Motorcycle Assembly & Preparation Manual

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1 VULCAN 900 CLASSIC VN900 CLASSIC VULCAN 900 CLASSIC LT Motorcycle Assembly & Preparation Manual

3 Foreword In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most commonly removed parts have a direct bearing on a vehicle s reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needless warranty claims and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers. This Assembly and Preparation Manual explains 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 responsibility for any unauthorized modifications prior to sale. Refer to your Service Binder for any Service Bulletins specifying Factory Directed Modifications (Special Claims) which must be performed before the vehicle is ready for sale. Whenever you see the following symbols heed their instructions! Always follow safe operating and maintenance practices. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE NOTICE is used to address practices not related to personal injury. This note symbol indicates points of particular interest for more efficient and convenient operation. 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 accurate as possible. All procedures and specifications subject to change without notice. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury Kawasaki Heavy Industries, Ltd. May, 2009

4 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 Wiring Clamps Front Wheel Installation Front Fender Front Brake Hose Grommet Front Footboards (Left and Right) Rear View Mirrors (Left and Right) Front Axle/Nut Rubber Caps (VN900B European Models Only). 15 Windshield (VN900D Models Only) Backrest (VN900D Models Only) Saddlebags (Left and Right) (VN900D Models Only) Brake Disc Cleaning Preparation Battery Service Front Brake Fluid Rear Brake Fluid Clutch Lever and Cable Throttle Grip and Cable Drive Belt Coolant Rear Shock Absorber Tire Air Pressures Fuel Engine Oil (4-stroke) Idle Speed Adjustment Rear Brake Light Switch Headlight Aim Fastener Check Standard Torque Table Test Ride the Motorcycle A & P Check List... 34

UNCRATING 3 Uncrating Opening Crate WARNING Crates have sharp edges and may have nails or screws that can cause cuts and injury.

Unscrew the two bolts (D = 6, L = 8) and remove the master cylinder from the crate bracket, and then remove the bolt (D = 8, L = 14) and crate 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. Place the crate upright on its base.

5 UNCRATING 3 Uncrating Opening Crate WARNING Crates have sharp edges and may have nails or screws that can cause cuts and injury. Always wear protective gloves, boots and eye protection when uncrating to prevent injury. Unscrew the two bolts (D = 6, L = 8) and remove the master cylinder from the crate bracket, and then remove the bolt (D = 8, L = 14) and crate bracket. Discard the removed bolts and crate bracket. WARNING The steel crate panel plates and fasteners have sharp edges. 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) First, unscrew the two bolts (D = 10, L = 14) from the steering stem head, and then remove the two bolts (D = 8, L = 14) and crate 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. Place the crate upright on its base. Remove the cardboard cover. Remove the handlebar, front wheel, and the parts box. NOTICE 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 components with the crate bracket. A. Bolts (D = 10, L = 14) B. Bolts (D = 8, L = 14) C. Crate Bracket Take out all the bolts and screws and remove the top and sides of the crate.

6 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.

7 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 (VN900B6F/D6F/B7F/D7F/B8F/D8F/B9F/D9F Models) Plastic Clamp, Wiring and Hose, RH 1 L = 80.5 ***Plastic Clamp, Wiring, LH (Australian Models and 1 L=58 VN900B6F/D6F/B7F/D7F Models) ****Plastic Clamp, Wiring, LH & RH 3 L=58 (other than Australian Models of the VN900B8F/D8F/B9F/D9F/BAF/DAF) 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 (European Models Only) 1 Marked 19 *Rubber Cap, Front Axle (European Models Only) 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

8 6 UNCRATING

9 UNCRATING 7 No. Part Name Qty Remarks 4 Windshield Assembly with (VN900D Models Only) 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 = 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 (VN900D Models Only) 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 (VN900D Models Only) 2 Flat Washer, Saddlebag, Black 8 D = 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

8 ASSEMBLY Assembly Handlebar Position the handlebar clamp on the handlebar with the slanted side facing rearward.

Throttle Grip and Right Switch Housing Apply a light coat of grease on the exposed portion of the throttle inner cables.

