Target Audience:
Owners and mechanics of the 1990 Kawasaki KDX-200, catering to both DIY enthusiasts and professional service centers.
Value Proposition:
Provides comprehensive, professional-grade repair and maintenance information at a significantly lower cost and with greater accessibility than a physical manual.
Content Detail:
Extremely detailed, covering diagnostic procedures, repair steps, and technical specifications essential for restoring or maintaining the motorcycle.
Illustration Quality:
Includes detailed illustrations, drawings, photos, and enlarged insets to aid in part identification and procedural understanding.
Navigation:
Numbered table of contents for quick information retrieval, with bold figure numbers to link text to illustrations.
Electrical Coverage:
Dedicated section for troubleshooting and electrical service procedures, integrated with detailed wiring diagrams.
Engine:
Complete engine overhaul, tuning, carburetor service, cooling system (if applicable), lubrication system.
Transmission:
Clutch operation, gearbox disassembly and reassembly, shift mechanism, transmission fluid checks and changes.
Chassis:
Frame inspection, suspension (forks, rear shock), steering system, wheels, spokes, bearings.
Electrical System:
Ignition system, lighting, charging system, battery, wiring diagrams, troubleshooting electrical faults.
Brakes:
Front and rear brake system maintenance, hydraulic fluid, brake pad replacement, caliper service.
Fuel System:
Fuel tank, fuel lines, fuel filter, carburetor settings and cleaning.
Exhaust System:
Exhaust pipe and muffler inspection and maintenance.
Bodywork And Trim:
Fairings, fenders, seat, handlebars, controls.
Maintenance:
Regular service checks, oil changes, filter replacements, chain adjustment, general lubrication.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based fault finding.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation.
Rebuild:
Detailed procedures for engine and component rebuilds.
Depth:
Comprehensive; suitable for professional technicians and advanced DIY mechanics.
Searchability:
Likely text-searchable within PDF viewer (depends on PDF creation).
Printability:
Full Printable
Binding:
N/A (Digital PDF Download)
Paper:
N/A (Digital PDF Download)
Software Requirements:
Adobe PDF Reader, WinRAR (for potential archives)
Operating Systems:
Compatible with all versions of Windows & Mac
Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
198cc (approximate, based on model heritage)
Bore X Stroke:
Typically around 66.0 x 58.0 mm for this model line.
Compression Ratio:
Around 7.7:1 to 8.0:1 (typical for performance 2-strokes of this era).
Horsepower Estimate:
Approx. 25-30 HP at 7000-8000 RPM (estimated, exact figure may vary).
Torque Estimate:
Approx. 19-22 lb-ft at 6000-7000 RPM (estimated).
Carburetor:
Single Mikuni VM series carburetor (e.g., VM29 or VM30) with KIPS (Kawasaki Integrated Power Valve System).
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Mix:
Premix or oil injection system (check specific model variant).
Dry Weight:
Approximately 220-230 lbs (100-104 kg) (estimated based on model history).
Wet Weight:
Approx. 240-250 lbs (109-113 kg) (with all fluids).
Length:
Around 83.5 inches (2120 mm).
Width:
Around 31.1 inches (790 mm).
Height:
Around 47.6 inches (1210 mm).
Wheelbase:
Around 55.5 inches (1410 mm).
Ground Clearance:
Approx. 12.2 inches (310 mm).
Seat Height:
Approx. 35.4 inches (900 mm).
Crash Test Data:
N/A (Motorcycle, not subject to automotive crash testing standards).
Brakes:
Front: Disc brake; Rear: Disc brake. (No ABS).
Lighting:
Headlight, taillight, brake light, turn signals (may vary by market).
Oil Change:
Every 1,000 miles or 6 months (engine oil/transmission oil). Check manual for specific recommendations.
Air Filter Cleaning:
Every 500 miles or as needed based on riding conditions.
Spark Plug Inspection:
Every 1,000 miles or as needed.
Chain Adjustment:
Every 500 miles or as needed to maintain proper slack.
Engine Oil Type:
2-stroke engine oil, specific JASO FD or TCW3 rated oil (check manual for exact grade and premix ratio if applicable).
Transmission Oil Type:
API GL-4 or GL-5 SAE 80W-90 gear oil.
Coolant Type:
Ethylene glycol-based coolant mixed with distilled water (50/50 ratio) for liquid-cooled models.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Power Valve Sticking:
The KIPS (Kawasaki Integrated Power valve System) can accumulate carbon and stick, leading to poor performance. Regular cleaning is crucial.
Carburetor Fouling:
Carburetors on 2-stroke bikes can be prone to fouling from incorrect fuel/oil mixture or poor quality fuel, requiring periodic cleaning and adjustment.
Clutch Wear:
Heavy use or improper adjustment can lead to premature clutch wear.
Suspension Seals:
Fork seals and rear shock bushings can degrade over time, leading to leaks and reduced damping performance.
Kawasaki Legacy:
Kawasaki has a long-standing reputation for producing high-performance off-road motorcycles, with the KDX line being a prominent part of their motocross and enduro heritage.
Kdx Lineage:
The KDX-200 was part of a popular lineage of off-road bikes known for their potent 2-stroke engines, tractable power delivery, and off-road capability, evolving through various iterations from the early 1980s.
Manufacturing Location:
Typically manufactured in Japan.
Production Period:
The KDX-200 was produced for many years, with the 1990 model representing a specific iteration within its production run.
Model Reputation:
The KDX-200 series was highly regarded in its time for its performance, reliability, and versatility as a trail bike and light enduro machine, often praised by enthusiasts and in period reviews.
Period Reviews:
Likely received favorable reviews in off-road motorcycle publications of the late 1980s and early 1990s for its class-leading power and handling.
