Kawasaki KDX 200 1996 Digital Service Repair Manual

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Basic Information Identification Make: Kawasaki Model: KDX200 Year: 1996 Vehicle Type: Dual-Sport Motorcycle Introduction Market Position Market Segment: Off-road/Dual-sport enthusiast, DIY mechanics Competitive Analysis Manual Advantage: Provides dealer-level service information...

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Type: Motorcycle

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Sku: 51149

Tags: 1996 Kawasaki KDX 200 KDX Models Motorcycle Motorcycles

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Description

Basic Information
Identification
Make:	Kawasaki
Model:	KDX200
Year:	1996
Vehicle Type:	Dual-Sport Motorcycle

Introduction
Market Position
Market Segment:	Off-road/Dual-sport enthusiast, DIY mechanics
Competitive Analysis
Manual Advantage:	Provides dealer-level service information accessible to the end-user, covering all aspects of repair and maintenance for the 1996 KDX200.
Key Features
Key Features Manual:	Step-by-step instructions, detailed diagrams, comprehensive coverage of all vehicle systems, essential technical data (torque settings, fluid capacities).

Manual Details
Coverage
Coverage Areas:	General Information, Fuel System, Cooling System, Engine Top End, Engine Right Side, Engine Removal/Installation, Engine Bottom End Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Electrical System, Appendix
Format
Format:	PDF
Requirements:	Adobe PDF Reader, WinZip
Functionality
Zoom Capability:	Yes
Compatibility
Operating Systems:	All Versions of Windows & Mac
Language
Language:	English
Manual Type
Manual Type:	Service/Repair Manual

Manual Coverage
Systems
Systems Covered:	Engine (Top End, Right Side, Bottom End, Transmission), Fuel System, Cooling System, Drivetrain (Final Drive), Brakes, Suspension, Steering, Electrical System, Wheels/Tires
Procedures
Procedures Included:	Maintenance, Troubleshooting, Repair, Component Installation/Removal, Electrical Diagnosis, Torque Specifications, Fluid Capacities
Depth
Technical Depth:	Comprehensive workshop procedures, detailed step-by-step diagrams, diagnostic information, specifications for repairs and maintenance

Manual Specifications
File Attributes
File Format Detail:	Digital PDF
Quality
Print Quality Expectations:	High-resolution for clear viewing of diagrams and text.
Binding Type
Binding Type:	N/A (Digital Download)
Paper Type
Paper Type:	N/A (Digital Download)

Engine Specifications
Primary Engine
Engine Type:	2-Stroke, Liquid-Cooled, Reed Valve
Displacement:	198 cc
Bore X Stroke:	66.0 x 58.0 mm
Performance
Estimated Horsepower:	Approx. 35-40 HP (depending on specific tuning/conditions)
Estimated Torque:	Approx. 20-22 lb-ft
Fuel System
Carburetor Type:	Keihin PWK35 (likely)
Fuel Type:	Unleaded gasoline
Lubrication
Oil Mixture Ratio:	50:1 (Pre-mix or Injection, manual will specify)
Ignition
Ignition System:	CDI (Capacitor Discharge Ignition)

Transmission
Standard
Transmission Type:	6-speed constant mesh
Clutch Type:	Wet, multi-disc
Features
Transmission Oil Type:	Kawasakii Genuine Motorcycle Oil SAE 10W-40 (or equivalent API SE/SF/SG)
Transmission Oil Capacity:	Approx. 1.0 Liters (refer to manual for exact)

Dimensions
Exterior
Overall Length:	Approx. 2185 mm (86.0 in)
Overall Width:	Approx. 820 mm (32.3 in)
Overall Height:	Approx. 1245 mm (49.0 in)
Weights
Dry Weight:	Approx. 112 kg (247 lbs)
Wet Weight:	Approx. 117 kg (258 lbs)
Fuel Tank Capacity:	9.0 Liters (2.4 US gal)
Seat Height:	Approx. 910 mm (35.8 in)
Ground Clearance:	Approx. 320 mm (12.6 in)

Safety Features
Ratings
Safety Features General:	Headlight, Taillight, Brake Light, Turn Signals, Horn
Active Features
Braking System Front:	Hydraulic Disc
Braking System Rear:	Hydraulic Disc
Passive Features
Frame Type:	Semi-double cradle, Steel

Technology Features
Infotainment
Infotainment Features:	N/A (Basic instrumentation: speedometer, odometer, neutral indicator, high-beam indicator).
Driver Assistance
Driver Assistance Features:	N/A
Connectivity
Connectivity Features:	N/A

Maintenance
Service Intervals
Spark Plug Maintenance:	Inspect and clean every 6-10 hours of operation; replace as needed (refer to manual for specific plug type and gap).
Air Filter Maintenance:	Clean and re-oil every 10-15 hours of operation or as conditions dictate.
Chain Maintenance:	Lubricate and adjust tension every 5-8 hours of operation.
Engine Oil Change:	Transmission oil change every 20-30 hours of operation or annually.
Fluid Specifications
Coolant Type:	Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant (50% mixture with distilled water).
Brake Fluid Type:	DOT 4 Hydraulic Brake Fluid
Known Issues
Common Wear Items:	Clutch plates, piston rings, power valve components, chain and sprockets, wheel bearings, fork seals.
Typical Problems:	Carburetor jetting issues due to altitude or temperature changes, sticky power valve operation, wear in the engine's top end (piston/rings), fork seal leaks.

Vehicle History
Brand Heritage
Kawasaki Motorcycle Heritage:	Kawasaki Heavy Industries boasts a long history of producing high-performance motorcycles, including renowned off-road and dual-sport models.
Model Evolution
Kdx Series Evolution:	The KDX series has a lineage of capable off-road and dual-sport machines, known for their potent 2-stroke engines and versatility. The 1996 model represents an evolution within this established line.
Production
Production Era:	The KDX200 was produced across several generations, with the mid-1990s models being a significant period for this versatile dual-sport.

Awards & Recognition
Recognitions
Model Recognition:	The KDX200 series was generally well-regarded in its era for its performance and off-road capability, often favored by riders looking for a potent 2-stroke dual-sport.