly follow the Battery Service
instructions in this Manual.
Make sure to use the electrolyte packed in the
crate with the unit.

A. Cap Nuts (D = 8)
• Make sure that the model name of the elec-
trolyte container matches the model name of
B. Flat Washers (D = 8.5) the battery. These names must be the same.
C. Flanged Bolt (D = 6, L = 16) Battery Model Name for
D. Right Saddlebag VN900B6F/D6F: YTX12-BS

• Install the left saddlebag in the same manner

as the right saddlebag.

Brake Disc Cleaning

• Clean the front and rear brake discs using
oilless solvent.
WARNING
If not removed, the anticorrosive treat-
ment applied to the brake disc surface
will interfere with brake action, and an
unsafe riding condition could result. A. Model Name of the Electrolyte
B. Model Name of the Battery

CAUTION
Sealed battery electrolyte has a higher
concentration of sulfuric acid. Each
container contains the proper amount
of electrolyte for its specific battery.
Insufficient or incorrect electrolyte will
reduce battery performance and service
life. Electrolyte over capacity can lead
to battery cracking or leaking and result
in corrosion damage to the vehicle.

Seat Removal
Preparation • Insert the ignition key into the seat lock lo-
cated on the left side cover.
Battery Service
The battery used in this motorcycle is a sealed
• Turn the key clockwise while pulling the rear
end of the seat, and remove the seat.
type and never needs to be refilled. Follow the
procedure for activating a new battery to ensure
the best possible battery performance.
Activating the battery requires two steps, fill-
ing the battery with electrolyte, and charging.
18 PREPARATION

• Place the battery on a level surface.

• peeling,totears,
Check see that the sealing sheet [A] has no
or holes in it.
• Remove the sealing sheet [A].
NOTE
○The battery is vacuum sealed. If the sealing
sheet has leaked air into the battery, it may
require a longer initial charge.

A. Seat
B. Seat Lock
C. Ignition Key
D. Rearward
E. Left Side Cover

Battery Removal
• Take the battery out of the battery case.
• Remove
vinyl bag.
the electrolyte container from the

• Detach the strip of caps [A] from the container

and set aside, these will be used later to seal
the battery.
NOTE
○Do not pierce or otherwise open the sealed
cells [B] of the electrolyte container. Do not
attempt to separate individual cells.

A. Battery

• Clean the terminals.

Battery Specifications
Make Yuasa
Battery Type YTX12-BS
Battery Capacity 12 V 10 Ah
Electrolyte Capacity 0.60 L
Battery/Electrolyte Set P/No. 26012-1330

Battery Activation
Filling the Battery with Electrolyte
CAUTION
Do not remove the aluminum sealing
sheet [A] from the filler ports [B] until
just prior to use. Be sure to use the ded-
icated electrolyte container for correct
electrolyte volume.
• Place the electrolyte container upside down
with the six sealed cells into the filler ports
of the battery. Hold the container level, push
down to break the seals of all six cells. You
will see air bubbles rising into each cell as the
ports fill.
NOTE
○Do not tilt the electrolyte container.
 PREPARATION 19

• Check the electrolyte flow. A. Strip

• filler ports,bubbles
If no air [A] are coming up from the
or if the container cells have not
emptied completely, tap the container [B] a
• Newly activated sealed batteries require an
initial charge.
few times. Standard Charge 1.2 A × 5 ∼ 10 hours

• Iflowusing a recommended battery charger, fol-

the charger’s instructions for newly acti-
vated sealed battery.
Kawasaki-recommended chargers:
Optimate III
Yuasa 1.5 Amp Automatic Charger
Battery Mate 150-9

• Ifequivalent
the above chargers are not available, use
one.

• Keep the container in place for 20 minutes or NOTE

more. Don’t remove the container from the
battery until it’s empty, the battery requires all
the electrolyte from the container for proper
operation.
CAUTION
Removal of the container before it is
completely empty can shorten the ser-
vice life of the battery. Do not remove
the electrolyte container until it is com-
pletely empty and 20 minutes have
elapsed.
○Charging rates will vary depending on how
long the battery has been stored, tempera-
ture, and the type of charger used. Let battery
sit 60 minutes after initial charge, then check
voltage using a voltmeter. If it is not at least
12.8 volts, repeat charging cycle.
• After charging is completed, press down
firmly with both hands to seat the strip of
caps [A] into the battery (don’t pound or ham-
mer). When properly installed, the strip of
caps will be level with the top of the battery.

• Gently remove the container from the battery.

