|
Introduction
|
|
Market Position
|
|
Positioning:
|
The Kawasaki KDX200, particularly the 1994 model, was positioned as a capable and relatively affordable off-road and trail-riding ATV. It offered a good balance of performance and durability for its class.
|
|
Competitive Analysis
|
|
Competitors:
|
Competed with similar displacement ATVs from brands like Yamaha (e.g., Warrior 350, though slightly larger), Suzuki (e.g., QuadSport series), and Honda (e.g., FourTrax 300).
|
|
Key Features
|
|
Features Of Vehicle:
|
Known for its agile handling, responsive two-stroke engine, and suitability for trail riding and light competition. Often praised for its simplicity and ease of maintenance for its era.
|
|
Manual Value Proposition
|
|
Value:
|
Provides official dealer-level repair and maintenance information, enabling owners to perform a wide range of tasks, from basic servicing to complex engine rebuilds, saving on labor costs and ensuring proper upkeep.
|
|
Manual Coverage
|
|
Systems Covered
|
|
Engine Systems:
|
Top end (cylinder, piston, head), right side components (clutch, gearbox internals), bottom end (crankshaft, bearings), cooling system (radiator, water pump), fuel system (carburetor, fuel lines).
|
|
Drivetrain Systems:
|
Transmission (gearbox operation, ratios), final drive (chain, sprockets, rear axle).
|
|
Chassis Systems:
|
Wheels and tires, suspension (front forks, rear shock absorber, linkage), steering system (handlebars, steering stem, tie rods), brakes (front and rear calipers, master cylinders, lines, pads).
|
|
Electrical System:
|
Wiring diagrams, ignition system, lighting, battery, charging system.
|
|
Procedures Included
|
|
Maintenance:
|
Routine checks, lubrication, filter replacement, spark plug changes, fluid level checks and changes.
|
|
Repair:
|
Engine rebuilds, transmission overhauls, brake system repairs, suspension adjustments and rebuilds, steering component replacement, electrical diagnostics and repair.
|
|
Troubleshooting:
|
Diagnostic procedures for common issues across all systems.
|
|
Installation:
|
Engine removal and installation procedures.
|
|
Technical Depth
|
|
Depth:
|
Comprehensive workshop-level detail, including step-by-step instructions, exploded diagrams, torque specifications, fluid capacities, and diagnostic information.
|
|
Engine Specifications
|
|
Primary Engine
|
|
Engine Type:
|
Liquid-cooled, 2-stroke, reed valve induction
|
|
Displacement:
|
198 cc (Cubic Centimeters)
|
|
Bore X Stroke:
|
66.0 x 58.0 mm (2.60 x 2.28 in)
|
|
Compression Ratio:
|
Approximately 7.2:1 (typical for this era, specific to 1994 needs verification within manual)
|
|
Ignition:
|
Digital CDI (Capacitor Discharge Ignition)
|
|
Performance
|
|
Horsepower:
|
Estimated 28-30 HP (typical for this engine configuration)
|
|
Torque:
|
Estimated 22-24 lb-ft (typical for this engine configuration)
|
|
Fuel System
|
|
Carburetor:
|
Keihin PWK33 (33mm flat slide carburetor) - common configuration
|
|
Fuel Type:
|
Unleaded gasoline (87-91 octane recommended)
|
|
Fuel Mixture:
|
Premix (2-stroke oil mixed with gasoline) - specific ratio typically 50:1 or 40:1
|
|
Dimensions
|
|
Exterior
|
|
Length:
|
Approximately 1830 mm (72.0 in) - typical for this model
|
|
Width:
|
Approximately 1120 mm (44.1 in) - typical for this model
|
|
Height:
|
Approximately 1050 mm (41.3 in) - typical for this model
|
|
Wheelbase:
|
Approximately 1260 mm (49.6 in) - typical for this model
|
|
Weights
|
|
Dry Weight:
|
Approximately 188 kg (414.5 lbs) - typical for this model
|
|
Fuel Tank Capacity:
|
Approximately 10 Liters (2.6 US gal) - typical for this model
|
|
Wheels Tires
|
|
Front Tire Size:
|
AT22x7-10 or similar
|
|
Rear Tire Size:
|
AT22x10-9 or similar
|
|
Wheel Type:
|
Spoked steel rims
|
|
Suspension
|
|
Front Suspension:
|
Independent, telescopic fork with adjustable pre-load
|
|
Rear Suspension:
|
Swingarm with single shock absorber (monoshock) with adjustable pre-load and damping
|
|
Safety Features
|
|
Ratings
|
|
Crash Test Ratings:
|
N/A (ATVs are not typically crash-tested or rated by agencies like NHTSA or IIHS in the same way as passenger cars).
|
|
Active Features
|
|
Braking System:
|
Hydraulic disc brakes front and rear. Specifics on rotor size and caliper piston count would be in manual.
|
|
Throttle Limiter:
|
Some ATVs of this era had thumb throttle restrictors; manual would detail adjustment if present.
|
|
Passive Features
|
|
Frame Construction:
|
High-tensile steel frame, designed for off-road durability.
|
|
Operator Safety:
|
Emphasis on rider training and use of safety gear (helmet, gloves, boots, protective clothing) is paramount for this type of vehicle, typically covered in the owner's manual section often included in service manuals.
|
|
Maintenance
|
|
Service Intervals
|
|
Oil Change Transmission:
|
Recommended every 100 hours of operation or annually. Specific interval details in manual.
|
|
Air Filter Cleaning:
|
Clean every 5-10 hours of riding, depending on conditions. Replace as needed.
|
|
Spark Plug Replacement:
|
Inspect every 50 hours, replace as needed or every 100 hours. Recommended plug type: NGK BR9ES or equivalent.
|
|
Chain Lubrication Adjustment:
|
Lubricate chain every 20 hours, adjust tension every 10 hours or as needed.
|
|
Fluid Specifications
|
|
Engine Oil Type:
|
2-stroke engine oil meeting API-TC, JASO FD, or ISO-L-EGD standards.
|
|
Coolant Type:
|
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
|
|
Brake Fluid Type:
|
DOT 3 or DOT 4 hydraulic brake fluid.
|
|
Known Issues
|
|
Carburetor Issues:
|
Carburetor jetting may require adjustment based on altitude and modifications. Pilot jets can get clogged over time.
|
|
Ignition System Reliability:
|
While generally reliable, CDI units or stator coils can fail over extended periods, requiring diagnostic testing.
|
|
Suspension Seals:
|
Worn fork seals or rear shock seals can lead to fluid leaks and reduced damping performance, common on older ATVs.
|
|
Engine Seals Gaskets:
|
Vibration and age can lead to oil leaks from crank seals, transmission seals, or cylinder base gaskets.
|
