The Kawasaki KDX 200 is a versatile All-Terrain Vehicle (ATV) celebrated for its robust engineering and spirited performance, particularly in off-road environments. Produced across a significant period from 1989 to 1999, this model is recognized for its liquid-cooled, two-stroke engine, capable Kayaba suspension components, and reliable disc braking system. Its design emphasizes rider control and durability, making it a favored choice for both entry-level and intermediate riders seeking a capable machine for various terrain types. The KDX 200 line has a strong legacy within Kawasaki's powersports offerings, known for a balance of performance, affordability, and ease of maintenance, distinguishing it among its contemporaries.
This comprehensive Factory Service Repair Manual provides in-depth technical information essential for the maintenance, repair, and diagnosis of Kawasaki KDX 200 ATVs from 1989 through 1999. It covers a wide array of critical systems, including the engine (top end, right side, bottom end, transmission), fuel system, cooling system, final drive, wheels, tires, brakes, suspension, steering, and electrical system. The manual details diagnostic procedures, routine maintenance schedules, component removal and installation, adjustments, and troubleshooting guides. Its extensive coverage, presented in a searchable format, equips owners, mechanics, and technicians with the necessary knowledge to ensure the optimal performance and longevity of their KDX 200.
Vehicle Type:
All-Terrain Vehicle (ATV)
Engine Family Code:
KDX200
Segment:
Entry-level to intermediate off-road performance ATV, known for its versatility and capability in various terrain types.
Competitors:
Competed with models such as Yamaha Warrior, Suzuki LT-Z series, and Honda TRX series during its production run, offering a balance of performance and affordability.
Model Highlights:
Liquid-cooled, two-stroke engine, Kayaba suspension components, disc brakes, aggressive off-road styling, and a reputation for reliability and ease of maintenance.
Suspension System:
Equipped with robust suspension, typically adjustable front forks and a rear monoshock, providing good off-road capability. Manual details setup and maintenance.
Model Years Covered:
1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Estimated Page Count:
Extensive (Specific number not provided, but consistent with factory service manuals covering over a decade of model variations)
Type:
Factory Service Repair Manual
Searchability:
Fully bookmarked and searchable PDF, allowing users to quickly locate specific information by keywords.
Primary Systems:
Engine (Top End, Right Side, Bottom End, Transmission), Fuel System, Cooling System, Final Drive, Wheels & Tires, Brakes, Suspension, Steering, Electrical System
Appendix Contents:
The Appendix section typically includes valuable technical data such as torque specifications, wiring diagrams, troubleshooting charts, and special tool requirements, enhancing the diagnostic capabilities of the manual.
Electrical System Detail:
Comprehensive coverage of the electrical system, including wiring diagrams, component testing (ignition, lighting, charging system), and troubleshooting electrical faults.
Repair And Maintenance:
Diagnostic procedures, repair instructions, routine maintenance, component removal and installation, adjustments, troubleshooting guides, specifications
Diagnostic Procedures:
Includes systematic troubleshooting guides for common performance issues, electrical faults, and mechanical problems, aiding in efficient problem diagnosis.
Depth:
Comprehensive factory-level technical information, suitable for both experienced technicians and dedicated enthusiasts. Covers detailed component disassembly, inspection, repair, and reassembly procedures.
Additional Formats:
Included within a WINRAR archive for extraction.
Compatibility:
Compatible with a wide range of operating systems including Windows (95 through 10), Linux, and macOS.
Printability:
Fully printable, allowing users to print specific sections or the entire manual as needed.
Binding:
Digital Download (PDF) - No physical binding.
Paper Type:
Not Applicable (Digital Format).
Engine Type:
Liquid-cooled, 2-stroke, reed valve, piston-port induction
Displacement:
198 cc (approximate, exact for specific year may vary slightly)
Bore X Stroke:
64.0 x 62.0 mm (typical for KDX200)
Compression Ratio:
7.1:1 (typical for early models, subject to change)
Carburetion:
Single Mikuni VM28SS (typical, may vary by year)
Horsepower Estimate:
Approximately 30-35 HP (at crankshaft, varies by year and tuning)
Engine Cooling System:
Liquid-cooled, with radiator and fan (if applicable to specific year). The manual details the cooling system components, flush procedures, and coolant specifications.