• chargingbattery
Let the sit for 30 minutes prior to
to allow the electrolyte to permeate
into the plates for optimum performance.
NOTE
○Charging the battery immediately after filling
can shorten service life. Let the battery sit for
at least 30 minutes after filling.

Initial Charge
• Place
ports.
the strip of caps loosely over the filler
20 PREPARATION

CAUTION
Once the strip of caps [A] is installed
onto the battery, never remove the caps,
nor add water or electrolyte to the bat-
tery.

NOTE
○To ensure maximum battery life and customer
satisfaction, it is recommended the battery be
load tested at three times its amp-hour rating
for 15 seconds.
Re-check voltage and if less than 12.8 volts A. Screws (D =6, L = 26)
repeat the charging cycle and load test. If still
B. Helmet Holder
below 12.8 volts the battery is defective.
C. Battery Cover
Battery Installation
• Turn the ignition switch OFF. • Install the tool kit in the case of the battery
• Route the
Place battery into the battery case. cover, and install the tool kit case cover.
• Route
• connect thebattery
the cables as shown, and first
red capped positive cable (+) to
the rear sub-harness through the
guides of the battery cover.
the positive terminal, and then negative cable • Route the seat lock cable through the guide
of the battery cover and cable clamp (steel).
(–) to the negative terminal.
• Put a light coat of grease on the terminals to
prevent corrosion.
• Cover the terminal with its protective cap.

A. Positive Cable (+)

B. Negative Cable (–)
C. Battery
D. Battery Cover Screws (D = 6, L = 26)

• Remove
26).
the battery cover screws (D = 6, L =

Battery Cover Installation

• Install the battery cover and helmet holder
with the screws (D = 6, L = 26) (2) removed
as shown, and tighten the screws.
 PREPARATION 21

A. Battery Cover
B. Run the rear sub-harness through the guide of the battery cover.
C. Tool Kit Case Cover
D. Battery Cover Screw (D = 6, L = 26)
E. Guide (Steel)
F. Rear Sub-harness
G. Seat Lock Cable
H. Cable Clamp (Steel)
I. Run the seat lock cable through the guide of the battery cover.
J. Helmet Holder (Install the helmet holder over the coolant reservoir tank hose.)
K. Coolant Reservoir Tank Hose
22 PREPARATION
Front Brake Fluid
Front Brake Fluid Level Inspection
• With the front brake fluid reservoir held hori-
zontal, check that the fluid level is above the
lower level line.
A. Front Brake Fluid Reservoir
B. Lower Level Line
• Ifthethelower
fluid level in the reservoir is lower than
level line, check for fluid leaks in the
front brake line and fill the reservoir.
• Loosen the screws to remove the front brake
fluid reservoir cap and diaphragm.
• Fill the reservoir to the upper level line with
DOT4 brake fluid. Inside the front brake
reservoir is a stepped line showing the upper
level line.
A. Front Brake Fluid Reservoir
B. Upper Level Line
WARNING
Never reuse old brake fluid.
Do not use fluid from a container that
has been left unsealed or that has been
open for a long time.
Do not mix two types of fluid for use in
the brakes. This lowers the brake fluid
boiling point and could reduce brake ef-
fectiveness. It may also cause the rub-
ber brake parts to deteriorate.
Don’t leave the reservoir cap off for any
length of time to prevent moisture con-
tamination of the fluid.
Don’t add or change brake fluid in the
rain or during conditions of blowing dust
or debris.
CAUTION
Brake fluid quickly ruins painted sur-
faces. Wipe up any spilled fluid immedi-
ately.
• Operate the brake lever several times.
• brake line.spongy, there might be air in the
If it feels
• Ifline.necessary, bleed the air in the front brake
• Also check for fluid leakage around the fit-
tings, and bleed the air in the front brake line.
Front Brake Line Air Bleeding
• Remove the reservoir cap and diaphragm,
and check that there is plenty of fluid in the
reservoir.
NOTE
○The fluid level must be checked several times,
during the bleeding operation and replenished
as necessary. If the fluid in the reservoir runs
completely out any time during bleeding, the
bleeding operation must be repeated from the
beginning since air will have entered the line.
 PREPARATION 23

