Vehicle Market Segment:
Off-road/Enduro motorcycle, known for its versatility in trail riding and competitive motocross/enduro events.
Key Competitors Era:
Honda CR250R, Yamaha YZ250, Suzuki RM250, KTM EXC models of the late 80s and early 90s.
Vehicle Unique Selling Points:
Liquid-cooled, reed-valve, two-stroke engine; Kayaba USD front forks; Uni-Trak rear suspension; powerful torque delivery for its class; durable chassis.
Manual Benefit To Owner:
Enables owners to perform comprehensive maintenance, repairs, and optimizations, saving costs and ensuring longevity and peak performance of their KDX200.
Engine System:
Complete engine disassembly, assembly, inspection, and repair; carburetor tuning and rebuilding; cooling system (liquid-cooled).
Transmission And Drivetrain:
Clutch operation and service, gearbox inspection and repair, final drive (chain and sprockets).
Chassis And Suspension:
Front fork (USD telescopic) overhaul and service, rear monoshock suspension system inspection and adjustment, frame inspection, steering head bearing service.
Brakes:
Front and rear hydraulic disc brake system service, caliper overhaul, master cylinder service, bleeding procedures.
Electrical System:
Ignition system (CDI), lighting, charging system (stator, regulator/rectifier), wiring diagrams, troubleshooting electrical faults.
Fuel System:
Fuel tank service, petcock operation, fuel line inspection, carburetor (Keihin PWK type) specifications and servicing.
Cooling System:
Radiator, hoses, water pump inspection and service, coolant specifications and capacities.
Exhaust System:
Exhaust pipe and silencer inspection and maintenance.
Wheels And Tires:
Wheel bearing service, spoke tensioning, tire pressure specifications, rim and spoke maintenance.
Preventative Maintenance:
Scheduled maintenance intervals, lubrication points, filter replacement (air, spark plug), chain adjustment.
Troubleshooting Guides:
Systematic diagnostic procedures for common performance issues, starting problems, and system failures.
Engine Rebuild:
Complete top-end and bottom-end overhaul procedures, piston, ring, and cylinder inspection and replacement, crankshaft and connecting rod service.
Suspension Tuning:
Front and rear suspension adjustment procedures for optimal performance based on rider weight and terrain.
Carburetor Adjustment:
Detailed instructions for jetting, float level adjustment, and idle speed control for various atmospheric conditions.
Electrical Diagnostics:
Step-by-step guides for diagnosing ignition, charging, and lighting system faults using multimeters and wiring diagrams.
Brake System Maintenance:
Pad replacement, caliper servicing, master cylinder rebuild, brake fluid flush and bleeding.
Depth Of Information:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete engine and chassis rebuilds.
Diagnostic Tools:
Details required tools for specific diagnostic procedures, including torque wrenches, feeler gauges, and multimeter usage.
Specifications Data:
Extensive torque specifications, clearances, measurements, and tolerances for all critical components.
Digital Format Details:
Searchable text, high-resolution scans for clarity, printable pages.
Print Quality If Applicable:
High-quality reproduction of original factory manual specifications.
Binding Type If Applicable:
Professionally bound for durability in a workshop environment (if sold as print).
Paper Type If Applicable:
Durable paper stock to withstand workshop conditions.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Bore X Stroke:
66.0 x 58.0 mm (approximate for this generation)
Compression Ratio:
7.2:1 (typical)
Valve Mechanism:
Reed valve intake, KIPS (Kawasaki Integrated Powervalve System) exhaust valve
Horsepower:
Approximately 35-40 HP (at crank, varies by year and tuning)
Torque:
Approximately 20-23 lb-ft (at crank, varies)
Carburetor Type:
Keihin PWK (e.g., PWK35 or similar) single carburetor
Fuel Type:
Unleaded gasoline (91+ octane recommended), Pre-mix 2-stroke oil
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., Kawasaki Coolant or equivalent).
2 Stroke Oil Mix Ratio:
Typically 20:1 or 32:1, depending on oil type and usage (refer to manual for specific recommendation).
Length:
Approx. 2,170 mm (85.4 in)
Width:
Approx. 820 mm (32.3 in)
Height:
Approx. 1,220 mm (48.0 in)
Wheelbase:
Approx. 1,435 mm (56.5 in)
Ground Clearance:
Approx. 330 mm (13.0 in)
Dry Weight:
Approx. 106 kg (233.7 lbs)
Wet Weight:
Approx. 116 kg (255.7 lbs) (fully fueled, ready to ride)
Fuel Capacity:
10.5 Liters (2.8 US gal)
Seat Height:
Approx. 945 mm (37.2 in)
Safety Certification Era:
Not applicable for off-road motorcycles in the same way as street vehicles; focused on structural integrity and component reliability.
Braking System Type:
Hydraulic disc brakes front and rear.
Suspension Damping:
Adjustable compression and rebound damping on front forks and rear shock.
Frame Construction:
High-tensile steel perimeter frame for rigidity and impact resistance.
Ergonomics:
Designed for active rider control and stability.
Oil Change Interval Transmission:
Every 20-30 hours of operation or annually (refer to manual for precise intervals).
Air Filter Cleaning:
Clean every 5-10 hours of riding, depending on conditions.
Spark Plug Inspection:
Inspect every 10-15 hours, replace as needed.
Chain And Sprockets Maintenance:
Lubricate every 500-1000 km or after wet riding, adjust tension as needed.
Top End Rebuild:
Recommended every 50-80 hours for optimal performance, or when signs of wear are present.
Coolant Capacity:
Approximately 1.5 Liters (refer to manual for exact capacity).
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation).
Common Wear Items:
Clutch plates, piston rings, spark plugs, chain and sprockets, wheel bearings, suspension seals.
Kips System Maintenance:
Requires periodic cleaning and lubrication of the powervalve mechanism to prevent sticking.
Carburetor Tuning Sensitivity:
Can be sensitive to altitude and temperature changes, requiring occasional re-jetting.
Kawasaki Motorsports Legacy:
Kawasaki has a long and successful history in off-road and motocross racing, with the KDX line being a significant part of that heritage.
Kdx Line Development:
The KDX200 evolved from earlier models, incorporating advancements like liquid cooling, disc brakes, and improved suspension to meet changing demands of off-road riding.
Kawasaki Manufacturing Plant:
Likely manufactured in Japan.
Kdx200 1989 1994 Impact:
This generation represented a significant step forward, solidifying the KDX200's reputation as a capable and competitive trail bike.
