Target Audience:
Professional Technicians, DIY Mechanics, Owners with Basic Mechanical/Electrical Knowledge
Manual Type Comparison:
Comparable to factory service manuals and owner's manuals, often containing information not readily available in stores. Offers convenience over traditional paper manuals.
Value Proposition:
Enables owners to perform maintenance and repairs effectively, understand their vehicle better, and make informed decisions about servicing. Emphasizes factory-level knowledge transfer.
Content Focus:
Step-by-step repair procedures, critical specifications, illustrations/pictures, maintenance, disassembly, assembly, cleaning, and reinstalling.
Engine:
Complete engine overhaul, top-end and bottom-end rebuilds, carburetor tuning, ignition system diagnostics and repair, cooling system (if applicable, though typically air-cooled), exhaust system.
Transmission:
Clutch operation and adjustment, gearbox disassembly and reassembly, shift mechanism, lubrication.
Suspension:
Front forks (KYB USD forks typical for this era), rear shock absorber, linkage system, seals and bushings, adjustment procedures.
Brakes:
Front and rear hydraulic disc brake system service, master cylinder, caliper, brake lines, bleeding procedures.
Electrical:
Wiring diagrams, lighting system, ignition system, charging system (stator, flywheel), troubleshooting common electrical faults, component testing.
Chassis And Body:
Frame inspection, sub-frame, footpegs, handlebars, plastics, seat, fuel tank removal and installation, bearing checks (steering head, swingarm).
Maintenance:
Regular service intervals, oil changes, filter replacements, chain adjustment and lubrication, spark plug inspection/replacement, air filter cleaning.
Disassembly Assembly:
Detailed, step-by-step instructions for component removal, disassembly, cleaning, inspection, and reassembly.
Troubleshooting:
Diagnostic flowcharts and guidance for identifying and resolving common performance issues, starting problems, and system malfunctions.
Rebuilds:
Complete engine rebuild procedures, including piston, rings, cylinder, crankshaft, and bearing replacement.
Depth:
Comprehensive, suitable for professional technicians and advanced DIY mechanics with basic mechanical and electrical knowledge. Covers intricate details for full rebuilds and diagnostics.
Engine Type:
2-Stroke, Liquid-Cooled, Reed Valve
Displacement:
198 cc (12.09 cubic inches)
Bore X Stroke:
66.0 mm x 58.0 mm (2.60 in x 2.28 in)
Compression Ratio:
7.2:1 (Typical for this era)
Power Output:
Approximately 30-35 HP (estimated, actual may vary)
Torque:
Not explicitly stated, but significant for its class
Ignition:
CDI (Capacitor Discharge Ignition)
Starting System:
Kick Starter
Carburetor Model:
Keihin PWK (typically 33mm)
Fuel Type:
Unleaded Gasoline (87 Octane or higher recommended)
Fuel Mixture:
Pre-mix gasoline and 2-stroke oil (ratio specified in manual, typically 50:1 or 40:1)
Fuel Tank Capacity:
Approximately 2.6 US gallons (9.8 Liters)
Overall Length:
Approx. 84.6 in (2150 mm)
Overall Width:
Approx. 31.7 in (805 mm)
Overall Height:
Approx. 47.6 in (1210 mm)
Dry Weight:
Approx. 229.3 lbs (104 kg)
Wet Weight:
Not specified, but higher than dry weight.
Wheelbase:
Approx. 56.3 in (1430 mm)
Ground Clearance:
Approx. 13.0 in (330 mm)
Seat Height:
Approx. 35.2 in (895 mm)
Safety Ratings:
N/A (Off-road motorcycle, not subjected to automotive safety crash tests)
Braking System:
Hydraulic Disc Front and Rear
Suspension Control:
Adjustable front forks and rear shock for varying terrain conditions.
Lighting:
Headlight, taillight, brake light for visibility.
Ergonomics:
Designed for off-road control and rider confidence.
Oil Change Engine:
Refer to manual for specific interval based on usage (e.g., every 10-15 hours of riding or annually).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions. Specific interval in manual.
Chain Lubrication Adjustment:
Regularly, every 200-300 miles or after wet rides. Check tension frequently.
Spark Plug Inspection:
Every 10-15 hours of riding. Check gap and condition.
2 Stroke Oil:
API TC or JASO FD certified 2-stroke oil. Refer to manual for specific brand/viscosity recommendations.
Transmission Oil:
Kawasaki Motorcycle Gear Oil or equivalent SAE 10W-30 API GL-4. Capacity: Approx. 0.8 Liters (0.85 US qt).
Coolant:
N/A (Air-cooled engine)
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Carburetor Cleaning:
Can be prone to gumming if fuel sits; regular cleaning and proper fuel stabilizer use is advised.
Power Valve System:
The KIPS (Kawasaki Integrated Powervalve System) can accumulate carbon and require periodic cleaning/servicing for optimal performance.
Suspension Seals:
Fork seals can degrade over time, leading to oil leaks; regular inspection and replacement as needed.
Clutch Wear:
Clutch plates can wear with aggressive use, requiring adjustment or replacement.
Kawasaki Motorcycles:
Kawasaki has a long-standing reputation for performance-oriented motorcycles, particularly in the off-road and motocross segments.
Kdx Lineage:
The KDX series, particularly the KDX-200, was a highly successful and popular line of off-road motorcycles known for their versatility, performance, and reliability in enduro and trail riding.
Production Era:
The KDX-200 was produced over several generations, with significant updates throughout its lifespan. The 1991 model represents a key iteration of this well-regarded platform.
Manufacturing Location:
Japan