• Attach a clear plastic hose to the bleed valve

on the front brake caliper and run the other
end of the hose into a container.
• With the reservoir cap off, slowly pump the
brake lever several times until no air bubbles
can be seen rising up through the fluid from
the holes at the bottom of the reservoir. This
bleeds the air from the brake master cylinder
end of the line.
• Pump the brake lever a few times until it
becomes hard and then, holding the lever
squeezed, quickly open (turn counterclock-
wise) and close the bleed valve. Then release A. Cover
the lever. Repeat this operation until no more
B. Rear Brake Fluid Reservoir
air can be seen coming out into the plastic
hose. C. Bolt
D. Upper Level Line
E. Lower Level Line

• Ifthethelower
fluid level in the reservoir is lower than
level line, check for fluid leaks in the
brake line, and fill the reservoir.
• Loosen the bolt to remove the reservoir and
the cover.
• Remove the reservoir cap and diaphragm,
and fill the reservoir to the upper level line with
DOT4 brake fluid.
NOTE
A. Hold the brake lever applied.
○First, tighten the rear brake fluid reservoir cap
B. Quickly open and close the bleed valve. clockwise by hand until slight resistance is felt
C. Release the brake lever. indicating that the cap is seated on the reser-
voir body, then tighten the cap an additional
• When air bleeding is finished, check that the
fluid level is between the upper and lower
1/6 turn while holding the brake fluid reservoir
body.
level lines.
• Install the diaphragm and reservoir cap.
• Tighten the bleed valve to the specified
torque.
Torque : 7.8 N·m (0.80 kgf·m, 69 in·lb)
• Apply the brake forcefully for a few seconds,
and check for fluid leakage around the fittings.

Rear Brake Fluid

Rear Brake Fluid Level Inspection
• With the rear brake fluid reservoir held hor-
izontal, check that the fluid level is between A. Reservoir
the upper and lower level lines.
B. Cap
C. Clockwise
D. 1/6 turn
24 PREPARATION

• Reinstall the reservoir and the cover with bolt.
• If it feels spongy,
Operate the brake pedal several times.
• brake line. there might be air in the
• Ifline.necessary, bleed the air in the rear brake
• Also check for fluid leakage around the fit-
tings, and bleed the air in the rear brake line.
Rear Brake Line Air Bleeding
• Loosen the bolt to remove the reservoir and
the cover.
• Remove the rear brake reservoir cap and di-
aphragm, and check that there is plenty of
fluid in the reservoir.
• Reinstall the reservoir with bolt.
NOTE
○The fluid level must be checked several times,
during the bleeding operation and replenished
as necessary. If the fluid in the reservoir runs
completely out any time during bleeding, the
bleeding operation must be repeated from the
beginning since air will have entered the line.
• Attach a clear plastic hose to the bleed valve
on the rear brake caliper and run the other
end of the hose into a container.
• With the reservoir cap off, slowly pump the
brake pedal several times until no air bub-
• When air bleeding is finished, check that the
fluid level is between the upper and lower
level lines.
• Tighten the bleed valve(s) to the specified
torque.
Torque : 7.8 N·m (0.80 kgf·m, 69 in·lb)
• Install the diaphragm and reservoir cap.
NOTE
○First, tighten the rear brake fluid reservoir cap
clockwise by hand until slight resistance is felt
indicating that the cap is seated on the reser-
voir body, then tighten the cap an additional
1/6 turn while holding the brake fluid reservoir
body.
• Reinstall the reservoir and the cover with bolt.
• and checkbrake
Apply the forcefully for a few seconds,
for fluid leakage around the fittings.
Clutch Lever and Cable
Clutch Lever Free Play Inspection
• Check that the clutch lever has the specified
amount of free play as shown in the figure.
Clutch Lever Free Play:
2 ∼ 3 mm (0.08 ∼ 0.12 in.)

bles can be seen rising up through the fluid

from the holes at the bottom of the reservoir.
This bleeds the air from the rear brake master
cylinder end of the line.
• Pump the brake pedal a few times until it
becomes hard and then, holding the pedal
pushed down, quickly open (turn counter-
clockwise) and close the bleed valve. Then
release the pedal. Repeat this operation until
no more air can be seen coming out into the
plastic hose.

