Market Segment:
Performance-oriented off-road/enduro motorcycle.
Target Audience:
Enthusiasts, off-road riders, dual-sport users, mechanics, and owners requiring detailed maintenance and repair information.
Key Competitors:
Yamaha YZ250, Honda CR250R, Suzuki RM250 (during the same era).
Vehicle Strengths:
Lightweight chassis, strong powerband, capable suspension, reliable two-stroke engine, dual-sport versatility (depending on configuration).
Manual Utility:
Essential resource for maintaining peak performance, diagnosing issues, and performing cost-effective repairs, extending the lifespan of the KDX200.
Engine:
Complete engine overhaul, top-end rebuild (cylinder, piston, rings, head), bottom-end rebuild (crankshaft, connecting rod, bearings), cooling system (liquid-cooled), lubrication system.
Fuel System:
Carburetor (Mikuni VM series typically), fuel tank, fuel lines, fuel petcock, fuel filter.
Ignition System:
CDI ignition, spark plug, ignition coil, stator, flywheel, timing.
Transmission:
Gearbox inspection, disassembly, assembly, clutch (wet multi-plate), shift mechanism.
Drivetrain:
Final drive (chain and sprockets), chain adjustment and replacement, countershaft sprocket.
Suspension:
Front fork (USD - Upside Down forks typically), rear shock absorber (Uni-Trak system), fork seal replacement, fork oil change, shock linkage maintenance.
Brakes:
Front disc brake, rear drum brake (early models), rear disc brake (later models), brake caliper service, master cylinder service, brake fluid flush, pad replacement.
Electrical System:
Lighting system (headlight, taillight, indicators), wiring diagrams, battery, charging system (stator/regulator/rectifier), fuses, switches.
Cooling System:
Radiator, hoses, coolant, water pump, thermostat (if applicable).
Frame And Bodywork:
Frame inspection, fairings, seat, handlebars, footpegs, fenders, exhaust system.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain lubrication, spark plug checks, general inspection.
Troubleshooting:
Diagnostic procedures for common starting problems, running issues, electrical faults, and performance degradation.
Repair:
Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.
Assembly Disassembly:
Complete guidance on taking apart and putting back together all major mechanical and electrical components.
Specifications:
Torque specifications for critical fasteners, clearances, tolerances, and fluid levels.
Wiring Diagrams:
Comprehensive electrical schematics for all model years and variations.
Tool Requirements:
Lists of specialized tools and standard tools required for various repair procedures.
Depth Level:
Comprehensive, covering everything from basic owner maintenance to full engine and transmission rebuilds, including advanced diagnostics and chassis work.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
198 cc (for most variants)
Bore X Stroke:
66.0 x 58.0 mm (typical, verify for specific year/model)
Compression Ratio:
Approx. 7.4:1 to 7.8:1 (varies slightly by year)
Ignition:
Digital CDI (Capacitor Discharge Ignition)
Valve Mechanism:
Reed valve intake, KIPS (Kawasaki Integrated Power-valve System) exhaust power valve.
Horsepower Approx:
35-40 HP (estimated, actual output varies)
Torque Approx:
25-30 lb-ft (estimated, actual output varies)
Carburetor Type:
Mikuni VM28SS (common for most years)
Fuel Type:
Unleaded gasoline (Octane rating 91 or higher recommended)
Oil Mixture:
Pre-mix: 20:1 or 32:1 ratio of gasoline to 2-stroke oil (refer to manual for exact specification).
Oil Type:
High-quality 2-stroke motorcycle engine oil meeting JASO FD or ISO-L-EGD standards.
Oil Capacity Premix:
N/A (mixed with fuel)
Length:
Varies by year, approx. 2150-2200 mm
Width:
Varies by year, approx. 800-850 mm
Height:
Varies by year, approx. 1230-1260 mm
Wheelbase:
Approx. 1430-1440 mm
Ground Clearance:
Approx. 300-330 mm
Dry Weight:
Approx. 106-110 kg
Wet Weight:
Approx. 115-120 kg (with fluids)
Front Tire Size:
80/100-21 (common, verify for specific model)
Rear Tire Size:
100/100-18 or 110/100-18 (common, verify for specific model)
Engine Oil Change:
Every 10-15 hours of riding, or every 1-2 months, whichever comes first.
Air Filter Cleaning:
Before every ride or as needed, depending on riding conditions.
Spark Plug Inspection:
Every 20-30 hours of riding.
Chain And Sprockets Lubrication:
Every 5-10 hours of riding, and after washing.
Chain Tension Adjustment:
As needed, check regularly for proper slack.
Fork Oil Change:
Every 12-24 months or 50-100 hours of riding.
Brake Fluid Flush:
Every 12-24 months.
Fork Oil Type:
Specific viscosity grade for front fork oil (e.g., Showa SS-8 or equivalent, typically 5W or 10W).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (non-silicone based).
Common Wear Items:
Clutch plates, piston rings, wheel bearings, steering head bearings, swingarm bearings, fork seals, exhaust packing.
Kips System Maintenance:
Requires regular cleaning and adjustment to prevent performance issues.
Carburetor Cleaning:
Mikuni carbs can require periodic cleaning due to fuel deposits, especially with ethanol fuels.
Cooling System Maintenance:
Check coolant levels and hose integrity regularly to prevent overheating.
Kawasaki Legacy:
Kawasaki has a long history of producing high-performance motorcycles, particularly in the off-road and motocross segments.
Kdx Lineage:
The KDX line has been a staple for Kawasaki in the off-road market, evolving from earlier models to incorporate advancements like liquid cooling and power valves.
1989-1994 Updates:
This generation saw significant updates, including the adoption of USD front forks, improved KIPS power valve systems, chassis refinements, and styling updates to keep pace with competitor technology.
Production Period:
The KDX200 was produced for many years, with the 1989-1994 period representing a distinct and popular iteration.
Manufacturing Location:
Japan (primary)
