🏷️ Basic Information Identification Make: Kawasaki Model: KDX200 / KDX220 Model Variants: KDX200, KDX220 Production Years Covered: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Vehicle Type: Off-road Motorcycle 👋 Introduction Market Position Segment: Lightweight Off-Road / Enduro Motorcycle Target Audience: Enthusiasts, DIY Mechanics, Trail Riders, Competitors Competitive Analysis Competitors: Yamaha YZ series, Suzuki RM series, Honda CR series (off-road variants), KTM EXC series Key Features Vehicle Heritage: The KDX line was known for its accessible performance, user-friendliness, and strong low-to-midrange power delivery, making it a popular choice for recreational trail riding and enduro competitions. Manual Benefit 1: Enables DIY maintenance and repairs, saving on labor costs. Manual Benefit 2: Provides instant access to critical information for on-trail repairs. Manual Benefit 3: Environmentally friendly digital format. 📋 Manual Details Coverage Areas Manual Type: Repair Manual / Workshop Manual Language: English Format: Electronic Downloadable PDF Distribution Method: Instant Download after Payment Additional Offerings: Owner's Manuals, Parts Catalogs 📖 Manual Coverage Systems Covered Engine: 2-Stroke Engine Service, Overhaul, and Tuning Fuel System: Carburetor (Keihin PWK) Adjustment, Cleaning, and Rebuild; Fuel Tank and Lines Lubrication And Cooling: 2-Stroke Oil Injection System, Radiator, Coolant System Transmission Drive: Transmission, Clutch, Drive Chain, Sprockets, Shifting Mechanism Steering Suspension: Steering Head Bearings, Handlebars, Front Forks (Conventional), Rear Shock Absorber, Linkage System Brakes: Front and Rear Hydraulic Disc Brakes (Pads, Calipers, Master Cylinders, Hoses) Electrical System: Ignition System (CDI), Lighting, Battery, Wiring Diagrams, Troubleshooting Intake Exhaust: Airbox, Reed Valves, Exhaust Pipe, Silencer Bodywork Frame: Seat, Fenders, Fuel Tank, Side Panels, Frame Inspection and Repair Procedures Included Maintenance: Routine Service Intervals, Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service Troubleshooting: Advanced Diagnostic Procedures, Common Faults and Fixes Repair: Engine Overhaul, Transmission Rebuild, Suspension Service, Brake System Repair, Electrical Component Replacement Installation: Engine Removal and Installation, Component Replacement Technical Depth Depth: Comprehensive: Covers routine maintenance to full engine rebuilds and advanced troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely Searchable Text (common for quality PDF manuals) Printability: Printable pages for on-site use Resolution: High-quality (implied for effective repair use) Data Protection: Lifetime Protection Policy (if lost or damaged) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 2-stroke, Reed-valve induction Kdx200 Displacement: 198 cc (approx.) Kdx220 Displacement: 215 cc (approx.) Bore X Stroke Kdx200: 66.0 x 58.0 mm (approx.) Bore X Stroke Kdx220: 68.0 x 59.0 mm (approx.) Compression Ratio: Varies slightly by year, typically around 7.6:1 Performance Horsepower Kdx200: Approx. 35-40 HP (at crankshaft, estimates vary) Horsepower Kdx220: Approx. 38-43 HP (at crankshaft, estimates vary) Torque: Strong low-to-midrange torque delivery characteristic of the KDX series. Fuel System Carburetor: Keihin PWK (typically 33mm or 35mm depending on model year and variant) Fuel Type: Unleaded gasoline (87 octane or higher recommended) Oil Injection: Automatic 2-stroke oil injection system (Kawasaki's KIPS system is related to exhaust port timing, not lubrication directly but often discussed in conjunction) 🔧 Transmission Standard Type: 6-speed constant mesh Optional Features: Wide-ratio gearing suitable for off-road use Features Clutch Type: Wet, multi-plate Drive Chain: O-ring sealed chain (e.g., 520 pitch) 📐 Dimensions Exterior Seat Height Approx: 37-38 inches Wheelbase Approx: 57-58 inches Weights Dry Weight Approx: 220-235 lbs Fuel Capacity: Approx. 2.4 - 2.6 gallons 🛡️ Safety Features Ratings NHTSA Rating: N/A (Motorcycles are not typically rated by NHTSA for crash safety in the same way as cars). Active Features Braking: Hydraulic disc brakes front and rear for reliable stopping power. Suspension: Long-travel suspension for absorbing impacts and maintaining control on uneven terrain. Passive Features Frame Design: Strong steel perimeter frame for chassis rigidity and durability. 💡 Technology Features Infotainment Features: N/A (This is a performance-oriented off-road motorcycle, lacking typical automotive infotainment features). Driver Assistance Features: N/A (Focus is on rider control and mechanical function). 🔧 Maintenance Service Intervals Oil Change Frequency: Typically every 10-15 hours of riding or annually. Refer to manual for exact details. Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions (e.g., every few rides). Spark Plug Replacement: Consult manual; typically based on hours or performance degradation. Fluid Specifications Engine Oil Type Injector: High-quality 2-stroke synthetic or semi-synthetic oil (e.g., Kawasaki K-Premix, Yamalube 2-Stroke Oil, or equivalent spec oil). Transmission Oil Type: API GL-4, SAE 10W-40 or 10W-30 motorcycle gear oil (e.g., Kawasaki Gear Oil, Bel-Ray Gear Saver, Motul Gear 300). Coolant Type: Ethylene glycol-based antifreeze coolant mixed with distilled water (50/50 ratio typical). Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake fluid. Known Issues Piston Rings Wear: Common wear item on 2-strokes; requires periodic inspection and replacement based on compression readings. Reed Valve Damage: Can be damaged by debris or improper setup, leading to performance loss. Carburetor Cleaning: Carburetors can get gummed up with stale fuel or debris, requiring regular cleaning and adjustment, especially for ethanol-laced fuels. Kawasaki Integrated Power Valve System (Kips) Maintenance:...