This is the maintenance schedule with associated service intervals for the Kawasaki Vulcan 900, including the Classic.
The Kawasaki Vulcan is an easy-going but classy cruiser motorcycle. The Vulcan range goes from tiny (125cc) all the way to massive (2000), so 900 sits roughly right in the middle. Despite being a little old-tech (no ABS!), the Vulcan 900 is still being made today (as of 2021, anyway), with no mechanical changes since 2006 other than tweaks.
The Kawasaki Vulcan 900 Classic is a mid-sized motorcycle cruiser, first introduced in 2006. It is powered by a liquid-cooled 903 cc V-Twin engine, with a five-speed transmission, putting power down through a belt drive.
For a while the Vulcan 900 had its own category, before the mid-size Yamaha Bolt came along.
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What you need to service the Vulcan 900
Here’s a shopping list of replaceable items you need to service the Kawasaki Vulcan 900.
|Part||Kawasaki Vulcan 900 Spec|
|Oil||You need 3.2L (3.4 US qt) (when the filter is removed) of SAE 10W-40 engine oil “with API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 rating”, preferably Kawasaki 10W-40 Engine Oil.|
Don’t over-torque the drain bolt (spec is 20 Nm/14.5 lb-ft per the manual) — use a torque wrench if you don’t have experience with how much torque is enough.
|Oil filter||Oil filter is part 16097-1058, or you can use HF303RC. Torque for oil filter is 18 Nm (13 ft-lb) (use a torque wrench, and it’s easier on the K&N one)|
|Brake pads||Everyone on the Vulcan forums recommends double-sintered EBC brake pads. They’re cheaper and better. You need FA229HH for the front and FA231HH for the rear.|
|Spark plugs||NGK CPR7EA-9, with a spark plug gap of 0.8-0.9mm (use a spark plug gapping tool), torqued to 18 Nm or 13 ft-lb (use a torque wrench).|
|Air filter||Genuine part number is 11013-0015. You can also use the K&N equivalent KA-9006.|
|Cable lubricant||Remember to lubricate your clutch cable (and brake cables if you have them) with a cable lubricant. Protect All Cable Life is a good general-purpose lubricant.|
|Belt tension tool||Use this tool to check that the belt tension is within spec.|
|Brake fluid||Spec is to use DOT-4 brake fluid.|
|Coolant||Use nitrate-free, phosphate-free, ethylene glycol-based coolant with anti-corrosion inhibitors, e.g. Valvoline Zerex G05|
|Grease||Use a lithium soap-based grease and silicone grease for all the important greasing points.|
Maintenance Schedule for Kawasaki Vulcan 900
Below is the maintenance schedule for the Kawasaki Vulcan 900.
The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.
For convenience, I’ve rounded the converted mileages. Nobody does a service at 15,200 miles (it’s not that precise!) — I’ve written it in as 15,000.
- For higher odometer readings, repeat at the frequency interval established here.
- K: Per Kawasaki “Should be serviced by an authorized Kawasaki dealer”
- #: Service more frequently when operating in severe conditions: dusty, wet, muddy,
high speed, or frequent starting/stopping.
- (e): Emission related item
The maintenance for the Kawasaki Vulcan 900 is broken into three sections:
- Engine Related Items,
- Chassis Related Items, and
- Change/Replacement Items.
1. Periodic inspection (Engine Related Items)
|Operation (Engine Items)||Every||1,000 km (600 mi)||12,000 km (7,500 mi)||24,000 km (15,200 mi)||36,000 km (22,500 mi)||48,000 km (30,000 mi)|
|Valve clearance – inspect (e)||•||•|
|Throttle control system (play, smooth return, no drag) – inspect (e)||year||•||•||•||•||•|
|Idle speed – inspect||•||•||•||•||•|
|K||Fuel leak (fuel hose and pipe) – inspect||•||•||•||•||•|
|K||Fuel hoses damage – inspect||year||•||•||•||•||•|
|K||Fuel hoses installation condition – inspect||year||•||•||•||•||•|
|Coolant level – inspect||year||•||•||•||•||•|
|Coolant leak – inspect||year||•||•||•||•||•|
|Radiator hose damage – inspect||year||•||•||•||•||•|
|Radiator hoses installation condition – inspect||year||•||•||•||•||•|
|Air suction system damage – inspect (e)||•||•||•||•|
|Evaporative emission control system – function (California model only) (e)||•||•|
2. Periodic Inspection (Chassis Related Items)
