Segment:
Competition Enduro Motorcycle
Target Audience:
Off-road riders, enduro enthusiasts, mechanics, DIY enthusiasts
Key Competitors:
Yamaha WR250, Honda CR250 (off-road variants), KTM EXC series
Vehicle Emphasis:
Lightweight, powerful two-stroke engine, capable suspension for off-road terrain
Manual Value Proposition:
Authoritative guide for maintaining peak performance and executing repairs efficiently
Engine Mechanical:
Engine assembly, disassembly, tuning, internal components, lubrication system, cooling system (if applicable)
Engine Management:
Carburetion, ignition system, CDI unit, spark plug specifications, jetting information
Transmission:
Clutch operation, gearbox disassembly and assembly, gear selection mechanisms, transmission fluid specifications
Suspension:
Front forks (KYB/Showa typically), rear shock absorber, linkage system, suspension adjustments, seal replacement
Brakes:
Front and rear hydraulic brake systems, caliper overhaul, master cylinder, brake fluid specifications, bleeding procedures, pad replacement
Electrical:
Wiring diagrams, lighting system, ignition coil, stator, CDI, battery, fuses, troubleshooting electrical faults
Fuel System:
Fuel tank, fuel lines, fuel filter, carburetor cleaning and adjustment, petcock operation
Exhaust System:
Exhaust pipe, silencer, packing replacement, de-carbonizing
Cooling System:
Liquid cooling system (if applicable), radiator, hoses, coolant specifications
Frame And Bodywork:
Frame integrity checks, fairings, seat, handlebars, footpegs, plastic components
Scheduled Maintenance:
Oil changes, filter replacements, spark plug service, chain adjustment, air filter cleaning/replacement
Troubleshooting:
Diagnostic flowcharts, common problems and solutions, fault identification guides
Repair And Rebuild:
Engine rebuilding, transmission overhaul, suspension fork repair, brake caliper servicing, carburetor rebuilding
Adjustments:
Carburetor adjustments, clutch cable adjustment, throttle cable adjustment, suspension sag adjustment
Disassembly And Assembly:
Step-by-step instructions for removing and reinstalling all major components and sub-assemblies
Depth:
Comprehensive (from basic maintenance to complete engine rebuilds)
Diagnostic Level:
Advanced diagnostics with specific troubleshooting procedures and potential fault codes
Special Tools:
Identification and usage of specialized tools required for specific procedures
Engine Type:
Two-stroke, liquid-cooled, single-cylinder
Bore X Stroke:
66.0 x 58.0 mm (typical)
Compression Ratio:
7.2:1 (typical, can vary slightly by year/spec)
Horsepower:
Approx. 35-40 HP (estimated, unconfirmed official figures for these years)
Torque:
Approx. 25-28 lb-ft (estimated)
Carburetor Type:
Keihin PWK35 (typical for this model range)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Premix Ratio:
50:1 (typical for two-stroke oil)
Fuel Capacity:
Approx. 2.6 gallons (9.8 L)
Length:
Approx. 85.6 inches (2175 mm)
Width:
Approx. 31.5 inches (800 mm)
Height:
Approx. 47.4 inches (1205 mm)
Wheelbase:
Approx. 56.3 inches (1430 mm)
Dry Weight:
Approx. 230 lbs (104 kg)
Curb Weight:
Approx. 240 lbs (109 kg) (with fluids)
Front Suspension Travel:
Approx. 11.4 inches (290 mm)
Rear Suspension Travel:
Approx. 11.0 inches (280 mm)
Front Tire Size:
80/100-21 (typical)
Rear Tire Size:
100/100-18 (typical)
Engine Oil Change:
Every 5-10 hours of riding (or as specified in manual, depending on severity of use)
Air Filter Cleaning:
Every 1-2 hours of riding in dusty conditions, or as needed
Spark Plug Inspection:
Every 10-20 hours of riding
Chain Lubrication Adjustment:
Every ride or every 5 hours
Engine Oil:
2-stroke engine oil (e.g., Yamalube 2R, Motul 800, Bel-Ray Si-7) mixed with gasoline at 50:1 ratio
Transmission Oil:
Gear oil SAE 10W-30 (e.g., Kawasaki Genuine Gear Oil or equivalent)
Brake Fluid:
DOT 4 brake fluid (for hydraulic systems)
Coolant:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio)
Power Valve Cleaning:
Carbon buildup on the powervalve system can lead to sluggish performance; requires periodic cleaning.
Carburetor Jetting:
Can require adjustment based on altitude, temperature, and modifications.
Clutch Wear:
Friction plates can wear over time, especially with aggressive riding, requiring replacement.
Suspension Seals:
Fork and shock seals can degrade, leading to leaks and requiring replacement.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine division
Brand Reputation:
Known for performance-oriented motorcycles, particularly in off-road and racing disciplines
Kdx Lineage:
The KDX series has a long history of producing capable and competitive off-road motorcycles, evolving from earlier models like the KDX200 A series.
Changes 1998 2004:
While major platform changes were less frequent in this era, updates typically involved suspension tuning, minor engine refinements, graphics, and sometimes slight carburetor or ignition mapping adjustments.
Production Period:
The KDX200 was produced for many years, with the 1998-2004 models representing a specific generation.