A. Clutch Cable
B. Adjuster
C. Locknut
D. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

• Ifplay.
the free play is incorrect, adjust the free

Clutch Lever Free Play Adjustment

• Loosen the locknut at the clutch lever, and
turn the adjuster so that the clutch lever will
have 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of free play.
A. Hold the brake pedal applied.
B. Quickly open and close the bleed valve.
• If it cannot be done, use the adjuster at the
middle of the clutch cable.
C. Release the brake pedal.
 PREPARATION 25

A. Clutch Cable A. Throttle Grip

B. Dust Cover B. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
C.
D.
Adjuster
Locknut
• Run the engine at idle speed, and turn the
handlebar all the way to the right and left to
ensure that the idle speed does not change.
• Slide the dust cover up and loosen the lock-
nut.
If the idle speed increases, check the throttle
grip free play.
• Turn the adjuster so that the clutch lever will
have the specified amount of free play. WARNING
• Tighten the locknut. Operation with an improperly adjusted,
• Slide back the dust cover. incorrectly routed, or damaged cable
• Adjust the upper cable adjuster again. could result in an unsafe riding condi-
NOTE tion.
○After the adjustment is made, start the engine Throttle Grip Free Play Adjustment
and check that the clutch does not slip and
that it releases properly. • Loosen both locknuts of the throttle cables
and turn both adjusters in completely to give
○For minor corrections, use the adjuster at the the throttle grip plenty of play.
clutch lever.
• Turn out the decelerator cable adjuster until
there is no play when the throttle grip is com-
pletely closed. Tighten the locknut.
Throttle Grip and Cable
Throttle Grip Free Play Inspection
• Inspect the throttle grip free play. If the free
play is incorrect, adjust the throttle cables.
Throttle Grip Free Play:
2 ∼ 3 mm (0.08 ∼ 0.12 in.)

• Check that the throttle grip moves smoothly

from full open to close, and the throttle closes
quickly and completely in all steering posi-
tions by the return spring. If the throttle grip
does not return properly, check the throttle ca-
ble routing, grip free play, and for possible ca- A. Accelerator Cable
ble damage. Then lubricate the throttle ca- B. Locknuts
bles.
C. Adjusters
D. Decelerator Cable

• Turn out the accelerator cable adjuster un-

til the specified amount of play is obtained.
Tighten the locknut.
26 PREPARATION

Drive Belt
NOTE
○Do not inspect and adjust the drive belt de-
flection for preparation (first service) because
it’s already adjusted by the factory.

Coolant
Coolant Level Inspection
• Situate the motorcycle so that it is perpendic-
ular to the ground.
A. Screw (D = 6, L = 26)
B. Left Side Cover
• Check the coolant level through the coolant
level gauge located at the left rear of the en- C. Projections
gine. The coolant level should be between
the F (Full) and L (Low) level lines. • Unscrew the bolt (D = 6, L = 12) and washer
(D = 6.2), and remove the reservoir tank cover
NOTE by pulling it outward to clear the projections.
○Coolant level must be checked and adjusted
when the engine is cold (room or atmospheric
temperature).

A. Bolt (D = 6, L = 12) and Washer (D = 6.2)

B. Reservoir Tank Cover
C. Projections
A. Reserve Tank
B. F (Full) Level Line
• Open the cap from the reservoir tank, and
add coolant through the filler opening to the
C. L (Low) Level Line F (Full) level line.

• Ifcoolant.
the amount of coolant is insufficient, add

Coolant Filling
• Unscrew the screw (D = 6, L = 26), and re-
move the left side cover by pulling it outward
to clear the projections.

A. Reserve Tank
B. Reserve Tank Cap
C. F (Full) Level Line
D. L (Low) Level Line
 PREPARATION 27

• Install the cap after filling coolant. NOTE

NOTE ○When removing the reserve tank, hook the
bottom of the reserve tank to the holder of the
○A permanent type of antifreeze is installed in frame as shown in the figure.
the cooling system when shipped. It is col-
ored green and contains ethylene glycol. It is
mixed at 50% and has the freezing point of
–35°C (–31°C).

Rear Shock Absorber

Spring Preload Adjustment
• Check the position of the spring preload ad-
juster on the rear shock absorber.
STD Spring Preload: No.4 position

A. Bottom of the Reserve Tank

B. Holder
C. Reserve Tank

• Turn the preload adjuster to the No.4 position

with the wrench in the tool kit.
• Reinstall the reserve tank with two socket
bolts (D = 6, L = 15).
• Reinstall the reserve tank cover inserting the
projections into the grommets, and reinstall
the socket bolt (D = 6, L = 12) and washer
A. Spring Preload Adjuster (D = 6.2), and tighten the bolt.
B. Wrench

• Remove the left side cover and the reservoir

tank cover if necessary. See the “Coolant
Filling” section on page 25.
• To adjust the standard position, remove the
socket bolts (D = 6, L = 15) and the reserve
tank.

