Kawasaki KDX-200 1994 Repair Service Manual

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Type: Motorcycle

Vendor:

Sku: 58346

Tags: 1994 Kawasaki KDX Models KDX-200 Motorcycle Motorcycles

Product variants

Description

The 1994 Kawasaki KDX-200 is a capable off-road motorcycle renowned for its reliable two-stroke engine and agile handling, offering strong performance for enduro and dual-sport applications. Building on Kawasaki's established reputation for performance and innovation in the off-road segment, this model represents a refined iteration of the celebrated KDX lineage. Its design prioritizes robust off-road capability and a competitive spirit, making it a favored choice for riders seeking a potent and versatile machine. This comprehensive service manual provides essential information for the professional technician and experienced DIY mechanic. It covers all aspects of repair and maintenance, including detailed procedures for the engine, transmission, chassis, electrical, and braking systems. The manual offers step-by-step instructions, critical specifications, and troubleshooting guidance to ensure the KDX-200 is maintained in optimal condition, empowering owners to perform routine servicing and complex repairs.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KDX-200

Year:

Vehicle Type:

Off-Road Motorcycle / Dual-Sport

Category:

Enduro/Off-Road

👋 Introduction

Market Position

Market Segment:

Competitive entry-level to mid-range off-road/enduro motorcycle

Competitive Analysis

Competitors:

Yamaha YZ/WR series, Honda CR/CRF series, Suzuki RM/RMX series, KTM EXC series

Key Features

Key Selling Points:

Reliable two-stroke engine, capable off-road performance, dual-sport potential with proper modification

Manual Value Proposition

Value For Owner:

Empowers owners to perform maintenance and repairs, saving costs and ensuring longevity

📋 Manual Details

Coverage Areas

Coverage Type:

Comprehensive Repair and Service

Intended Audience:

Professional Technicians and Experienced DIY Mechanics

Page Count

Page Count:

Unknown (PDF document size varies)

Manual Type

Manual Type:

Service Manual / Repair Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

File Format:

Print Quality:

Full Printable

Zoom Capability:

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinZip

Compatibility

Operating Systems:

All Versions of Windows & Mac

📖 Manual Coverage

Systems Covered

Engine System:

Complete overhaul, top-end, bottom-end, cooling, lubrication, ignition, fuel delivery

Transmission System:

Clutch, gearbox internal components, shifting mechanism, lubrication

Chassis System:

Frame, suspension (front forks, rear shock), steering, swingarm

Electrical System:

Wiring diagrams, lighting, charging system, ignition system, component testing

Braking System:

Front and rear brake assembly, hydraulic system, disc and caliper servicing

Fuel System:

Carburetor disassembly, cleaning, adjustment, fuel tank, fuel lines

Exhaust System:

Muffler, header pipe, mounting, maintenance

Cooling System:

Liquid cooling system components, radiator, water pump, coolant specifications

Wheels And Tires:

Wheel bearing service, tire installation, spoke tensioning

Bodywork:

Fairings, fenders, seat, tank removal and installation

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication

Disassembly:

Component-level disassembly and identification

Assembly:

Reassembly procedures with torque specifications

Cleaning:

Cleaning procedures for various engine and chassis components

Reinstalling:

Proper installation of serviced components

Troubleshooting:

Diagnostic procedures for common faults and issues

Rebuilding:

Detailed instructions for engine and component rebuilding

Adjustments:

Carburetor, clutch, brake, and suspension adjustments

Technical Depth

Depth Level:

Comprehensive, covering routine maintenance to complete engine and transmission rebuilds

Detail Level:

Step-by-step instructions, detailed illustrations/pictures, critical specifications

📊 Manual Specifications

File Format

File Type:

Print Quality

Print Capability:

Binding Type

Binding Type:

Digital (N/A for printed)

Paper Type

Paper Type:

Digital (N/A for printed)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke, reed valve induction

Displacement:

198 cc

Bore X Stroke:

66.0 mm x 58.0 mm

Compression Ratio:

9.2:1 (typical, check manual for exact)

Performance

Horsepower:

Approx. 35-40 HP (estimated, varies with tuning and condition)

Torque:

N/A (manual data required)

Fuel System

Carburetor Type:

Mikuni VM29SS (typical)

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Fuel Oil Mixture:

50:1 ratio with high-quality 2-stroke oil (manual specification is critical)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Features

Clutch Type:

Wet, multi-disc

Gear Ratios:

Manual data required (typically specified in manual)

Transmission Fluid Type:

API GL-4, SAE 80W/90 hypoid gear oil (check manual for exact specification)

📐 Dimensions

Exterior

Length:

N/A (manual data required)

Width:

N/A (manual data required)

Height:

N/A (manual data required)

Weights

Dry Weight:

Approximately 227 lbs (103 kg) (check manual for exact specification)

Wet Weight:

N/A (manual data required)

Fuel Capacity:

Approximately 2.4 US gallons (9.0 L) (check manual for exact specification)

🛡️ Safety Features

Ratings

Safety Certification:

N/A (Motorcycle, not typically rated by consumer safety organizations in the same way as cars)

Active Features

Braking System:

Hydraulic disc front and rear

Passive Features

Frame Construction:

High-tensile steel semi-double cradle frame

💡 Technology Features

Infotainment

Infotainment System:

None (This is a 1994 off-road motorcycle)

Driver Assistance

Driver Assistance Features:

None (This is a 1994 off-road motorcycle)

Connectivity

Connectivity Options:

None (This is a 1994 off-road motorcycle)

🔧 Maintenance

Service Intervals

Oil Change Frequency:

Refer to manual for specific intervals based on usage (e.g., every 5-10 hours of off-road use for gearbox oil).

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (e.g., every few rides).

Spark Plug Replacement:

Recommended every 10-20 hours of riding or as per manual's recommendation.

Fluid Specifications

Coolant Type:

Ethylene glycol-based coolant, 50/50 mixture with distilled water (check manual for precise specification).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (check manual for exact specification).

Known Issues

Common Wear Items:

Piston rings, clutch plates, reed valves, fork seals, wheel bearings, chain and sprockets.

Engine Tuning:

Proper jetting is crucial for optimal performance and longevity of the two-stroke engine.

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycle Division:

Long-standing reputation for performance and innovation in off-road and sport motorcycles.

Model Evolution

Kdx Lineage:

The KDX series has a distinguished history in motocross and enduro racing, known for its potent two-stroke engines and agile handling. The 1994 model represents a refinement of earlier designs.

Production

Production Period:

The KDX200 was produced through multiple generations, with the 1994 model belonging to a significant iteration of the platform.

🏆 Awards & Recognition

Recognitions

Model Achievements:

The KDX series consistently received praise in its era for its performance and capability in off-road and enduro competitions. Specific awards for the 1994 model would require historical publication review.