Model Variant:
Off-road Motorcycle
Production Years Covered By Manual:
1998, 1999, 2000, 2001, 2002, 2003, 2004
Chassis Codes:
KDX200-SR (specific to model year variants)
Category:
Dual-Sport / Off-Road Motorcycle
Target User:
Enthusiasts, Enduro riders, Trail riders, DIY mechanics
Competitors Era:
Honda CR250R/CRF250X, Yamaha YZ250/WR250, Suzuki RM250/RMX250, KTM EXC series (comparable engine size and segment)
Powertrain Highlight:
Liquid-cooled, two-stroke, single-cylinder engine with Kawasaki's Intelligent Power valve System (KIPS) for broad powerband.
Suspension Highlight:
High-performance conventional upside-down (USD) front forks and adjustable rear shock absorber providing excellent off-road capability.
Manual Value Proposition:
Essential resource for maintaining, repairing, and optimizing the performance of the KDX200 across its production lifespan covered.
Primary Coverage:
Service, Repair, Workshop, Maintenance
Secondary Coverage:
Troubleshooting, Diagnostics, Specifications
Estimated Page Count:
300-400 pages (typical for comprehensive service manuals of this era)
Type:
Factory Authorized Service Manual / Workshop Manual
Format:
Digital (PDF - assumed for modern sales)
Engine:
Complete engine overhaul, top-end rebuild, bottom-end assembly, carburetor service and tuning (including KIPS system), cooling system, lubrication system, ignition system (CDI, spark plugs).
Transmission:
Clutch operation and adjustment, gearbox inspection and repair, shift mechanism, transmission fluid replacement.
Chassis And Suspension:
Front fork (USD) disassembly, service, and reassembly (including oil changes and seal replacement), rear shock absorber service, linkage lubrication, swingarm bearing inspection.
Brakes:
Front and rear disc brake system service, caliper overhaul, brake pad replacement, master cylinder service, bleeding procedures.
Electrical System:
Wiring diagrams, lighting system, ignition system, battery maintenance, troubleshooting electrical faults, component testing.
Fuel System:
Fuel tank inspection, petcock service, fuel line maintenance, carburetor disassembly, cleaning, and adjustment (including jetting information).
Exhaust System:
Exhaust pipe and silencer inspection, packing replacement (if applicable).
Cooling System:
Radiator service, coolant replacement, fan operation (if equipped).
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning, brake bleeding.
Repair:
Complete engine rebuild, transmission disassembly and repair, suspension overhaul, brake caliper rebuild, electrical component replacement.
Troubleshooting:
Systematic diagnosis of common and uncommon issues, fault finding guides, diagnostic charts.
Specifications:
Torque specifications for all fasteners, engine clearances, fluid capacities, tuning specifications, electrical resistance values.
Depth:
Comprehensive, covering everything from basic rider maintenance to full engine and chassis rebuilds. Suitable for both amateur mechanics and professional technicians.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Bore X Stroke:
66.0 x 58.0 mm
Compression Ratio:
7.5:1 (typical, may vary slightly by year)
Power Valve System:
Kawasaki Intelligent Power valve System (KIPS)
Horsepower:
Approx. 35-40 HP (at crankshaft, estimated for early 2000s models)
Torque:
Approx. 20-23 lb-ft (at crankshaft, estimated)
Carburetor:
Mikuni VM29SS (typical for this era)
Fuel Type:
Unleaded gasoline (minimum 91 octane recommended)
Fuel Mixture:
Requires 2-stroke oil mixed with gasoline at a ratio of 50:1 (refer to manual for specific oil type).
Oil Type:
Dedicated 2-stroke synthetic or semi-synthetic oil (specified in manual).
Type:
6-speed constant mesh
Options:
N/A (standard configuration)
Clutch:
Wet multi-disc, cable operated
Gear Ratios:
Specific ratios detailed in manual, essential for performance tuning.
Transmission Oil Type:
Kawasaki Transmission Oil SS or equivalent (API GL-4, SAE 10W-40, or specified viscosity).
Transmission Oil Capacity:
Approx. 0.8 Liters (refer to manual for exact capacity).
Overall Length:
Approx. 2155 mm (84.8 in)
Overall Width:
Approx. 805 mm (31.7 in)
Overall Height:
Approx. 1250 mm (49.2 in)
Wheelbase:
Approx. 1435 mm (56.5 in)
Ground Clearance:
Approx. 330 mm (13.0 in)
Seat Height:
Approx. 960 mm (37.8 in)
Dry Weight:
Approx. 107 kg (236 lbs)
Curb Weight:
Approx. 113 kg (249 lbs) (with all fluids)
Fuel Tank Capacity:
Approx. 10 Liters (2.6 US gal)
Safety Certification:
N/A (Off-road motorcycle, not subject to road vehicle safety ratings like NHTSA/Euro NCAP)
Braking System:
Hydraulic disc brakes front and rear for reliable stopping power in varied conditions.
Suspension Stability:
High-quality suspension system contributes to stability and control during aggressive riding.
Frame Construction:
Strong steel perimeter frame designed for durability and rider feedback.
Ergonomics:
Designed for upright riding position, promoting rider control and reducing fatigue.
Oil Change Frequency:
Every 10-15 hours of riding or annually. Refer to manual for specific recommendations based on usage.
Spark Plug Inspection:
Every 15-20 hours of riding. Replacement as needed based on condition.
Air Filter Cleaning:
After every few rides, especially in dusty conditions. Detailed cleaning and re-oiling procedure in manual.
Chain Lubrication Adjustment:
Lubricate every 500 km (300 miles) or more frequently if exposed to water/dirt. Adjust chain slack regularly.
Fork Oil Change:
Recommended every 100-200 hours of riding or annually for optimal suspension performance.
Engine Top End Rebuild:
Recommended every 100-200 hours of riding, depending on usage and maintenance. Manual provides detailed procedures.
Coolant:
Mixture of distilled water and permanent antifreeze (ethylene glycol based, typically 50/50 ratio). Refer to manual for specific type.
Fork Oil Type:
Specific suspension fluid (e.g., Showa SS-01, KYB SS-7, or equivalent SAE 5W/10W). Refer to manual for exact viscosity.
Kips System Maintenance:
The KIPS exhaust valve system requires regular cleaning and lubrication to prevent sticking, which can affect power delivery. Manual details this procedure.
Carburetor Jetting:
Proper carburetor jetting is crucial for optimal performance and is dependent on altitude and temperature. Manual provides baseline settings and tuning guidance.
Clutch Wear:
Clutch plates can wear over time; manual provides wear limits and replacement procedures.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine division.
Brand Legacy:
Kawasaki has a long-standing reputation for producing high-performance, reliable motorcycles, particularly in the off-road and motocross segments.
Kdx Lineage:
The KDX line has been a staple in Kawasaki's off-road lineup for decades, known for its versatility and competitive performance in enduro and trail riding.
Generation Update 1998:
The 1998 model year saw significant updates, including revised suspension, engine tuning, and chassis improvements, building on the KDX200's established platform.
Production Period:
The KDX200 was produced for many years, with the 1998-2004 models representing a specific iteration of this enduring off-road machine.
