Segment:
Dual-sport/Off-road motorcycle, positioned as a capable and versatile trail bike with street-legal capabilities.
Competitors:
Competed with other Japanese manufacturers' offerings in the 200cc to 250cc dual-sport class, such as Yamaha WR200, Suzuki DR200S, and Honda XR200R.
Features:
Lightweight two-stroke engine, tractable power delivery for off-road use, long-travel suspension, durable construction, often street-legal options.
Primary Coverage:
Comprehensive service and repair for the 1989-1994 Kawasaki KDX200 model.
Pages:
Not specified in product description. Expect a typical range for a service manual of this era (e.g., 300-500 pages).
Type:
Service/Repair Manual
Language:
English (standard for North American market manuals)
Format:
Likely Digital (PDF) given modern sales, though historically printed. Specify if actual format is known.
Engine:
Complete overhaul, tuning, carburetor, ignition system, cooling (liquid-cooled variants), lubrication.
Transmission:
Clutch operation, gear shifting mechanisms, gearbox disassembly and assembly, lubrication.
Chassis And Suspension:
Front forks (e.g., Kayaba USD forks on later models), rear shock absorber (Uni-Trak system), swingarm, bearings, linkages.
Brakes:
Front and rear disc brake systems, hydraulic components, pad replacement, bleeding procedures.
Electrical:
Wiring diagrams, lighting system, ignition system components, battery, fuses, troubleshooting electrical faults.
Fuel System:
Fuel tank, fuel lines, carburetor (likely Keihin), jetting, cleaning, and adjustment.
Bodywork And Controls:
Handlebars, levers, footpegs, seat, plastics, fenders, cable routing and adjustment.
Maintenance:
Regular servicing, oil changes, filter replacements, spark plug checks, chain adjustment, pre-ride inspections.
Troubleshooting:
Diagnostic guides for common problems, symptom-based troubleshooting charts, identification of faulty components.
Repair:
Step-by-step instructions for engine rebuilds, suspension component replacement, brake caliper overhauls, electrical component repair.
Disassembly And Assembly:
Detailed instructions for complete vehicle breakdown and reassembly, including torque specifications.
Depth:
Comprehensive. Covers everything from routine maintenance and adjustments to full engine and transmission overhauls, electrical system diagnostics, and chassis component repairs.
Digital Format:
PDF (assumed). High-resolution scans of original manual pages. Searchable text functionality is a desirable feature.
Quality:
If digital, quality is dependent on original scan. If physical, expect clarity suitable for technical reference.
Binding:
Not applicable for digital format. For physical copies, typically spiral-bound or saddle-stitched for ease of use.
Paper Type:
Not applicable for digital format. Original manuals used durable paper stock suitable for workshop environments.
Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
198cc (or approximately 198 cubic centimeters)
Bore X Stroke:
Typically around 66.0 mm x 58.0 mm (specific values should be confirmed in the manual).
Compression Ratio:
Varies by year, but generally in the range of 7.0:1 to 7.5:1 (requires manual verification).
Horsepower:
Estimated 30-35 HP at peak RPM (specific figures depend on year and tuning, requires manual verification).
Torque:
Estimated 20-23 lb-ft at peak RPM (specific figures depend on year and tuning, requires manual verification).
Carburetor Type:
Likely Keihin PJ or PWK series, single downdraft carburetor. Specific model and jetting are crucial and detailed in the manual.
Fuel Type:
Unleaded gasoline, octane rating specified in manual (typically 87-91 RON/AKI).
Fuel Tank Capacity:
Typically around 2.6 to 3.0 gallons (10-11.5 liters).
Oil System:
Premix or Autolube system (Kawasaki's KIPS - Kawasaki Integrated Powervalve System often integrated with lubrication/exhaust).
Ignition Type:
CDI (Capacitor Discharge Ignition) system.
Type:
6-speed constant mesh manual transmission.