Front Half (Right Switch Housing) B. Throttle Cable (Accelerator) C. Cable Tips: Apply Grease. D. Throttle Grip E. Throttle Cable (Decelerator) F.

Handlebar Clamp Bolt Tightening Tighten the front clamp bolts first, and then the rear clamp bolts to the specified torque.

10 8 ASSEMBLY Assembly Handlebar Position the handlebar clamp on the handlebar with the slanted side facing rearward. 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). Throttle Grip and Right Switch Housing Apply a light coat of grease on the exposed portion of the throttle inner cables. Fit the throttle cable tips into the nearest sockets in the throttle grip. A. Front Bolts (D = 10, L = 23) B. Slanted Side C. Gap D. Punched Mark E. No Gap F. Forward A. Front Half (Right Switch Housing) B. Throttle Cable (Accelerator) C. Cable Tips: Apply Grease. D. Throttle Grip E. Throttle Cable (Decelerator) F. Rear Half (Right Switch Housing) Fit the two halves of the right switch housing so that the pin on the front half fits into the hole in the handlebar. 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 handlebar clamp bolts. A. Plastic Plugs B. Handlebar Clamps 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.

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.

90 kgf m, 78 in lb) For other than VN900BAF/DAF models, push the small plastic plugs (2) into the master cylinder clamp bolts. A. Right Switch Housing B.Screws(D=5,L=25) C.

Holder Screw Front Brake Master Cylinder Connect the right switch lead connectors to the front brake light switch terminals on the front brake master cylinder.

Plastic Plugs B. Master Cylinder Clutch Cable Apply a light coat of grease on the clutch inner cable. Line up the slots on the clutch lever, locknut and adjuster.

11 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) For other than VN900BAF/DAF models, push the small plastic plugs (2) into the master 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 Connect the right switch lead connectors to the front brake light switch terminals on the 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). A. Plastic Plugs B. Master Cylinder Clutch Cable Apply a light coat of grease on the clutch inner cable. 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 adjuster. A. Front Master Cylinder B. Punched Mark C. Clamp D. Socket Bolts (D = 6, L = 20) E. Right Switch Harness F. Front Brake Light Switch G. Connectors and Dust Cover A. Clutch Cable B. Adjuster C. Locknut D. Tip E. Clutch Lever

10 ASSEMBLY Left Switch Housing Connect the left switch lead connector to the starter lock-out switch on the clutch lever holder.

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. A. Handlebar (Right Side) B. Plastic Clamp (L = 80.

Front Brake Hose Fasten the left switch harness to the left side of the handlebar with the plastic clamp(s) (L = 58).

12 10 ASSEMBLY Left Switch Housing 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. 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. A. Handlebar (Right Side) B. Plastic Clamp (L = 80.5) (Australian Models and VN900B6F/D6F/B7F/D7F Models) Plastic Clamps (L = 80.5, 58) (other than Australian Models of the VN900B8F/D8F/B9F/D9F/BAF/DAF) C. Right Switch Harness D. Front Brake Hose Fasten the left switch harness to the left side of the handlebar with the plastic clamp(s) (L = 58). Wiring Clamps Fasten the front brake hose and the right switch harness to the right side of the handlebar with the plastic clamp(s) (L = 80.5, 58). A. Handlebar (Left Side) B. Plastic Clamp (L = 58) (Australian Models and VN900B6F/D6F/B7F/D7F Models) Plastic Clamps (L = 58) (other than Australian Models of the VN900B8F/D8F/B9F/D9F/BAF/DAF) C. Clutch Cable D. Left Switch Harness

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.

Run the left switch harness and clutch cable through the clamp. J. Run the clutch cable through the brake hose front side. K.

