Positioning:
The KDX200 was a highly regarded and popular off-road/enduro motorcycle, known for its potent two-stroke engine, capable suspension, and versatility for trail riding and competition.
Competitors Era:
Competed directly with models like the Yamaha YZ series, Suzuki RM series, and Honda CR series in the enduro and motocross segments, as well as other manufacturers' dedicated off-road machines.
Engine Type:
Liquid-cooled, piston-reed valve induction, two-stroke single-cylinder engine.
Suspension Type:
Long-travel telescopic front forks (often USD in later models) and a single rear shock absorber with linkage (Uni-Trak).
Chassis Design:
Lightweight steel perimeter frame, designed for agility and durability in off-road conditions.
Braking System:
Powerful front and rear hydraulic disc brakes for superior stopping power.
Power Delivery:
Known for strong mid-range and top-end power characteristics, making it effective for both trail riding and competition.
Covered Years:
1989, 1990, 1991, 1992, 1993, 1994
Approximate Pages:
Refer to product listing for exact page count; typically 300-600 pages for comprehensive manuals of this era.
Type:
Service and Repair Manual
Format:
Likely Digital (PDF); Print version may be available.
Engine:
Detailed overhaul, diagnosis, troubleshooting, carburetor, ignition, cooling (liquid-cooled models), lubrication.
Transmission:
Clutch, gearbox, shift mechanism, lubrication, troubleshooting, rebuild procedures.
Chassis:
Frame, suspension (front forks, rear shock), steering, swingarm, wheel bearings.
Brakes:
Hydraulic disc brakes (front and rear), master cylinders, calipers, brake lines, bleeding procedures.
Electrical:
Ignition system (CDI), lighting, charging system (alternator/stator), battery, wiring diagrams, troubleshooting.
Fuel System:
Fuel tank, petcock, fuel lines, carburetor (Mikuni VM series typical), jetting, tuning.
Exhaust System:
Expansion chamber, muffler, service and cleaning.
Bodywork:
Body panels, seat, fenders, handlebars, levers, cables.
Maintenance:
Regular service checks, oil changes, filter replacements, chain adjustment, spark plug service, pre-ride inspections.
Troubleshooting:
System-specific diagnostic charts, common problem identification and solutions.
Repair:
Engine rebuilds, transmission overhaul, suspension service, brake system repairs, electrical component replacement.
Disassembly Assembly:
Step-by-step guides for component removal and reinstallation.
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds. Includes detailed specifications and diagnostic procedures.
Digital Format Details:
Searchable PDF, allowing for quick information retrieval by keyword. High-resolution scans of original factory manuals.
Print Quality Notes:
If printed, expect clear text and diagrams. Designed for clarity during workshop use.
Binding Type Notes:
If printed, typically spiral-bound or comb-bound for lay-flat use on a workbench.
Paper Type Notes:
If printed, durable paper stock suitable for workshop environments.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder, reed valve induction
Displacement:
198cc (approximately)
Bore X Stroke:
Typically around 66.0 x 58.0 mm
Compression Ratio:
Generally around 7.0:1 to 7.5:1 (varies by year)
Ignition:
Digital CDI (Capacitor Discharge Ignition)
Power Output:
Estimates range from 30-35 HP, depending on specific model year and tuning.
Torque Output:
Torque figures typically around 20-23 lb-ft, optimized for off-road performance.
Carburetor:
Mikuni VM series, typically a VM29 or similar, with variable jetting for altitude and conditions.
Fuel Type:
Unleaded gasoline with a minimum octane rating of 91 (RON+MON)/2 (e.g., 87 AKI). Premixing with 2-stroke oil required.
Oil Type:
High-quality 2-stroke engine oil, specifically formulated for air-cooled or liquid-cooled engines, meeting JASO FD or similar specifications.
Cooling Medium:
Liquid-cooled (ethylene glycol based antifreeze mixture)
Mixture Ratio:
Pre-mix 2-stroke oil at a ratio of 40:1 or 50:1 with gasoline, as specified by Kawasaki.
Transmission Type:
6-speed constant mesh manual transmission
Clutch Type:
Wet, multi-plate, manual clutch
Gear Ratios:
Specific gear ratios will be detailed in the manual, optimized for off-road performance across various terrains.
