Target Audience:
Owners of 1991 Kawasaki KDX-200 seeking comprehensive repair and maintenance information
Value Proposition:
Provides professional-level technical data and repair guidance, empowering users to maintain and repair their KDX-200 effectively.
Comparison To Oem:
Mirrors or surpasses the depth of information found in official Kawasaki service manuals.
Feature 1:
Instant PDF download for immediate access.
Feature 2:
Printable format for easy workshop use.
Feature 3:
Combines repair, maintenance, and diagnostics in a single document.
Primary Coverage:
Full service, repair, maintenance, and restoration
Diagnostic Coverage:
Comprehensive diagnostic and repair procedures
Electrical Coverage:
Detailed troubleshooting and electrical service procedures with wiring diagrams
Page Count:
Not explicitly stated, but described as 'comprehensive' and 'detailed'
Manual Type:
Full Service Repair Manual
File Format:
PDF Download
Delivery Method:
Instant Download
Printability:
Full Printable
Software Requirements:
Adobe PDF Reader, WinRAR
Compatibility:
All Versions of Windows & Mac
Engine:
Complete engine overhaul, tuning, and troubleshooting
Fuel System:
Carburetor service, fuel tank, fuel lines
Cooling System:
Radiator, hoses, coolant specifications
Ignition System:
Spark plug, ignition coil, CDI unit, timing
Transmission:
Clutch, gearbox, internal components
Suspension:
Front forks (Kayaba/Showa), rear shock absorber, linkage
Brakes:
Front and rear disc brake systems, fluid specifications
Electrical System:
Wiring diagrams, lighting, battery, charging system, sensors
Chassis And Frame:
Frame inspection, steering head bearings
Wheels And Tires:
Wheel bearing service, tire pressure recommendations
Bodywork And Trim:
Fairings, seat, fenders, graphics
Maintenance:
Regular service intervals, oil changes, filter replacements, lubrication
Repair:
Step-by-step repair instructions for all major components
Rebuilding:
Comprehensive engine, transmission, and suspension rebuild procedures
Restoration:
Guidance for refurbishing and restoring the motorcycle to original specifications
Troubleshooting:
Extensive troubleshooting guides for common and uncommon problems
Diagnostics:
Detailed diagnostic procedures for identifying issues
Depth:
Suitable for professional technicians and experienced DIY mechanics
Detail Level:
Detailed sub-steps, notes, cautions, and warnings
Type Of Illustrations:
Detailed illustrations, drawings, and photos
Illustration Features:
Enlarged insets for detailed part examination
Navigation:
Numbered table of contents for quick information retrieval
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
198 cc (Cubic Centimeters)
Bore X Stroke:
66.0 x 58.0 mm
Valvetrain:
ATAC (Automatic Torque Amplification Chamber) system
Horsepower:
Approximately 35-40 HP (at Crankshaft, estimated)
Torque:
Not explicitly stated, but characteristic of a potent 2-stroke single
Carburetor:
Keihin PWK33 (likely, common for this model)
Fuel Type:
Unleaded gasoline (min. 91 octane recommended)
Oil Mixture:
Pre-mix (50:1 ratio with high-quality 2-stroke oil)
Cooling Type:
Liquid-cooled
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Transmission Type:
6-speed constant mesh
Clutch:
Wet, multiple-disc, cable-actuated
Gear Ratios:
Detailed gear ratios available within the manual
Transmission Oil:
Kawasaki specified gear oil or equivalent (e.g., SAE 80W-90)
Length:
Approximately 2180 mm (85.8 in)
Width:
Approximately 800 mm (31.5 in)
Height:
Approximately 1230 mm (48.4 in)
Dry Weight:
Approximately 107 kg (236 lbs)
Gross Weight:
Not specified, but typically around 120-130 kg with fluids and rider
Front Tire Size:
80/100-21 48M
Rear Tire Size:
110/100-18 64M
Wheelbase:
Approximately 1440 mm (56.7 in)
Fuel Tank Capacity:
10 Liters (2.6 Gallons)
Safety Ratings:
Motorcycles are not typically subject to the same formal safety ratings as cars; focus is on operational safety and design integrity.
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Frame Construction:
Robust perimeter frame designed for off-road durability and handling.
Lighting:
Headlight, taillight, and brake light for visibility.
Oil Change Interval:
Recommended every 1,000-1,500 miles or annually, as detailed in the manual.
Spark Plug Inspection:
Inspect at 1,000-mile intervals, replace as needed.
Air Filter Cleaning:
Clean or replace at regular intervals, especially in dusty conditions.
Chain Lubrication Adjustment:
Lubricate and adjust drive chain at 500-mile intervals.
Coolant Flush:
Recommended every 2 years or as per manual specifications.
Engine Oil Type:
High-quality 2-stroke engine oil, mixed with fuel at 50:1 ratio.
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid (check manual for specific recommendation)
Coolant:
Kawasaki specific coolant or a 50/50 mix of ethylene glycol and distilled water.
Typical Wear Items:
Piston rings, clutch plates, swingarm bearings, fork seals are common wear items on older two-stroke dual-sports.
Power Valve Sticking:
The ATAC system, while enhancing low-end power, can sometimes suffer from carbon buildup leading to sticking, affecting engine performance. The manual will detail cleaning procedures.
Carburetor Tuning:
Two-stroke carburetors require periodic tuning and cleaning, especially when altitude or environmental conditions change. The manual provides jetting information.
Kawasaki Legacy:
Kawasaki has a long-standing reputation for performance-oriented motorcycles, particularly in the off-road and dual-sport segments.
Kdx Lineage:
The KDX series has been a cornerstone of Kawasaki's off-road lineup, known for its powerful two-stroke engines and trail-riding capability. The 1991 model represents an evolution of the platform, incorporating refinements for improved performance and reliability.
Production Period:
The KDX-200 was produced from the mid-1980s through the late 1990s, with significant updates and revisions throughout its run. The 1991 model falls within the second generation of this popular dual-sport machine.