13 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. J. Run the clutch cable through the brake hose front side. K. Fasten the right switch harness with the plastic clamp (other than Australian Models of the VN900B8F/D8F/B9F/D9F/BAF/DAF) L. Fasten the left switch harness with the plastic clamp (other than Australian Models of the VN900B8F/D8F/B9F/D9F/BAF/DAF) Front Wheel Installation Remove the crate bolts (D = 8, L = 30) to take off the crate bracket holding the front axle and discard them. A. Crate Bolts (D = 8, L = 30) B. Crate Bracket C. Front Axle D. Axle Clamp Bolt (Right)

12 ASSEMBLY Lift the motorcycle off the crate base and support the motorcycle with a suitable stand or jack to install the front wheel. Discard the crate base.

Install the wheel so that the rotation mark coincides with wheel rotational direction. A. Front Axle B. Collar (Right) C. Axle Clamp Bolt (Right) D. Collar (Left) E.

0 kgf m, 15 ft lb) Install one front brake caliper mounting bolt (D = 10, L = 47) at the lower side of the caliper. A. Front Tire B. Arrow C.

14 12 ASSEMBLY Lift the motorcycle off the crate base and support the motorcycle with a suitable stand or jack to install the front wheel. Discard the crate base. Loosen the right axle clamp bolt and remove the front axle. Check the wheel rotation mark on the front tire. 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. Front Axle B. Collar (Right) C. Axle Clamp Bolt (Right) D. Collar (Left) E. Front Axle Nut (D = 18) Tighten the axle clamp bolt on the right fork leg to the specified torque. 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. A. Front Tire B. Arrow C. Rotation Fit the axle collars on both sides of the front wheel hub. The collars are identical. Position the front wheel assembly between the fork legs. Insert the front brake disc between the brake pads of the caliper. Insert the front axle from the right side of the wheel and push it completely through. Tighten the front axle nut (D = 18) to the specified torque. Torque : 108 N m (11.0 kgf m, 79.6 ft lb) A. Bolt (D = 10, L = 47) B. Front Caliper Tighten the front caliper mounting bolts to the specified torque. Torque : 34 N m (3.5 kgf m, 25 ft lb) WARNING It may take several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc.

ASSEMBLY 13 Front Fender Front Fender Installation Install the front fender with its more rounded end facing forward. A. Front Brake Hose B. Grommet C. Front Brake Hose Clamp A. Front Fender B.

Front Footboards (Left and Right) Before installing the front footboard assembly, make sure the bank sensor is installed on the rear side of the front footboard. A. Front Fender B.

Front Brake Hose Grommet Fit the grommet onto the front brake hose, and install it in the clamp. A. Rear B. Bank Sensor C. Front Footboard (Left) D. Return Spring E. Link Pin F.

15 ASSEMBLY 13 Front Fender Front Fender Installation Install the front fender with its more rounded end facing forward. A. Front Brake Hose B. Grommet C. Front Brake Hose Clamp A. Front Fender B. Forward 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. Front Footboards (Left and Right) Before installing the front footboard assembly, make sure the bank sensor is installed on the rear side of the front footboard. A. Front Fender B. Bolts (D = 8, L = 14) C. Front Brake Hose Clamp Install the two bolts (D = 8, L = 14) on the right side of the fender and tighten them. Front Brake Hose Grommet Fit the grommet onto the front brake hose, and install it in the clamp. A. Rear B. Bank Sensor C. Front Footboard (Left) D. Return Spring E. Link Pin F. Circlip Apply grease to the pivots of the front footboard. Hang the end of the return spring to the hole in the bottom of the left footboard. Install the left footboard assembly on the footboard 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.

14 ASSEMBLY Turning Stay Type Screw the mounting area of the right rear view mirror into the holder all the way, and tighten the lower hexagonal area securely. A. Bank Sensor B. Rear C.

Rear View Mirrors (Left and Right) Conventional Type (Single Nut) Loosen the locknut completely. Screw the rear view mirror in completely, and then back it two turns out.

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) C.

