Motorcycle Segment:
Competitive 2-stroke, off-road/enduro motorcycle, known for its balance of performance and usability in its era.
Key Competitors:
Yamaha WR200, Suzuki DR250 (4-stroke competitor, but in same displacement class), Honda CR250 (more MX-focused).
Vehicle Highlights:
Powerful 2-stroke engine, robust chassis, adjustable suspension, tractable power delivery for off-road conditions, durable construction.
Benefit To Owner:
Enables owners to perform all necessary maintenance and repairs, diagnose issues, and keep their KDX200 running optimally, saving significant costs compared to dealership service.
Years Covered:
1989, 1990, 1991, 1992, 1993, 1994
Page Count:
Likely between 300-500 pages (typical for comprehensive service manuals)
Manual Type:
Service Manual / Repair Manual
Format:
Likely printed paper manual, potentially available as PDF
Engine System:
Complete overhaul, top-end, bottom-end, cooling system, lubrication system, fuel injection/carburetion system, ignition system.
Transmission System:
Clutch assembly, gearbox, shift mechanism, gear ratios, lubrication.
Chassis System:
Frame, suspension (front forks, rear shock absorber), steering, wheels, tires, brakes (front and rear disc), swingarm.
Electrical System:
Wiring diagrams, lighting, charging system (stator, regulator/rectifier), ignition system, battery.
Bodywork And Cosmetics:
Plastics, seat, fenders, handlebars, controls, exhaust system.
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, chain maintenance, brake fluid flush, coolant service, air filter cleaning/replacement.
Troubleshooting Guides:
Diagnostic procedures for common starting, running, and electrical issues. Specific sections for engine performance problems.
Repair Procedures:
Detailed step-by-step instructions for engine rebuilds, carburetor overhaul, suspension servicing, brake caliper repair, electrical component replacement.
Adjustment Procedures:
Carburetor adjustment, clutch adjustment, brake lever adjustment, chain tension adjustment, suspension sag adjustment.
Depth Of Information:
Comprehensive; covers routine maintenance to complete engine and chassis overhauls. Includes detailed torque specifications, clearances, and diagnostic charts.
Digital Format Details:
If PDF, expect searchable text, bookmark navigation, and high-resolution diagrams. Printable pages.
Print Quality Details:
Professional printing with clear diagrams, legible text, and durable binding. High-quality paper stock to withstand workshop use.
Binding Type:
Likely saddle-stitched or perfect bound for durability and ease of use in a workshop environment.
Paper Type:
Matte or semi-gloss paper to reduce glare and resist grease/oil stains.
Engine Type:
Liquid-cooled, 2-stroke, reed valve induction
Bore X Stroke:
66.0 mm x 58.0 mm
Compression Ratio:
Approx. 7.5:1 (varies slightly by sub-model/year)
Cylinder Arrangement:
Single cylinder, forward-inclined
Horsepower Output:
Approx. 35-40 HP (at crank, varies by year and specific tune)
Torque Output:
Approx. 25-28 lb-ft (at crank, varies by year)
Carburetor Type:
Keihin PWK33 (typically)
Fuel Type Recommendation:
Unleaded gasoline with octane rating of 91 or higher. Pre-mix oil ratio (typically 40:1 or 50:1) with high-quality 2-stroke oil.
Fuel Tank Capacity:
Approx. 2.6 gallons (10 liters)
Cooling Method:
Liquid-cooled
Coolant Type:
Permanent type antifreeze coolant (e.g., 50/50 mix of ethylene glycol and distilled water)
Lubrication System:
Premixed fuel and oil, separate oil injection system (may vary by specific year model)
Overall Length:
Approx. 2,170 mm (85.4 in)
Overall Width:
Approx. 820 mm (32.3 in)
Overall Height:
Approx. 1,210 mm (47.6 in)
Wheelbase:
Approx. 1,440 mm (56.7 in)
Ground Clearance:
Approx. 335 mm (13.2 in)
Dry Weight:
Approx. 107 kg (236 lbs)
Curb Weight:
Approx. 115 kg (253.5 lbs) (with all fluids)
Front Suspension Travel:
Approx. 270 mm (10.6 in)
Rear Suspension Travel:
Approx. 275 mm (10.8 in)
Safety Ratings:
Motorcycle safety is primarily assessed through handling characteristics, braking performance, and rider protection equipment, not formal crash test ratings like cars.
Braking System:
Hydraulic disc brakes front and rear. Dual-piston caliper front, single-piston caliper rear.
Tire Specifications:
Front: 80/100-21, Rear: 110/100-18 (typical)
Lighting:
Headlight, taillight/brake light, turn signals (depending on market homologation).
Infotainment Features:
N/A (basic off-road motorcycle with no digital infotainment system).
Assistance Systems:
N/A (basic off-road motorcycle with no electronic rider aids).
Connectivity Options:
N/A (basic off-road motorcycle with no connectivity features).
Kawasaki Kips System:
Likely features Kawasaki Integrated Power Valve System (KIPS) for improved powerband across RPM range. Manual will detail its operation and maintenance.
Oil Change Interval:
Every 6-12 hours of riding or annually. Check manual for specific recommendations based on usage.
Spark Plug Service:
Inspect every 12-24 hours, replace as needed. Use NGK BR8ES or equivalent.
Air Filter Cleaning:
Clean after every few rides, especially in dusty conditions. Use specific foam filter cleaner and oil.
Chain Maintenance:
Lubricate and adjust chain tension every 3-5 rides. Check manual for specific tension specifications.
Engine Oil Type:
High-quality 2-stroke engine oil specifically for motorcycles. (e.g., Motul 800 2T, Castrol Power RS 2T)
Coolant Specifications:
Permanent type antifreeze coolant, typically a 50/50 mix of ethylene glycol and distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Piston rings, piston, cylinder wear due to 2-stroke nature. Clutch wear. Fork seals. Chain and sprockets. Carburetor jets clogging.
Potential Problems:
Overheating if cooling system is not maintained. Carburetor jetting can be sensitive to altitude and temperature changes. Exhaust port deposits can affect performance.
Carburetor Tuning:
Manual will cover jetting changes for different altitudes and conditions. Importance of proper float height and needle setting.
Kawasaki Offroad Legacy:
Kawasaki has a strong history in motocross and off-road racing, with iconic models like the KX series. The KDX line blended performance with off-road practicality.
Kdx200 Development:
The KDX200 was developed as a capable off-road machine, evolving from earlier KDX models with improvements in engine performance, suspension, and chassis design. The 1989-1994 generation saw significant updates, including revised bodywork, chassis geometry, and engine tuning for enhanced performance and handling.
Manufacturing Period:
The KDX200 was produced from the early 1980s through the early 2000s, with this specific generation spanning 1989-1994. Production typically occurred in Japan.
Reputation:
The KDX200 gained a reputation as a user-friendly yet potent off-road bike, suitable for trail riding, enduro, and occasional motocross. It was often praised for its strong low-to-mid-range power delivery.