Fuel Type:
Unleaded gasoline (87 octane or higher recommended, pre-mix with 2-stroke oil)
Fuel Tank Capacity:
Approximately 2.6 US gallons (9.8 L, subject to change)
Final Drive Type:
Chain drive. Manual covers chain inspection, adjustment, lubrication, and replacement procedures.
Gearbox Lubrication:
Specific transmission fluid type and capacity are crucial for longevity and smooth operation, detailed in the manual.
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multi-disc
Gear Ratios:
Specific gear ratios are detailed within the manual, essential for performance tuning and diagnostics.
Overall Length:
Approximately 70.5 inches (1790 mm, subject to change)
Overall Width:
Approximately 45.3 inches (1150 mm, subject to change)
Overall Height:
Approximately 42.7 inches (1085 mm, subject to change)
Wheelbase:
Approximately 49.2 inches (1250 mm, subject to change)
Front Tire Size:
Typically 21 x 7-10. Manual specifies recommended tire pressures.
Rear Tire Size:
Typically 20 x 10-9. Manual specifies recommended tire pressures.
Dry Weight:
Approximately 368 lbs (167 kg, subject to change)
Curb Weight:
Not explicitly stated but typically higher than dry weight due to fluids.
Ground Clearance:
Approximately 7.9 inches (200 mm, subject to change)
Safety Certifications:
Designed to meet industry safety standards for ATVs; specific ratings for this era may not be directly comparable to modern automotive standards.
Braking System:
Front: Dual hydraulic disc; Rear: Single hydraulic disc. Manual provides detailed inspection and servicing procedures.
Chassis Design:
Robust frame construction designed for off-road durability. Handlebar design and seating position contribute to rider control.
Infotainment System:
Not Applicable - Basic analog instrumentation (speedometer, odometer, indicator lights) is typical for this model.
Rider Aids:
No electronic rider aids such as ABS, traction control, or ride modes are present on this model; it relies on rider skill and mechanical capability.
Connectivity Features:
Not Applicable - No digital connectivity features.
Typical Maintenance:
The manual outlines detailed service intervals for engine oil changes, spark plug checks, air filter cleaning/replacement, chain lubrication, brake fluid checks, and suspension servicing. Specific intervals are year-dependent and provided within the document.
Ignition System Maintenance:
Manual details spark plug type, gap settings, and replacement intervals. It also covers ignition coil and CDI unit testing procedures.
Engine Oil Type:
Kawasaki recommends specific grades of 2-stroke engine oil for pre-mix lubrication (e.g., SAE 10W-30 API TC, JASO FD) and transmission oil (e.g., SAE 10W-40 API GL-4).
Coolant Type:
Kawasaki specifies a specific mixture of ethylene glycol-based antifreeze and distilled water for its liquid-cooled engines.
Common Wear Points:
Based on the KDX 200's design, common wear points often include the piston rings, cylinder bore, clutch plates, wheel bearings, and suspension bushings. The manual addresses inspection and replacement of these components.
Carburetor Maintenance:
Carburetor cleaning and adjustment, particularly the Mikuni VM28SS, is a frequent maintenance task to ensure optimal performance and fuel delivery.
Clutch Troubleshooting:
The manual provides detailed steps for clutch adjustment, inspection of clutch plates and springs, and replacement procedures to address slipping or engagement issues.
Kawasaki Atv Legacy:
Kawasaki has a long-standing reputation in the powersports industry, including a significant history with off-road motorcycles and ATVs, known for performance and innovation.
Kdx Series Development:
The KDX 200 was a cornerstone of Kawasaki's off-road ATV lineup, evolving through various iterations during its production run, with this manual covering a significant period of its development.
Kdx200 Updates:
Over its production run, the KDX 200 received various updates including chassis refinements, engine tuning adjustments, and styling changes, all covered by the detailed sections of this manual.
Production Period:
The KDX 200 model line, including variants, was produced from the early 1980s through the early 2000s, with this manual specifically covering the 1989-1999 models.