16 14 ASSEMBLY Turning Stay Type Screw the mounting area of the right rear view mirror into the holder all the way, and tighten the lower hexagonal area securely. A. Bank Sensor B. Rear C. Front Footboard (Left) D. Return Spring E. Link Pin F. Apply Grease. G. Circlip Installation of the right side footboard is common with the left side. Follow the procedure specified for the left side. Rear View Mirrors (Left and Right) Conventional Type (Single Nut) Loosen the locknut completely. Screw the rear view mirror in completely, and then back it two turns out. Turn the mirror stay to assure visibility to the rear with the operator sitting on the motorcycle 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) C. Rear View Mirror (Right) NOTICE Do not force to tighten and/or loosen the upper hexagonal area (adapter) with a spanner or wrench. Disassembly of this area is not possible. Non-permanent locking agent is already applied to the threads of this inner area. Forcible loosening may damage the adapter and/or the turning mechanism of the stay. A. Lower Hexagonal Area for Tightening B. Upper Hexagonal Area (Adapter) C. Stay D. Non-permanent Locking Agent applied. A. Locknut B. Rear View Mirror (Right) Installation and adjustment of the left side mirror is common with the right side. Follow the procedure specified for the right side. Turnthestaytoassurevisibilitytotherear with the operator sitting on the motorcycle. Adjust the rear view mirror by slightly moving only the mirror portion of the assembly.

ASSEMBLY 15 A. Stay B. Mirror Installation and adjustment of the left side mirror is common with the right side. Follow the procedure specified for the right side. A. Windshield Assembly Install the windshield assembly on the windshield mounting brackets with the four socket bolts (D = 8, L = 16) and the cap nuts (D = 8).

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) A.

) in height to suit the rider s preference. Move the windshield up or down, and align both the left and right windshield stays. Tighten the bolts and nuts securely.

17 ASSEMBLY 15 A. Stay B. Mirror Installation and adjustment of the left side mirror is common with the right side. Follow the procedure specified for the right side. A. Windshield Assembly Install the windshield assembly on the windshield mounting brackets with the four socket bolts (D = 8, L = 16) and the cap nuts (D = 8). Front Axle/Nut Rubber Caps (VN900B European Models 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) A. Axle Nut Rubber Cap (Marked 19 ) B. Left Side C. Axle Rubber Cap (D = 23) D. Right Side Windshield Height Adjustment The windshield can be adjusted 50 mm (2.0 in.) in height to suit the rider s preference. Move the windshield up or down, and align both the left and right windshield stays. Tighten the bolts and nuts securely. Windshield (VN900D Models Only) NOTICE Be sure not to damage the surface of the windshield when installing or handling.

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

Tighten the bolts securely. A. Pad B. Cover C. Bolts (D = 6, L = 25) D. Backrest Assemble the rear reflector and each bracket with nut (D = 5).

18 16 ASSEMBLY A. Windshield B. Mounting Bolts (D = 8, L = 16) C. Positioning Marks D. Nuts (D = 8) Backrest (VN900D Models Only) Assemble the backrest, pad, and cover with the three flanged bolts (D = 6, L = 25) and tighten them securely. 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. Pad B. Cover C. Bolts (D = 6, L = 25) D. Backrest Assemble the rear reflector and each bracket with nut (D = 5). Only left bracket has L (Left) mark on its backside. A. Backrest Assembly B. Bolts (D = 8, L = 20) C. Rear Reflector Brackets (Left and Right) Saddlebags (Left and Right) (VN900D Models Only) 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.

PREPARATION 17 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.

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. A. Cap Nuts (D = 8) B. Flat Washers (D = 8.5) C.

WARNING An anticorrosive treatment applied to the brake discs will increase braking distance and can cause an accident resulting in serious injury or death.

19 PREPARATION 17 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. A. Cap Nuts (D = 8) B. Flat Washers (D = 8.5) C. Flanged Bolt (D = 6, L = 16) D. Right Saddlebag 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 An anticorrosive treatment applied to the brake discs will increase braking distance and can cause an accident resulting in serious injury or death. Remove the anticorrosive treatment using an oilless solvent. Preparation Battery Service The battery used in this motorcycle is a sealed 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, filling the battery with electrolyte, and charging. Read the electrolyte safety label and the following procedures carefully before battery activation. NOTICE 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. Make sure that the model name of the electrolyte container matches the model name of the battery. These names must be the same. Battery Model Name for VN900B/D: YTX12-BS A. Model Name of the Electrolyte B. Model Name of the Battery

18 PREPARATION NOTICE Sealed battery electrolyte has a higher concentration of sulfuric acid. Each container contains the proper amount of electrolyte for its specific battery.

