🏷️ Basic Information Identification Make: Kawasaki Model: KDX220 / KDX220R Product Name: Kawasaki KDX 220 & KDX 220R Motorcycle Complete Workshop Service Repair Manual Codes Applicable Years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Generation Generation Identifier: Second Generation KDX220 👋 Introduction Market Position Segment: Off-road motorcycle, Enduro/Trail riding segment. Competitive Analysis Competitors: Yamaha YZ250, Honda CR250R, KTM 250 EXC (for the era). Key Features Manufacturer Focus: Kawasaki's KDX line was known for its accessible performance, ease of maintenance, and adaptability for trail riding and light competition, often bridging the gap between pure motocross and dedicated trail bikes. Manual Benefit: Empowers owners to perform maintenance and repairs themselves, saving significant costs on dealer labor, and fostering a deeper understanding of their motorcycle. 📋 Manual Details Coverage Areas General Coverage: Complete Service and Repair Procedures A-Z Model Variants Covered: All KDX220 and KDX220R models, all engine types, all trim levels, all transmission types. Page Count Estimated Page Count: Detailed page count not specified, but described as 'complete' covering all procedures. Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, top-end rebuild (cylinder, piston, rings), bottom-end rebuild (crankshaft, connecting rod, bearings), cooling system (if applicable, though typically air-cooled), lubrication system, fuel system (carburetor, fuel pump, lines), ignition system, exhaust system, starting system. Drivetrain Systems: Transmission overhaul, clutch operation and adjustment, gear shift mechanism, drive chain maintenance and adjustment, rear suspension linkage. Chassis Systems: Frame inspection and repair, front suspension (forks, seals, oil changes), rear shock absorber, steering system, wheel bearing maintenance, brake systems (front and rear disc brakes, hydraulics, pads, calipers), electrical system (wiring diagrams, lighting, battery, charging system), bodywork (plastics, fenders, seat). Procedures Included Maintenance Procedures: Regular servicing, oil changes, filter replacements, chain lubrication and adjustment, brake pad inspection and replacement, spark plug replacement, carburetor cleaning and adjustment, air filter cleaning/replacement, suspension adjustments. Repair Procedures: Engine component replacement, transmission rebuild, clutch service, suspension overhaul, brake system repairs, electrical troubleshooting, carburetor rebuilding, body panel repair/replacement. Troubleshooting: Diagnostic flowcharts for common performance issues, starting problems, electrical faults, and operational anomalies. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including detailed disassembly and assembly instructions, specifications, and torque values. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Software Requirement: Adobe Reader (free download) Print Quality Printability: Fully printable, allowing users to print individual pages, chapters, or the entire manual. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, reed valve, single-cylinder Bore X Stroke: 66.0 x 64.0 mm Displacement: 217 cc (216 cm³) Compression Ratio: Approx. 7.8:1 (Actual values may vary slightly by year and specific tune) Carburetor Model: Keihin PWK35 (Typically, may vary slightly by year) Ignition: Digital CDI (Capacitor Discharge Ignition) Performance Horsepower: Approx. 45-48 HP (at crankshaft, depending on specific tune and year) Torque: Approx. 25-27 lb-ft (at crankshaft, depending on specific tune and year) Fuel System Fuel Type: Unleaded gasoline (91 octane or higher recommended) Fuel Mixture: Pre-mix (50:1 ratio with high-quality 2-stroke oil recommended for standard operation, check manual for specific oil type) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multiple-disc Features Gear Ratios: Specific gear ratios detailed in the manual, essential for performance tuning and diagnosis. Final Drive: Chain drive (typically 520 O-ring sealed chain) 📐 Dimensions Exterior Length: Approx. 84.4 inches (2,145 mm) Width: Approx. 31.7 inches (805 mm) Height: Approx. 47.4 inches (1,205 mm) Weights Dry Weight: Approx. 234 lbs (106 kg) Wet Weight: Approx. 250 lbs (113 kg) (with all fluids, but no fuel) Fuel Capacity: Approx. 2.4 US gallons (9 Liters) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycles are not subject to the same crash test ratings as passenger vehicles). Active Features Braking System: Hydraulic disc brakes front and rear. Dual-piston caliper front, single-piston caliper rear. Suspension Stability: Adjustable front forks (preload, compression, rebound on some models) and rear shock (preload, rebound damping) contribute to stable handling. Passive Features Lighting: Headlight, taillight, brake light, turn signals (standard on R models for street legality, often optional or removed for dedicated off-road use). 💡 Technology Features Infotainment Features: N/A (This is a mechanical off-road motorcycle with no infotainment systems). Driver Assistance Features: N/A (No electronic rider aids or driver assistance systems are present on this model). Connectivity Features: N/A (No connectivity features). 🔧 Maintenance Service Intervals Oil Change Engine: Refer to manual for transmission oil change interval. Engine lubrication is via pre-mix fuel. Chain Lube Adjust: Every 300-500 miles (500-800 km) or as needed based on riding conditions. Air Filter Cleaning: Every 5-10 hours of riding or as needed, especially in dusty conditions. Spark Plug Replacement: Approx. every 1,000-2,000 miles (1,600-3,200 km)...