Basic Information Identification Make: Kawasaki Model: KDX200 Year: 1992 Product Name: Kawasaki ATV KDX 200 1992 Digital Service Repair Manual PDF Download Vehicle Type: All-Terrain Vehicle (ATV) Introduction Market Position Target User: Kawasaki KDX200 owners, DIY mechanics, professional technicians Value Proposition: Provides official dealer-level repair information for cost-effective maintenance and repair. Competitive Analysis Manual Quality: Comparable to official dealer workshop manuals in detail and accuracy. Key Features Ease Of Use: Designed to be simple to use with step-by-step diagrams. Comprehensiveness: Covers every part of the vehicle for complete service needs. Manual Details Coverage Areas Primary Coverage: Complete workshop and service procedures Secondary Coverage: Electrical diagrams, torque settings, fluid capacities Page Count Estimated Page Count: Refer to specific manual content for exact count Manual Type Type: Service Repair Manual / Workshop Manual Language Language: English Format Format: PDF Manual Coverage Systems Covered Engine Disassembly Assembly: Engine Top End, Engine Right Side, Engine Removal/Installation, Engine Bottom End Transmission Fuel System: Carburetion, fuel tank, fuel lines, fuel pump (if applicable) Cooling System: Radiator, hoses, water pump, coolant specifications Drivetrain: Wheels/Tires, Final Drive, Transmission Braking System: Brakes (front and rear), hydraulic systems, pads, rotors Suspension Steering: Suspension (front and rear), Steering system components Electrical System: Wiring diagrams, ignition system, lighting, charging system General Information: Vehicle identification, safety precautions, general maintenance Appendix: Torque specifications, fluid capacities, special tools, troubleshooting charts Procedures Included Maintenance Tasks: Oil changes, spark plug replacement, filter replacement, chain adjustment (if applicable), brake fluid flush Diagnostic Procedures: Troubleshooting guides for common issues, electrical system diagnostics Repair Procedures: Engine rebuilds, transmission overhaul, brake caliper replacement, suspension component repair Installation Replacement: Component replacement (e.g., carburetor, exhaust system, lighting) Technical Data Provision: Torque specifications, fluid capacities, clearances, timing settings Technical Depth Depth: Comprehensive (from basic maintenance to full engine and component rebuilds) Manual Specifications File Format File Type: PDF Requirements: Adobe PDF Reader, WinZip Interactivity: Zoom in/out capability Compatibility: All Versions of Windows & Mac Print Quality Printability: Printable Binding Type Binding: Digital Download (PDF) Paper Type Paper: N/A (Digital) Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Displacement: 198 cc (12.09 cubic inches) Cooling System: Liquid-cooled Bore X Stroke: 66.0 x 58.0 mm (2.60 x 2.28 inches) Compression Ratio: Typically around 7.4:1 (check specific manual for exact value) Ignition: CDI (Capacitor Discharge Ignition) Performance Horsepower: Approx. 30-35 HP (verify with manual) Torque: Approx. 20-23 lb-ft (verify with manual) Fuel System Carburetor Type: Mikuni VM29SS (or similar) Fuel Type: Unleaded gasoline (recommend 87 octane or higher) Fuel Mixture: Pre-mix (2-stroke oil mixed with gasoline) or Oil Injection System (depending on specific KDX200 sub-model; manual will clarify) Fluid Specifications Engine Oil Type: 2-stroke engine oil (JASO FD or API TC rated) Transmission Oil Type: API GL-4 SAE 10W-30 or 10W-40 gear oil (verify with manual) Coolant Type: Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio) Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet multi-disc Final Drive: Chain drive Dimensions Exterior Length: Approx. 2010 mm (79.1 inches) Width: Approx. 800 mm (31.5 inches) Height: Approx. 1170 mm (46.1 inches) Weights Dry Weight: Approx. 107 kg (236 lbs) Fuel Tank Capacity: Approx. 9.5 liters (2.5 US gal) Wheelbase Wheelbase: Approx. 1365 mm (53.7 inches) Safety Features Ratings Safety Standards: Designed for off-road use; adherence to ATV safety guidelines is paramount. Active Features Braking System: Hydraulic disc brakes (front and rear) for reliable stopping power. Passive Features Ergonomics: Designed for rider control and stability during off-road operation. Warnings Protective Gear Recommendation: Always wear appropriate safety gear (helmet, goggles, gloves, boots, riding apparel). Technology Features Infotainment Infotainment System: N/A (Basic off-road ATV design) Driver Assistance Driver Assistance Features: N/A (Focus on rider control and basic functionality) Connectivity Connectivity Options: N/A Lighting System Headlight: Halogen (typical) Taillight: Incandescent (typical) Maintenance Service Intervals Engine Oil Change: Check owner's manual or service manual; typically every 10-20 hours of operation or annually. Air Filter Cleaning: Clean or replace every 5-10 hours of operation, or as needed based on riding conditions. Spark Plug Replacement: Inspect regularly, replace as needed or per manual recommendation (e.g., every 50-100 hours). Chain Lubrication Adjustment: Lubricate chain every ride, adjust tension every 10-20 hours. Brake System Inspection: Inspect brake pads, fluid level, and lines before each ride. Fluid Specifications Engine Oil Capacity: Refer to manual for specific pre-mix ratio or oil injection system capacity. Transmission Oil Capacity: Approx. 1.0 liter (1.1 US qt) (verify with manual) Known Issues Common Wear Items: Clutch plates, brake pads, tires, chain and sprockets, piston/cylinder wear (typical for high-performance 2-strokes). Carburetor Cleaning: Carburetors can require periodic cleaning due to fuel quality or usage patterns. Vehicle History Brand Heritage Kawasaki Atv Legacy: Kawasaki has a long-standing history in ATV development, focusing on performance and reliability. Model Evolution Kdx Lineage: The KDX line is renowned for its off-road prowess, often used in recreational...