Seat Removal Insert the ignition key into the seat lock located on the left side cover. Turn the key clockwise while pulling the rear end of the seat, and remove the seat.

20 18 PREPARATION NOTICE 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 Insert the ignition key into the seat lock located on the left side cover. Turn the key clockwise while pulling the rear end of the seat, and remove the seat. Battery Specifications Make Yuasa Battery Type YTX12-BS Battery Capacity 12 V 10 Ah Electrolyte Capacity 0.60 L Battery/Electrolyte Set P/No Battery Activation Filling the Battery with Electrolyte NOTICE Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. Place the battery on a level surface. peeling, tears, or holes in it. Remove the sealing sheet [A]. Check to see that the sealing sheet [A] has no 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 the electrolyte container from the vinyl bag. Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery. 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.

21 PREPARATION 19 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. Do not tilt the electrolyte container. NOTICE Removal of the container before it is completely empty can shorten the service life of the battery. Do not remove the electrolyte container until it is completely empty and 20 minutes have elapsed. Gently remove the container from the battery. Let the battery sit for 30 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance. Charging the battery immediately after filling can shorten service life. Let the battery sit for at least 30 minutes after filling. Initial Charge Place the strip of caps loosely over the filler ports. Check the electrolyte flow. If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times. Keep the container in place for 20 minutes or 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. A. Strip Newly activated sealed batteries require an initial charge. Standard Charge 1.2 A 5 10 hours If using a recommended battery charger, follow the charger s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate If the above chargers are not available, use equivalent one.

After charging is completed, press down firmly with both hands to seat the strip of caps [A] into the battery (don t pound or hammer).

22 20 PREPARATION Charging rates will vary depending on how long the battery has been stored, temperature, 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 hammer). When properly installed, the strip of caps will be level with the top of the battery. A. Positive Cable (+) B. Negative Cable ( ) C. Battery D. Battery Cover Screws (D = 6, L = 26) Remove the battery cover screws (D = 6, L = 26). 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. NOTICE Once the strip of caps [A] is installed onto the battery, never remove the caps, nor add water or electrolyte to the battery. 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 repeat the charging cycle and load test. If still below 12.8 volts the battery is defective. Battery Installation Turn the ignition switch OFF. Place the battery into the battery case. Route the battery cables as shown, and first connect the red capped positive cable (+) to the positive terminal, and then negative cable ( ) to the negative terminal. Put a light coat of grease on the terminals to prevent corrosion. Cover the terminal with its protective cap. A. Screws (D =6, L = 26) B. Helmet Holder C. Battery Cover Install the tool kit in the case of the battery cover, and install the tool kit case cover. Route the rear sub-harness through the guides of the battery cover. Route the seat lock cable through the guide of the battery cover and cable clamp (steel).

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.

23 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 horizontal, check that the fluid level is above the lower level line. A.

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.

24 22 PREPARATION Front Brake Fluid Front Brake Fluid Level Inspection With the front brake fluid reservoir held horizontal, check that the fluid level is above the lower level line. A. Front Brake Fluid Reservoir B. Lower Level Line If the fluid level in the reservoir is lower than the lower 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 Brake fluid that is contaminated by moisture or dirt, mixed or contains air hasalower boiling point and can cause the brake to be ineffective or fail, and it may cause rubber parts to deterioate, resulting in an accident causing injury or death. 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 and brands of fluid for use in the brake. Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid. Don t add or change the fluid in the rain or when a strong wind is blowing. NOTICE Brake fluid quickly ruins painted surfaces. Wipe up any spilled fluid immediately. Operate the brake lever several times. If it feels spongy, there might be air in the brake line. If necessary, bleed the air in the front brake line. Also check for fluid leakage around the fittings, 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. 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.

This bleeds the air from the brake master cylinder end of the line.