|Operation (Chassis Items)||Every||1,000 km (600 mi)||12,000 km (7,500 mi)||24,000 km (15,000 mi)||36,000 km (22,500 mi)||48,000 km (30,000mi)|
|Clutch and drive train:|
|Clutch operation (play, engagement, disengagement) – inspect||year||•||•||•||•||•|
|K||Drive belt deflection – inspect (Belt tension tool)||every 6000 km ( 3800 mile)|
|K||Drive belt wear- inspect||every 6000 km ( 3800 mile)|
|Wheels and tires:|
|Tire air pressure – inspect||year||•||•||•||•|
|Wheels/tires damage – inspect||year||•||•||•||•|
|Tire tread wear, abnormal wear – inspect||•||•||•||•|
|K||Wheel bearings damage – inspect||year||•||•||•||•|
|Spoke tightness and rim runout – inspect||•||•: every 6000 km ( 3800 mile)|
|Brake fluid leak – inspect||year||•||•||•||•||•|
|K||Brake hoses damage – inspect||year||•||•||•||•||•|
|Brake pad wear – inspect #||year||•||•||•||•|
|K||Brake hose installation condition – inspect||year||•||•||•||•||•|
|Brake fluid level – inspect (DOT 4 only to top up)||year||•||•||•||•||•|
|Brake operation (effectiveness, play, drag) – inspect||year||•||•||•||•||•|
|Brake light switch operation – inspect||year||•||•||•||•||•|
|K||Front forks/rear shock absorber operation (damping and smooth stroke) – inspect||year||•||•||•||•|
|K||Front forks/rear shock absorber oil leak – inspect||year||•||•||•||•|
|K||Swing arm pivot – lubricate (with lithium soap-based grease)||•||•|
|Uni-trak rocker arm operation – inspect||year||•||•||•||•|
|K||Uni-trak tie rods operation – inspect||year||•||•||•||•|
|K||Uni-trak rocker arm bearings – lubricate||•||•|
|K||Uni-trak tir rods bearings – lubricate||•||•|
|K||Steering play – inspect||year||•||•||•||•||•|
|K||Steering stem bearings – lubricate||2 years||•||•|
|Lights and switches operation – inspect||year||•||•||•||•|
|Headlight aiming – inspect||year||•||•||•||•|
|Side stand switch operation – inspect||year||•||•||•||•|
|Engine stop switch operation – inspect||year||•||•||•||•|
|Chassis parts – lubricate||year||•||•||•||•|
|Bolts and nuts tightness – inspect||•||•||•||•||•|
3. Change/replacement items
|3. Periodic Replacement||Every||1000 km (600 mi)||12000 km (7600 mi)||24000 km (15200 mi)||24000 km (15000 mi)||48000 km (30000 mi)|
|K||Air cleaner element # – replace (e) (KA-9006)||•||•||•||•|
|Engine oil # – change (Kawasaki 10W-40 Engine Oil)||year||•||•||•||•||•|
|K||Oil filter – replace (HF303RC)||year||•||•||•||•||•|
|K||Fuel hoses – replace||5 years|
|K||Coolant – change (Zerex G05)||3 years||•|
|K||Radiator hoses and O-rings – replace||3 years||•|
|K||Brake hoses – replace||4 years|
|K||Brake (front and rear) – change (EBC FA229HH, FA231HH)||2 years||•||•|
|K||Rubber parts of master cylinder and caliper – replace||4 years||•|
|K||Spark plug – replace (e) (NGK CPR7EA-9)||•||•||•||•|
Tyre size and tyre pressure for the Kawasaki Vulcan 900
The Kawasaki Vulcan 900 has the following tyres and tyre sizes standard (tubeless type), and the following recommended tyre pressures.
|Front||130/90-16 M/C 67H||DUNLOP “D404FP”|
|200 kPa/28 psi|
|Rear||180/70 – 15M/C 76H||DUNLOP “D404”|
|Less than 97.5kg/215 lb: 200 kPa/28 psi|
More than 97.5kg/215 lb: 225 kPa/32 psi
General information about the Kawasaki Vulcan 900
The Kawasaki Vulcan 900 has a 903cc V-Twin SOHC Engine tuned to deliver lots of torque from low rpm.
The Vulcan 900 is both liquid and air-cooled, with finned cylinder heads. It helps maintain consistent engine temperatures in a variety of conditions.
The Vulcan 900 has a number of features that make it more modern than rattly cruisers of the past. These include
- Rubber engine mounts to reduces excess engine vibration
- Positive neutral finder to help find neutral at a stop
- Fuel injection with dual throttle bodies. The sub throttles, located behind the main throttle valve, are controlled by the ECU so that the fuel injection system retains a more precise throttle response, similar to a constant velocity carburetor.
- Twin disc brakes
The Vulcan 900 has a very low 26.5-inch seat height that lets even shorter riders easily plant both feet on the ground at stops.
Manual for the Kawasaki Vulcan 900
The above maintenance schedule comes directly from the user’s manual for the 2020 Kawasaki Vulcan 900 Classic, which is available here.