Optional Types:
None, all KDX200 models featured a 6-speed manual.
Clutch:
Wet, multi-plate clutch, hydraulically or cable operated (check year for specifics).
Gear Ratios:
Specific gear ratios for each of the 6 speeds and the final drive ratio are detailed in the manual, crucial for performance tuning.
Transmission Fluid:
Manual specifies specific ATF or gear oil. Capacity also listed. Common usage is SAE 80 or 10W-40 motorcycle gear oil.
Length:
Approximately 85-86 inches (2160-2185 mm).
Width:
Approximately 32-33 inches (810-840 mm).
Height:
Approximately 48-50 inches (1220-1270 mm).
Wheelbase:
Approximately 56-57 inches (1420-1450 mm).
Dry Weight:
Typically in the range of 230-250 lbs (104-113 kg).
Wet Weight:
Not precisely specified in product info, but would include fluids and battery, adding approx. 20-30 lbs.
Front Travel:
Typically around 10.8 - 11.4 inches (275 - 290 mm).
Rear Travel:
Typically around 11.0 - 11.8 inches (280 - 300 mm).
Front Wheel:
21-inch spoked wheel.
Rear Wheel:
18-inch spoked wheel.
Front Tire:
Typically 80/100-21.
Rear Tire:
Typically 100/100-18 or 110/100-18.
Crash Test Ratings:
Not applicable for this type of off-road/dual-sport motorcycle from this era. Safety features are inherent to design and rider skill.
Active Safety:
Effective front and rear disc brakes for stopping power, well-balanced chassis for stable handling.
Passive Safety:
Rider positioning aids, sturdy frame construction, durable plastics.
Oil Change Interval:
Engine oil for gearbox: Every 6,000 km or 12 months (refer to manual for precise interval and specific oil grade).
Air Filter Cleaning:
Regular cleaning recommended, especially after dusty riding. Frequency depends on conditions, typically every few hundred kilometers.
Spark Plug Inspection:
Inspect and clean/replace every 1,000-2,000 km or as needed based on performance. Manual specifies type and gap.
Chain Lubrication Adjustment:
Lubricate every 500 km or after riding in wet conditions. Adjust chain slack as per manual specification (typically 20-30 mm).
Engine Oil:
Manual specifies viscosity and API rating for transmission/gearbox oil (e.g., SAE 10W-40 or API GL-4). For pre-mix, a specific 2-stroke oil is required.
Coolant:
For liquid-cooled models: Mixture of antifreeze and distilled water, typically 50/50. Manual specifies type and capacity.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. Manual specifies type and bleeding procedure.
Common Problems:
Carburetor clogging (especially after storage), KIPS valve sticking, clutch wear, fork seal leaks, exhaust pipe damage from impacts, crank seal leaks.
Preventative Maintenance:
Regular cleaning of the KIPS system, proper fuel storage, diligent chain maintenance, and timely fork seal replacement are key.
Heritage:
Kawasaki has a long history of producing high-performance off-road and dual-sport motorcycles, known for their potent two-stroke engines and innovative technologies like KIPS.
Evolution:
The KDX200 was a mainstay in Kawasaki's off-road lineup, evolving through several generations. The 1989-1994 period saw significant updates, including the adoption of liquid cooling, the KIPS powervalve system, and often USD front forks, improving performance and manageability.
Production Period:
The KDX200 line ran for many years, with this specific generation representing a key phase of its development.
Manufacturing Location:
Primarily Japan, with assembly potentially occurring in other regions depending on market.
Industry Acclaim:
The KDX series generally received positive reviews for its performance, handling, and durability within the dual-sport and off-road community during its production run.
Performance Ratings:
Consistently rated as a capable trail bike with a good balance of power and manageable handling for its class.
Emissions Certification:
While street-legal versions would meet emissions standards of the time, specific certifications are not detailed in product info and would vary by market. Manual may cover emissions control system components for specific regions.