25 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 counterclockwise) and close the bleed valve. Then release the lever. Repeat this operation until no more air can be seen coming out into the plastic hose. A. Hold the brake lever applied. B. Quickly open and close the bleed valve. C. Release the brake lever. When air bleeding is finished, check that the fluid level is between the upper and lower 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 horizontal, check that the fluid level is between the upper and lower level lines. A. Cover B. Rear Brake Fluid Reservoir C. Bolt D. Upper Level Line E. Lower Level Line If the fluid level in the reservoir is lower than the lower 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. First, tighten the rear brake fluid reservoir cap clockwise by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn while holding the brake fluid reservoir body. A. Reservoir B. Cap C. Clockwise D. 1/6 turn

24 PREPARATION Reinstall the reservoir and the cover with bolt. Operate the brake pedal several times. If it feels spongy, there might be air in the brake line.

Rear Brake Line Air Bleeding Loosen the bolt to remove the reservoir and the cover. Remove the rear brake reservoir cap and diaphragm, and check that there is plenty of fluid in the reservoir.

26 24 PREPARATION Reinstall the reservoir and the cover with bolt. Operate the brake pedal several times. If it feels spongy, there might be air in the brake line. If necessary, bleed the air in the rear brake line. Also check for fluid leakage around the fittings, 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 diaphragm, and check that there is plenty of fluid in the reservoir. Reinstall the reservoir with bolt. 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 bubbles 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 counterclockwise) 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. Hold the brake pedal applied. B. Quickly open and close the bleed valve. C. Release the brake pedal. 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. First, tighten the rear brake fluid reservoir cap clockwise by hand until slight resistance is felt indicating that the cap is seated on the reservoir 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. Apply the brake forcefully for a few seconds, and check 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 ( in.) A. Clutch Cable B. Adjuster C. Locknut D. 2 3mm( in.) If the free play is incorrect, adjust the free play. 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 ( in.) of free play. If it cannot be done, use the adjuster at the middle of the clutch cable.

PREPARATION 25 A. Clutch Cable B. Dust Cover C. Adjuster D. Locknut Slide the dust cover up and loosen the locknut.

After the adjustment is made, start the engine and check that the clutch does not slip and that it releases properly. For minor corrections, use the adjuster at the clutch lever.

12 in.) Check that the throttle grip moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by the return spring.

27 PREPARATION 25 A. Clutch Cable B. Dust Cover C. Adjuster D. Locknut Slide the dust cover up and loosen the locknut. Turn the adjuster so that the clutch lever will have the specified amount of free play. Tighten the locknut. Slide back the dust cover. Adjust the upper cable adjuster again. After the adjustment is made, start the engine and check that the clutch does not slip and that it releases properly. For minor corrections, use the adjuster at the clutch lever. 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 ( in.) Check that the throttle grip moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by the return spring. If the throttle grip does not return properly, check the throttle cable routing, grip free play, and for possible cable damage. Then lubricate the throttle cables. A. Throttle Grip B. 2 3 mm ( in.) 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. If the idle speed increases, check the throttle grip free play. WARNING Operation with incorrectly routed, improperly adjusted or damaged cables could result in an unsafe riding condition. Be sure the cables are routed correctly, properly adjusted and are not damaged in any way. Throttle Grip Free Play Adjustment Loosen both locknuts of the throttle cables and turn both adjusters in completely to give the throttle grip plenty of play. Turn out the decelerator cable adjuster until there is no play when the throttle grip is completely closed. Tighten the locknut. A. Accelerator Cable B. Locknuts C. Adjusters D. Decelerator Cable

26 PREPARATION Turn out the accelerator cable adjuster until the specified amount of play is obtained. Tighten the locknut.

Coolant Coolant Level Inspection Situate the motorcycle so that it is perpendicular to the ground.

Coolant level must be checked and adjusted when the engine is cold (room or atmospheric temperature). A. Screw (D = 6, L = 26) B. Left Side Cover C.

F (Full) Level Line C. L (Low) Level Line If the amount of coolant is insufficient, add coolant.

