Vehicle Category:
Off-Road / Enduro Motorcycle
Target Audience:
Enthusiasts and owners of the Kawasaki KDX 200 from 1989-1994 seeking detailed repair and maintenance guidance.
Segment Competitors:
Competed against other 200cc-class enduro bikes from brands like Yamaha (YZ250, WR250), Honda (CR250, XR250), and Suzuki (RM250, DR250).
Model Reputation:
Known for its strong performance for its displacement, reliability, and versatility in both trail riding and competitive enduro events.
Manual Value Proposition:
Provides essential technical data and procedures to maintain, diagnose, and repair the KDX 200, saving on labor costs and ensuring proper functionality.
Primary Coverage:
Engine, Chassis, Electrical Systems, Bodywork, Troubleshooting
Specific Systems:
Engine (top-end, bottom-end, cooling, lubrication), Fuel System (carburetor, fuel tank), Ignition System, Transmission, Clutch, Drive Chain, Suspension (front forks, rear shock), Brakes (front and rear), Wheels and Tires, Electrical System (lighting, wiring diagrams, battery), Frame, Body Panels, Exhaust System, Seat, Handlebars
Estimated Page Count:
Refer to product listing for exact count, typically 300-500 pages for this type of manual
Manual Type:
Service/Workshop/Repair Manual
Accessibility:
Instant download allows immediate access to repair information.
Engine Overhaul:
Complete disassembly, inspection, reassembly of engine components including cylinder, piston, crankshaft, connecting rod, and all associated seals and gaskets.
Transmission Repair:
Gearbox disassembly, inspection, and reassembly, including shift drum, forks, and gears. Clutch service and adjustment procedures.
Suspension Service:
Front fork seal replacement, oil changes, spring rate information, and rear shock absorber service. Linkage maintenance where applicable.
Brake Maintenance:
Front and rear brake pad replacement, caliper service, hydraulic fluid bleeding procedures, and inspection of brake lines and master cylinders.
Electrical Diagnostics:
Detailed wiring diagrams, troubleshooting charts for common electrical faults, lighting system service, ignition system diagnostics.
Routine Maintenance:
Oil change intervals and specifications, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, tire pressure checks.
Troubleshooting Guides:
Systematic diagnostic procedures for common performance issues, starting problems, and electrical faults.
Component Rebuilds:
Detailed step-by-step instructions for rebuilding major components like the carburetor, engine, and brake calipers.
Specifications Charts:
Torque specifications for all fasteners, engine clearances, fluid capacities, and tire pressure recommendations.
Frame And Body Repair:
Instructions for body panel removal/installation, frame inspection, and potentially minor frame straightening if applicable.
Depth Of Coverage:
Comprehensive from basic rider maintenance to full engine and transmission rebuilds, including electrical system diagnostics.
Diagnostic Capabilities:
Detailed troubleshooting trees and diagnostic flowcharts for identifying and resolving mechanical and electrical issues.
Electrical Schematics:
Includes detailed electrical schematics/wiring diagrams for all lighting, ignition, and accessory circuits.
Scope:
Comprehensive repair and service manual, equivalent to a factory service manual (FSM) for this model.
PDF Quality:
High resolution for clear text and diagrams, searchable text for easy navigation.
Searchable Text:
Yes, the PDF is typically text-searchable for quick access to information.
Printability:
Designed for easy printing of individual sections or the entire manual.
Diagram Clarity:
High-quality diagrams, illustrations, and exploded views essential for repair procedures.
Binding Type:
N/A (Downloadable PDF)
Paper Type:
N/A (Downloadable PDF)
Engine Type:
2-Stroke, Liquid-Cooled, Reed Valve
Bore X Stroke:
66.0 x 58.0 mm
Compression Ratio:
7.8:1 (approx.)
Power Output:
Approximately 35-40 HP (exact figures vary by year and tuning)
Torque:
Approximately 23-26 lb-ft (exact figures vary by year and tuning)
Engine Cooling:
Liquid-cooled with radiator and fan (or thermostatically controlled fan depending on specific year/variant).
Power Delivery:
Strong mid-range powerband characteristic of KDX models, suitable for trail riding and aggressive off-road use.
Carburetor Model:
Keihin PWK (typically 33mm for most years)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Mixture:
Requires 2-stroke oil mixed with gasoline (specific ratio detailed in manual).
Overall Length:
Refer to specific year specifications in manual, generally around 2160-2200 mm
Overall Width:
Refer to specific year specifications in manual, generally around 800-830 mm
Overall Height:
Refer to specific year specifications in manual, generally around 1210-1250 mm
Wheelbase:
Refer to specific year specifications in manual, generally around 1430-1450 mm
Dry Weight:
Approximately 105-108 kg (231-238 lbs)
Wet Weight:
Not typically specified, but significantly higher than dry weight.
Safety Standards:
As an off-road motorcycle, designed for closed-course competition and off-road use, not subject to typical road vehicle safety ratings.
Braking System:
Hydraulic disc brakes front and rear for effective stopping power in off-road conditions.
Chassis Design:
Steel frame designed for durability and rider control during aggressive off-road riding.
Infotainment System:
N/A (Off-road motorcycle, no infotainment system)
Driver Assistance Features:
N/A (Off-road motorcycle, no driver assistance features)
Connectivity Features:
N/A (Off-road motorcycle, no connectivity features)
Engine Oil Change:
Every 15-20 hours of riding or annually. Refer to manual for specific procedure and oil type.
Air Filter Cleaning:
After every few rides or as needed based on conditions. Manual details cleaning and re-oiling.
Spark Plug Replacement:
Every 20-30 hours of riding or as recommended by manual. Specific plug type and gap detailed.
Chain Lubrication:
Before every ride, or more frequently in wet/dirty conditions. Manual covers adjustment as well.
Clutch Adjustment:
Check and adjust clutch free play regularly, typically every few hundred miles or as needed for optimal engagement.
Engine Oil:
Premix 2-stroke oil, SAE 10W-30 for gearbox/clutch lubrication (refer to manual for exact specifications).
Coolant Type:
Mixture of distilled water and ethylene glycol-based antifreeze. Specific ratio and capacity in manual.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for exact specification).
Common Wear Items:
Piston rings, spark plug, chain and sprockets, wheel bearings, fork seals, exhaust packing.
Carburetor Tuning:
Can require periodic cleaning and jetting adjustments based on altitude and riding conditions. Manual provides detailed carburetor service.
Exhaust Pipe Damage:
Off-road riding can lead to dents or damage to the exhaust pipe. Manual covers inspection and potential repairs.
Kawasaki Legacy:
Kawasaki has a long history of producing high-performance motorcycles, including a strong presence in motocross and enduro racing.
Kdx Lineage:
The KDX line is renowned for its off-road prowess, with the KDX 200 being a popular and long-standing model known for its blend of power and manageable handling.
Generation Notes:
The 1989-1994 generation saw continuous refinement, including updates to suspension, engine tuning, and chassis components to maintain competitiveness.
Production Period:
The KDX 200 model range was produced for many years, with this specific manual covering the key mid-to-late 1980s and early 1990s iterations.