A. Reserve Tank Cover

B. Projections
C. Grommets

• Reinstall the left side cover inserting the pro-

jections into the grommets, and reinstall the
screw (D = 6, L = 26), and tighten it.
A. Reserve Tank
B. Socket Bolts (D = 6, L = 15)
28 PREPARATION

Tire Air Pressures

• To prevent flat-spotting during shipment, the
tires are over-inflated before crating. Adjust
the pressures to the specified values in the
front and rear, and make sure to tighten the
caps securely.
Tire Air Pressure [when cold]:
Front: 200 kPa (2.0 kgf/cm², 28 psi)
Rear: 200 kPa (2.0 kgf/cm², 28 psi)
[Up to 97.5 kg (215 lb) Load]
A. Left Side Cover
225 kPa (2.25 kgf/cm², 32 psi)
B. Projections
[97.5 ∼ 180 kg (215 ∼ 397 lb) Load]
C. Grommets

Seat Installation
• Insert
slot.
the tab at the front of the seat into the

• Insert the hooks at the rear of the seat into the

latch on the rear fender, and push down the
rear part of the seat until the lock clicks.

A. Tire Air Pressure Gauge

Fuel
WARNING
Fill the tank in a well-ventilated area, and
A. Tab take ample care that there are no sparks
B. Slot or open flames anywhere near the work
C. Hooks area.
D. Latch
• Open the fuel tank cap, and check for debris
in the fuel tank.
• Pull up the rear end of the seat to make sure
it is securely locked. • Fill the fuel tank with one gallon or four liters
of unleaded gasoline. Use a gasoline with a
minimum Antiknock Index rating according to
the recommendation of your country. Refer to
the following table.

The antiknock index is an average of the Re-

search Octane Number (RON) and the Motor
Octane Number (MON), as shown in the table.
Minimum
Octane Rating Method
Rating
Antiknock (RON + MON)
90
Index 2
Research Octane Number
95
(RON)
 PREPARATION 29

• Close
leaks.
the fuel tank cap, and check for any

Engine Oil (4-stroke)

Engine Oil Level Inspection
NOTE
○This vehicle’s engine is filled with 10W-40 oil
from the factory. DO NOT DRAIN and refill
the crankcase before use. Check oil level and
drain plug tightness.
A. Oil Level Sight Gauge
Engine Oil Drain Plug Torque: B. Oil Filler Cap
20 N·m (2.0 kgf·m, 15 ft·lb)
C. H (High) Level Line
D. L (Low) Level Line

• Ifoilthethrough
oil level is too high, remove the excess
the oil filler opening, using a sy-
ringe or some other suitable device.
• If the oil level is too low, add oil to reach the
correct level. Use the same type of oil that is
already in the engine.
• When replacing the cap, be sure the O-ring is
in place, and tighten the cap.
Recommended Engine Oil
Type: API SE, SF or SG
A. Engine Oil Drain Plug API SH, SJ or SL with JASO MA

• Park the vehicle on level ground. Viscosity: SAE 10W-40

• gine hasstarting
Before
oil.
the engine, check that the en- Capacity: 3.0 L (3.2 US qt)
[when filter is not removed]
• Check that the engine has oil through the oil
level sight gauge in the lower left side of the
3.2 L (3.4 US qt)
engine. [when filter is removed]
CAUTION Although 10W-40 engine oil is the recom-
If the engine is run without oil, it will be mended oil for most conditions, the oil viscosity
severely damaged. may need to be changed to accommodate
atmospheric conditions in your riding area.
• Start the engine and run it for several minutes
at idle speed. Stop the engine, then wait sev-
eral minutes until the oil settles.
• With the motorcycle held level, check the en-
gine oil level through the oil level sight gauge.
The oil level should come up between the
H (High) and L (Low) level lines next to the
gauge.
30 PREPARATION

Idle Speed Adjustment

• Start the engine and warm it up thoroughly.
• Adjust the idle speed to 950 ∼ 1 050 r/min
(rpm) by turning the idle adjusting screw.
Idle Speed: 950 ∼ 1 050 r/min (rpm)

A. Rear Brake Light Switch

B. Adjusting Nut
C. Lights sooner.
D. Lights later.

A. Idle Adjusting Screw
• Open and close the throttle grip a few times
to make sure that the idle speed does not
change.
• With the engine idling, turn the handlebar to
each side. If handlebar movement changes
the idle speed, check the throttle cable routing
and free play.
WARNING
Operation with improperly routed, or
damaged throttle cables could result in
an unsafe riding condition.
CAUTION
To avoid damaging the electrical con-
nections inside the switch, be sure that
the switch body does not turn during ad-
justment.
Headlight Aim
The headlight beam is adjustable both hori-
zontally and vertically. Headlight aim must be
correctly adjusted for safe riding as well as on-
coming drivers. In most areas it is illegal to ride
with an improperly adjusted headlight.
Horizontal Adjustment

• Check for any exhaust leaks and correct if

• Turn the horizontal adjusting screw on the
headlight rim in or out until the beam points
necessary. straight ahead.