28 26 PREPARATION Turn out the accelerator cable adjuster until the specified amount of play is obtained. Tighten the locknut. Drive Belt Do not inspect and adjust the drive belt deflection for preparation (first service) because it s already adjusted by the factory. Coolant Coolant Level Inspection Situate the motorcycle so that it is perpendicular to the ground. Check the coolant level through the coolant level gauge located at the left rear of the engine. The coolant level should be between the F (Full) and L (Low) level lines. Coolant level must be checked and adjusted when the engine is cold (room or atmospheric temperature). A. Screw (D = 6, L = 26) B. Left Side Cover C. Projections Unscrew the bolt (D = 6, L = 12) and washer (D = 6.2), and remove the reservoir tank cover by pulling it outward to clear the projections. A. Reserve Tank B. F (Full) Level Line C. L (Low) Level Line If the amount of coolant is insufficient, add coolant. Coolant Filling Unscrew the screw (D = 6, L = 26), and remove the left side cover by pulling it outward to clear the projections. A. Bolt (D = 6, L = 12) and Washer (D = 6.2) B. Reservoir Tank Cover C. Projections Open the cap from the reservoir tank, and add coolant through the filler opening to the F (Full) level line. 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. A permanent type of antifreeze is installed in the cooling system when shipped. It is colored green and contains ethylene glycol.

Rear Shock Absorber Spring Preload Adjustment Check the position of the spring preload adjuster on the rear shock absorber. STD Spring Preload: No.4 position A. Spring Preload Adjuster B.

To adjust the standard position, remove the socket bolts (D = 6, L = 15) and the reserve tank. A. Bottom of the Reserve Tank B. Holder C. Reserve Tank Turn the preload adjuster to the No.

29 PREPARATION 27 Install the cap after filling coolant. A permanent type of antifreeze is installed in the cooling system when shipped. It is colored green and contains ethylene glycol. It is mixed at 50% and has the freezing point of 35 C ( 31 C). When removing the reserve tank, hook the bottom of the reserve tank to the holder of the frame as shown in the figure. Rear Shock Absorber Spring Preload Adjustment Check the position of the spring preload adjuster on the rear shock absorber. STD Spring Preload: No.4 position A. Spring Preload Adjuster 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. 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 (D = 6.2), and tighten the bolt. A. Reserve Tank B. Socket Bolts (D = 6, L = 15) A. Reserve Tank Cover B. Projections C. Grommets Reinstall the left side cover inserting the projections into the grommets, and reinstall the screw (D = 6, L = 26), and tighten it.

28 PREPARATION A. Left Side Cover B. Projections C. Grommets Tire Air Pressures To prevent flat-spotting during shipment, the tires are over-inflated before crating.

0 kgf/cm², 28 psi) [Up to 97.5 kg (215 lb) Load] 225 kpa (2.25 kgf/cm², 32 psi) [97.5 180 kg (215 397 lb) Load] Seat Installation Insert the tab at the front of the seat into the slot.

Latch Pull up the rear end of the seat to make sure it is securely locked.

30 28 PREPARATION A. Left Side Cover B. Projections C. Grommets 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] 225 kpa (2.25 kgf/cm², 32 psi) [ kg ( lb) Load] Seat Installation Insert the tab at the front of the seat into the slot. 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 A. Tab B. Slot C. Hooks D. Latch Pull up the rear end of the seat to make sure it is securely locked. WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Never fill the tank completely to the top. If the tank is filled completely to the top, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately.

PREPARATION 29 Open the fuel tank cap, and check for debris in the fuel tank. Fill the fuel tank with one gallon or four liters of unleaded gasoline.

The antiknock index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON), as shown in the table.

