Target Audience:
Kawasaki KDX200 owners, mechanics, and enthusiasts seeking detailed repair information
Value Proposition:
Provides dealership-level repair information at a competitive price, offering instant digital access
Dealer Equivalent:
Corresponds to the official service manuals used by Kawasaki dealerships
Accessibility:
Instant download, eliminating shipping delays
Engine:
Comprehensive engine overhaul, tuning, and diagnostics
General Information:
Vehicle identification, safety precautions, general maintenance tips
Transmission:
Clutch, gearbox, and final drive system servicing
Chassis:
Frame, bodywork, and associated components
Lighting:
Headlight, taillight, and indicator system diagnostics and repair
Steering:
Handlebars, steering stem, bearings, and fork assembly
Seats System:
Seat mounting and removal procedures
Clutch:
Clutch operation, adjustment, and component replacement
Suspension:
Front fork (USD telescopic) and rear shock absorber servicing, adjustment, and rebuilds
Locks:
Ignition and steering lock mechanisms
Brakes:
Front and rear disc brake system servicing, including master cylinders, calipers, and fluid bleeding
Lubrication:
Lubrication points, fluid types, and capacities
Electrical:
Wiring diagrams, ignition system, charging system, starting system, and component testing
Frame:
Frame integrity checks and repair considerations
Fuel System:
Carburetor (likely Mikuni VM series) disassembly, cleaning, tuning, and fuel tank servicing
Battery:
Battery maintenance, charging, and replacement
Maintenance:
Regular scheduled maintenance, fluid changes, filter replacements, chain adjustment
Troubleshooting:
Diagnostic procedures for common problems and system failures
Repair:
Detailed step-by-step repair instructions for all major and minor components
Rebuild:
Complete engine and component rebuild procedures with torque specifications
Depth:
Comprehensive, suitable for dealership technicians and advanced DIY enthusiasts
Compatibility:
PC and Mac compatible
Searchability:
Likely text-searchable PDF
File Size:
Up to 1 GB (high-speed internet recommended)
Printable:
Printable sections or entire manual
Suggested Binding:
3-ring binder (for printed copies)
Recommended Paper:
Standard printer paper (for printed copies)
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
198cc (approximate, depending on specific KDX200 variants within the model range)
Bore X Stroke:
Typically around 66.0 x 58.0 mm (for later models, consult manual for exact figures)
Compression Ratio:
Varies by year, often around 7.1:1 to 7.7:1
Horsepower:
Approximately 35-40 HP at peak RPM (varies by year and tuning)
Torque:
Approximately 23-27 lb-ft at peak RPM (varies by year)
Carburetor Type:
Mikuni VM Series (e.g., VM29 or VM30, year dependent)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Mixture:
Premixed fuel/oil or separate oil injection system (depending on year/model variant)
Length:
Varies by year, typically around 2150 mm
Width:
Varies by year, typically around 800 mm
Height:
Varies by year, typically around 1230 mm
Dry Weight:
Approximately 100-106 kg (depending on year and equipment)
Curb Weight:
Approximately 110-115 kg (with all necessary fluids)
Oil Change:
Every 1000-2000 miles or 6-12 months (refer to manual for specific recommendations)
Spark Plug Replacement:
Every 2000-4000 miles or annually
Air Filter Cleaning:
Frequent cleaning required, especially after dusty conditions (e.g., every 5-10 hours of use)
Chain Lubrication Adjustment:
Every 500 miles or as needed
Coolant Type:
Permanent type anti-freeze coolant (e.g., ethylene glycol based)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
2-Stroke Oil Type:
High-quality 2-stroke engine oil specifically formulated for air-cooled or liquid-cooled high-performance engines (e.g., Motul 800, Yamalube 2R)
Carburetor Clogging:
Can be prone to jetting issues or clogging from fuel degradation if not stored properly
Power Valve Sticking:
2-stroke power valves can accumulate carbon and stick, affecting performance; regular cleaning is advised
Suspension Seals:
Fork and shock seals can wear over time, leading to leaks; rebuilds are part of routine maintenance