Final Drive:
Chain drive (RK or similar, 520 pitch typical)
Transmission Oil Type:
API GL-4, SAE 80W or 10W-40 motorcycle transmission oil (check specific manual for exact specification and capacity).
Overall Length:
Approx. 2150-2200 mm (varies slightly by year)
Overall Width:
Approx. 800-850 mm (at handlebars)
Overall Height:
Approx. 1230-1270 mm
Wheelbase:
Approx. 1420-1440 mm
Ground Clearance:
Approx. 310-340 mm
Seat Height:
Approx. 920-940 mm
Dry Weight:
Approx. 105-115 kg (varies by year and features)
Wet Weight:
Approx. 118-128 kg (with all fluids)
Fuel Tank Capacity:
Approx. 9.5 - 11 Liters (including reserve)
Safety Standards:
Designed for off-road use; road legality varies by region and specific model configuration. Not subject to typical automotive crash safety ratings.
Braking System:
Dual hydraulic disc brakes (front and rear) with ample stopping power for off-road conditions.
Suspension Setup:
Long-travel, adjustable suspension provides stability and control over rough terrain.
Ergonomics:
Designed for rider comfort and control during extended off-road excursions. Handlebar position, seat shape, and footpeg placement are optimized.
Lighting:
Headlight and taillight for visibility, especially crucial for trail riding and potential limited road use depending on local regulations.
Features:
As an off-road motorcycle from this era, the KDX200 does not feature infotainment systems. Focus is on core mechanical and electrical function.
Features:
No electronic driver assistance systems. Technology is focused on mechanical performance.
Features:
No digital connectivity features. Designed for pure off-road riding experience.
Oil Change Transmission:
Every 10-15 hours of riding or annually, whichever comes first. (Refer to manual for specific intervals).
Spark Plug Inspection Replacement:
Inspect every 10-15 hours, replace as needed. (NGK BR8ES or equivalent typical).
Air Filter Cleaning Replacement:
Clean after every few rides, especially in dusty conditions. Replace when damaged or degraded.
Chain Adjustment Lubrication:
Check and adjust chain slack every 5-10 hours of riding. Lubricate after washing or after riding in wet conditions.
Coolant Flush Replacement:
Flush and replace coolant every 1-2 years, or as recommended by the manual.
Engine Oil Premix:
High-quality 2-stroke motorcycle oil, e.g., Motul 800 2T Off Road, Yamalube 2R, or similar meeting JASO FD specification. Ratio: 40:1 or 50:1.
Transmission Oil:
API GL-4, SAE 80W or 10W-40 motorcycle gear oil. Capacity approximately 0.7-0.8 liters.
Coolant:
Permanent type coolant (ethylene glycol based), mixed 50/50 with distilled water. Capacity approximately 1.0-1.2 liters.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific requirement).
Carburetor Fouling:
Common in 2-stroke engines, requires regular cleaning and proper jetting.
Power Valve Sticking:
Kawasaki's KIPS (Kawasaki Integrated Power Valve System) can accumulate carbon and require periodic cleaning to maintain optimal performance.
Suspension Seals:
Wear and tear on fork seals and rear shock seals can lead to leaks, requiring replacement.
Clutch Wear:
Clutch plates can wear out over time, especially with aggressive riding, requiring replacement.
Ignition Coil Failure:
While generally reliable, ignition coils can fail, leading to no spark.
Exhaust Gasket Leaks:
Exhaust gaskets can degrade, leading to leaks and loss of power.
Kawasaki Motorsports:
Kawasaki has a long and storied history in motorcycle racing and off-road performance, building a reputation for powerful and reliable machines.
Kdx Lineage:
The KDX line has a lineage dating back to the early 1980s, with continuous development and refinement leading to models like the 1989-1994 KDX200, which saw significant updates including liquid cooling and improved suspension.
Production Period:
The KDX200 was produced for a significant period, with the 1989-1994 models representing a key generation known for its blend of power, handling, and durability. Production continued with further iterations beyond this range.
Manufacturing Location:
Primarily manufactured by Kawasaki Heavy Industries, Ltd. in Japan.