31 PREPARATION 29 Open the fuel tank cap, and check for debris in the fuel tank. 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 Research Octane Number (RON) and the Motor Octane Number (MON), as shown in the table. Minimum Octane Rating Method Rating Antiknock Index (RON + MON) 2 90 Research Octane Number 95 (RON) Close the fuel tank cap, and check for any leaks. Engine Oil (4-stroke) Engine Oil Level Inspection 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. Engine Oil Drain Plug Torque: 20 N m (2.0 kgf m, 15 ft lb) Park the vehicle on level ground. Before starting the engine, check that the en- A. Engine Oil Drain Plug gine has oil. Check that the engine has oil through the oil level sight gauge in the lower left side of the engine. NOTICE If the engine is run without oil, it will be severely damaged. Start the engine and run it for several minutes at idle speed. Stop the engine, then wait several minutes until the oil settles. With the motorcycle held level, check the engine 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. A. Oil Level Sight Gauge B. Oil Filler Cap C. H (High) Level Line D. L (Low) Level Line If the oil level is too high, remove the excess oil through the oil filler opening, using a syringe 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 SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 Capacity: 3.0 L (3.2 US qt) [when filter is not removed] 3.2 L (3.4 US qt) [when filter is removed] 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.

30 PREPARATION Rear Brake Light Switch Rear Brake Light Switch Adjustment Turn on the ignition switch. The brake light should illuminate when the brake pedal is depressed about 10 mm (0.4 in.

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.

32 30 PREPARATION Rear Brake Light Switch Rear Brake Light Switch Adjustment Turn on the ignition switch. The brake light should illuminate when the brake pedal is depressed about 10 mm (0.4 in.) If it does not, turn the adjusting nut at the rear brake light switch as required. Idle Speed Adjustment Start the engine and warm it up thoroughly. Adjust the idle speed to r/min (rpm) by turning the idle adjusting screw. Idle Speed: 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 incorrectly routed or improperly adjusted cables could result in an unsafe riding condition. Be sure the cables are routed correctly and properly adjusted. Check for any exhaust leaks and correct if necessary. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. Headlight Aim The headlight beam is adjustable both horizontally and vertically. Headlight aim must be correctly adjusted for safe riding as well as oncoming drivers. In most areas it is illegal to ride with an improperly adjusted headlight. Horizontal Adjustment Turn the horizontal adjusting screw on the headlight rim in or out until the beam points straight ahead.

PREPARATION 31 A. Vertical Adjusting Screw B. Horizontal Adjusting Screw Vertical Adjustment Turn the vertical adjusting screw on the headlight rim in or out to adjust the headlight vertically.

33 PREPARATION 31 A. Vertical Adjusting Screw B. Horizontal Adjusting Screw Vertical Adjustment Turn the vertical adjusting screw on the headlight rim in or out to adjust the headlight vertically. 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.

34 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.

35 PREPARATION 33 No. Fastener Torque N m kgf m ft lb Remarks Steering 1 Handlebar clamp bolts Brake 2 Front master cylinder clamp bolts in lb S 3 Front brake bleed valve (Left) in lb 4 Front caliper mounting bolts (Left) Rear master cylinder mounting bolts Rear caliper mounting bolts Rear brake bleed valves in lb Wheel 8 Front axle nut Front axle clamp bolt (Right) Others 10 Front footboard bracket bolts (Left and Right) Engine Oil Drain Plug 11 Engine oil drain plug 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 in lb in lb

36 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 serious injury or death. A break-in period of 160 km (100 miles) is necessary to establish normal tire traction. During break-in, avoid sudden and maximum braking, acceleration, and hard cornering. A & P Check List CompletetheA&PCheckList.

38 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 2008 VN900B8F VULCAN 900 CLASSIC 2008 VN900B8F VN900 CLASSIC 2008 VN900D8F VULCAN 900 CLASSIC LT 2009 VN900B9F VULCAN 900 CLASSIC 2009 VN900B9F VN900 CLASSIC 2009 VN900D9F VULCAN 900 CLASSIC LT 2010 VN900BAF VULCAN 900 CLASSIC 2010 VN900BAF VN900 CLASSIC 2010 VN900DAF VULCAN 900 CLASSIC LT Part No

VULCAN 900 Custom. VN900 Custom. Motorcycle Assembly & Preparation Manual

VULCAN 900 Custom. VN900 Custom. Motorcycle Assembly & Preparation Manual VULCAN 900 Custom VN900 Custom Motorcycle Assembly & Preparation Manual Foreword In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some