Target Audience:
Owners and technicians seeking detailed repair and maintenance information for Kawasaki KDX-200 models.
Value Proposition:
Provides professional-level diagnostic and repair data, often exceeding owner's manuals, at a fraction of the cost of physical manuals or dealer services.
Manual Enhancements:
Combines troubleshooting and electrical service with wiring diagrams for efficient diagnostics.
Instructional Design:
Numbered instructions and bold figure numbers facilitate quick reference and accuracy.
Coverage Summary:
Comprehensive repair, maintenance, rebuilding, refurbishing, and restoration of the Kawasaki KDX-200 (1989-1994).
Specific Systems Covered:
Engine, transmission, fuel system, lubrication, cooling, electrical system, ignition, chassis, suspension, brakes, bodywork, troubleshooting, diagnostics.
Estimated Page Count:
Detailed (specific page count not provided in product information, but described as comprehensive).
Manual Classification:
Service Manual / Repair Manual
File Format:
PDF Download
Engine Mechanical:
Detailed engine disassembly, inspection, assembly, and tuning procedures.
Fuel And Carburetion:
Carburetor tuning, cleaning, and overhaul; fuel tank and line maintenance.
Ignition System:
Spark plug specifications, ignition timing, CDI unit testing.
Transmission And Clutch:
Clutch operation, adjustment, and replacement; gearbox disassembly and inspection.
Suspension And Steering:
Front fork service (oil changes, seal replacement), rear shock absorber adjustment and service, steering head bearing maintenance.
Brake System:
Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, and bleeding procedures.
Electrical System:
Wiring diagrams, lighting system service, battery maintenance, starter system troubleshooting.
Exhaust System:
Exhaust pipe and silencer maintenance.
Cooling System:
Radiator service, coolant replacement, hoses and connections.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, tire pressure checks, lubrication points.
Troubleshooting:
Diagnostic guides for common problems, symptom-based troubleshooting trees.
Repair And Rebuild:
Step-by-step instructions for component disassembly, repair, and reassembly.
Electrical Diagnostics:
Combined troubleshooting with detailed wiring diagrams for ease of fault diagnosis.
Technical Specifications:
Torque specifications, clearances, fluid capacities, and critical measurements.
Tune Up Procedures:
Carburetor synchronization and adjustment, ignition timing setup.
Depth Of Coverage:
Comprehensive, suitable for professional technicians and experienced DIY mechanics.
Instruction Format:
Numbered steps, detailed sub-steps, notes, cautions, and warnings.
Visual Aids:
Detailed illustrations, drawings, photos, and enlarged inset diagrams.
Portability:
Downloadable, savable to hard-drive, burnable to CD-ROM.
Printability:
Full Printable Pages
Binding:
Digital (PDF) - no physical binding.
Paper Description:
N/A (Digital format).
Operating Systems:
All Versions of Windows & Mac
Software Requirements:
Adobe PDF Reader & WinRAR
Delivery Method:
Instant Download
Shipping Cost:
None (Digital Download)
Engine Type:
Two-stroke, liquid-cooled, single-cylinder (typical for KDX-200 models).
Engine Displacement:
Approximately 198cc (specific variants may exist).
Bore X Stroke:
Typically around 66.0 x 58.0 mm (requires confirmation from manual data for exact figures).
Compression Ratio:
Approximately 7.2:1 (typical for models of this era, needs manual verification).
Horsepower:
Estimated 30-35 HP (at crank, requires manual verification).
Torque:
Estimated 20-22 lb-ft (at crank, requires manual verification).
Carburetor Type:
Typically a Mikuni VM28 or similar, single carburetor.
Fuel Type:
Unleaded gasoline (minimum 91 octane recommended).
Fuel Mixture:
Requires two-stroke engine oil mixed with gasoline (typically 30:1 or 40:1, consult manual for exact ratio).
Engine Oil Type:
Specific 2-stroke motorcycle oil (e.g., API TC, JASO FD rated).
Cooling Medium:
Liquid (antifreeze/coolant mixture).
Start Method:
Kickstarter.
Overall Length:
Varies slightly by year, typically around 2140 mm (84.3 in).
Overall Width:
Varies slightly by year, typically around 800 mm (31.5 in).
Overall Height:
Varies slightly by year, typically around 1220 mm (48.0 in).
Dry Weight:
Approximately 108 kg (238 lbs) (may vary by year/spec).
Curb Weight:
Not typically specified for dirt bikes in this era, but would include fluids and battery.
Fuel Tank Capacity:
Approximately 10 Liters (2.6 US gallons).
Safety Standards:
Designed for off-road use; no specific crash ratings applicable.
Braking System:
Hydraulic disc brakes front and rear for enhanced stopping power.
Suspension Stability:
Adjustable front forks and rear suspension contribute to ride stability and control.
Frame Construction:
Durable perimeter frame designed for off-road conditions.
Engine Oil Change:
Every 1,000-2,000 km (600-1,200 miles) or annually, whichever comes first (consult manual for precise interval and conditions).
Air Filter Cleaning:
Every 500-1,000 km (300-600 miles) or more frequently in dusty conditions.
Spark Plug Inspection:
Every 1,000-2,000 km (600-1,200 miles), replace as needed.
Chain Lubrication Adjustment:
Every 500 km (300 miles) or after washing/wet conditions, adjust as needed.
Fork Oil Change:
Typically every 12-24 months or as recommended by usage.
Engine Oil Viscosity Mixture:
Consult manual for exact two-stroke oil ratio (e.g., 30:1, 40:1) and recommended oil grade.
Transmission Oil Viscosity:
SAE 80W or 10W-30 API GL-4 motorcycle gear oil (verify with manual).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (verify with manual).
Coolant Type:
Ethylene glycol based permanent antifreeze/coolant with a 50/50 mix of water (verify with manual).
Carburetor Fouling:
Common issue in two-strokes due to fuel/oil mixture and carbon buildup, requiring regular cleaning and tuning.
Power Valve Sticking:
The exhaust power valve mechanism can accumulate carbon and become sticky, affecting performance. Requires periodic cleaning and lubrication.
Clutch Wear:
Heavy use can lead to clutch plate wear, requiring adjustment or replacement.
Suspension Seals:
Fork seal leaks are not uncommon on off-road bikes of this age, requiring replacement.
Kawasaki Offroad Legacy:
Kawasaki has a long-standing reputation for producing capable and competitive off-road motorcycles, particularly in the dual-sport and motocross categories.
Kdx Series:
The KDX series has been a staple in Kawasaki's lineup, known for its performance in trail riding and enduro applications, blending off-road capability with some street legality in certain configurations.
Manufacturing Location:
Primarily manufactured in Japan by Kawasaki Heavy Industries.
Production Run:
The KDX-200 had a significant production run, with this manual covering a key era of its development.
Industry Acclaim:
The KDX series historically received positive reviews for its trail performance and versatility within the off-road community.
Performance Reviews:
Praised for its tractable power delivery, capable suspension, and durability for its intended use.
Emission Standards:
Designed to meet emissions standards applicable in its original production period and markets.