Rear Brake Light Switch

Rear Brake Light Switch Adjustment
• Turn on the ignition switch. The brake light
should illuminate when the brake pedal is de-
pressed about 10 mm (0.4 in.)
• If it does not, turn the adjusting nut at the rear
brake light switch as required.

A. Vertical Adjusting Screw

B. Horizontal Adjusting Screw

Vertical Adjustment
• Turn the vertical adjusting screw on the head-
light rim in or out to adjust the headlight verti-
cally.
 PREPARATION 31

NOTE
○On high beam, the brightest point should be
slightly below horizontal with the motorcycle
on its wheels and the rider seated. Adjust
the headlight to the proper angle according to
local regulation.
32 PREPARATION

Fastener Check
• The torque values listed are for assembly and preparation items only, see the appropriate Service
Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before
retail delivery. Also check to see that each cotter pin or circlip is in place.
 PREPARATION 33

Torque
No. Fastener Remarks
N·m kgf·m ft·lb
Steering
1 Handlebar clamp bolts 34 3.5 25
Brake
2 Front master cylinder clamp bolts 8.8 0.90 78 in·lb S
3 Front brake bleed valve (Left) 7.8 0.80 69 in·lb
4 Front caliper mounting bolts (Left) 34 3.5 25
5 Rear master cylinder mounting bolts 25 2.5 18
6 Rear caliper mounting bolts 34 3.5 25
7 Rear brake bleed valves 7.8 0.80 69 in·lb
Wheel
8 Front axle nut 108 11.0 79.6
9 Front axle clamp bolt (Right) 20 2.0 15
Others
10 Front footboard bracket bolts (Left and Right) 34 3.5 25
Engine Oil Drain Plug
11 Engine oil drain plug 20 2.0 15
Cotter pins or Circlips
12 Rear axle nut cotter pin – – –
13 Rear master cylinder rod cotter pin – – –
14 Front footboard bracket pin circlip (Left and Right) – – –
15 Rear footpeg pin circlip (Left and Right) – – –

S: Tighten the upper clamp bolt first, and then the lower clamp bolt.

Standard Torque Table

This table relating tightening torque to thread
diameter, lists the basic torque for bolts and
nuts. Use this table for only the bolts and nuts
which do not require a specific torque value.
All of the values are for use with dry solvent
-cleaned threads.
General Fasteners:
Threads Torque
dia. mm N·m kgf·m ft·lb
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240
34 PREPARATION

Test Ride the Motorcycle

• Complete the test ride checklist.
Control Cables:
Throttle control cables must work without
binding in any steering position.
Steering:
Action is free from lock-to-lock.
Suspension:
Check operation front and rear.
Engine:
Electric starter works properly and engine
starts promptly. Good throttle response and
return.
Transmission and Clutch:
Smooth operation.
Brakes:
Adequate, smooth stopping power, No drag.
Speedometer:
Check operation
Electrical System:
Headlight - check high and low beams.
Taillight - check operation.
Brake Light - check operation
Turn Signal Lights - check operation.
Horn - check operation
Instrument Lights and Indicator Lights -
Check operation.
Engine Stop Switch Works:
Starter Interlock Switch Works:
No Unusual Noises:
No Fuel, Oil, Brake Fluid, or Coolant
Leaks:
PREPARATION COMPLETE.

WARNING
New tires are slippery and may cause
loss of control and injury. A break-in pe-
riod of 160 km (100 miles) is necessary
to establish normal tire traction.
During break-in, avoid sudden and maxi-
mum braking and acceleration, and hard
cornering.

A & P Check List

• Complete the A & P Check List.
 MODEL APPLICATION
Year Model Name
2006 VN900B6F VULCAN 900 CLASSIC
2006 VN900B6F VN900 CLASSIC
2006 VN900D6F VULCAN 900 CLASSIC LT
2007 VN900B7F VULCAN 900 CLASSIC
2007 VN900B7F VN900 CLASSIC
2007 VN900D7F VULCAN 900 CLASSIC LT

Part No. 99931-1461-03