Target Audience:
Professional technicians and advanced do-it-yourself mechanics with basic electrical and mechanical knowledge.
Comparison To Paper:
Essentially identical in content to a printed factory service manual, offering the advantage of instant digital access and portability.
Features:
Step-by-step repair procedures, critical specifications, illustrations/pictures, maintenance schedules, disassembly/assembly guides, and troubleshooting tips.
Knowledge Transfer:
Aims to impart factory-trained technician knowledge, enabling owners to make informed maintenance and repair decisions.
Engine:
Detailed breakdown of the 199 cc liquid-cooled, two-stroke engine, including carburetor, ignition system, cooling system, lubrication, and internal components.
Transmission:
Service procedures for the six-speed constant mesh transmission, clutch, and drive chain.
Suspension:
In-depth coverage of front telescopic forks (including KIPS - Kawasaki Integrated Power-valve Control System), rear Uni-Trak suspension, and associated adjustments.
Brakes:
Front and rear brake system maintenance, including hydraulic disc brake service and component replacement.
Electrical:
Wiring diagrams, ignition system troubleshooting, lighting, battery, and charging system.
Fuel System:
Carburetor disassembly, cleaning, adjustment, and troubleshooting for optimal fuel delivery.
Cooling System:
Radiator, hoses, coolant, and water pump service for the liquid-cooled engine.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, and fuel tank service.
Maintenance:
Regularly scheduled maintenance, including oil changes, filter replacements, chain lubrication, and general inspection.
Troubleshooting:
Systematic diagnostic procedures for common issues, covering performance problems, starting difficulties, and electrical faults.
Repair:
Step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major systems.
Disassembly And Assembly:
Detailed guidance on taking apart and putting back together various vehicle components.
Cleaning And Reinstalling:
Proper methods for cleaning parts during service and correct reinstallation procedures.
Depth:
Comprehensive, covering basic DIY maintenance to advanced engine and transmission rebuilds, suitable for both hobbyists and professional technicians.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
199 cc (12.1 cu in)
Bore X Stroke:
66.0 x 58.0 mm (2.60 x 2.28 in)
Compression Ratio:
7.1:1 (typical for this era)
Horsepower:
Approximately 35-40 HP (exact figures may vary by region and tuning)
Torque:
Not readily specified in general product info, but substantial low-to-mid range torque characteristic of off-road engines.
Carburetor:
Mikuni VM29SS (typical, manual will specify exact model and jetting)
Fuel Type:
Unleaded gasoline (high octane recommended for optimal performance)
Fuel Mixture:
Pre-mix (e.g., 20:1 or 32:1 ratio of gasoline to 2-stroke oil, manual will specify)
Ignition:
CDI (Capacitor Discharge Ignition)
Length:
Approximately 2,145 mm (84.4 in)
Width:
Approximately 810 mm (31.9 in)
Height:
Approximately 1,215 mm (47.8 in)
Wheelbase:
Approximately 1,440 mm (56.7 in)
Dry Weight:
Approximately 108 kg (238 lbs)
Oil Change:
Refer to manual for specific interval, typically after a set number of riding hours or miles. Gear oil changes also critical.
Air Filter:
Frequent cleaning and oiling recommended, especially in dusty conditions, as detailed in the manual.
Spark Plug:
Check and clean/replace as per manual recommendations, often based on hours or performance issues.
Engine Oil Type:
Kawasaki recommends specific 2-stroke engine oil (e.g., SAE 10W-30 or 20W-40 depending on temperature) for premix and injector (if equipped). Manual is the definitive source.
Gear Oil Type:
Kawasaki Gear Oil GL-4 SAE 80W-90 is typically specified. Manual will confirm exact grade and capacity.
Coolant Type:
Permanent type antifreeze (ethylene glycol based) mixed with distilled water. Manual will specify ratio and capacity.
Carburetor Fouling:
Common with 2-stroke engines, requiring periodic cleaning and adjustment to maintain optimal performance. Manual details the process.
Kips System Maintenance:
The KIPS power valve system requires periodic cleaning and inspection to ensure proper operation. Manual provides detailed procedures.
Clutch Wear:
Clutch plates can wear over time, affecting engagement. Manual guides on inspection and replacement.
Suspension Seals:
Fork and shock seals can degrade, leading to leaks. Regular inspection and replacement are key, as described in the manual.
Kawasaki Offroad:
Kawasaki has a strong heritage in off-road racing and recreational vehicles, with the KDX line being a significant part of its history in enduro and trail riding.
Kdx Line:
The KDX-200 was a popular model in Kawasaki's line of off-road motorcycles, known for its blend of performance and usability for trail riding and light enduro competition. It evolved significantly through various iterations.
Production Era:
The KDX-200 model, including this 1992 variant, was produced across several years in the late 1980s and 1990s, catering to the demands of the off-road market.
