🏷️ Basic Information Identification Make: Kawasaki Model: KDX200 / KDX220 Product Type: Downloadable PDF Repair Manual Codes Model Years Covered: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Engine Type: 2-Stroke 👋 Introduction Market Position Target Audience: Owners and technicians of 1995-2006 Kawasaki KDX200 and KDX220 2-stroke motorcycles. Competitive Analysis Provider: GearHead Manuals - positioned as the sole source for these specific repair manual downloads. Key Features Accessibility: Instant download, no shipping costs, immediate access to repair information. Convenience: Accessible on smartphones for trailside or on-site repairs, minimizing downtime. Customer Service: Support for finding unlisted manuals. 📋 Manual Details Coverage Areas Manual Type: Repair Service Manual / Workshop Manual Language: English Format: Downloadable PDF Delivery Method: Instant Digital Download Additional Manual Types: Owner's Manuals, Parts Catalogs (implied availability) 📖 Manual Coverage Systems Covered Engine Systems: Engine Removal and Installation, Fuel System, Lubrication and Cooling System, Engine Specifications, Intake & Exhaust Drivetrain Systems: Transmission, Drive Chain & Sprockets Chassis Systems: Steering System, Shocks, Body Work Electrical Systems: Electrical System Procedures Included Maintenance: Routine Maintenance, General Information Troubleshooting: Advanced Troubleshooting Repair: Comprehensive repair procedures for all covered systems Technical Depth Depth: Detailed step-by-step instructions with diagrams and specifications for DIY and professional mechanics. 📊 Manual Specifications File Format File Type: PDF Usability: Plain, simple, easy-to-use PDFs; no ZIP files or additional software required. Print Quality Printing: Printable pages for on-site or workshop use, protecting the original digital file. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Support Protection Policy: Lifetime Protection Policy: Free replacement if lost or damaged. ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke Performance Displacement Kdx200: 198cc (approximate, varies slightly by year/sub-model) Displacement Kdx220: 215cc (approximate, varies slightly by year/sub-model) Cooling System: Liquid-cooled Fuel System Carburetion: Typically Keihin carburetors (specific models vary by year, e.g., PWK series) Fuel Type: Unleaded gasoline mixed with 2-stroke engine oil. Lubrication Oil Injection: Automatic oil injection system. Ignition System: Digital CDI (Capacitor Discharge Ignition) Engine Details Reed Valve Induction: Yes, a key feature of 2-stroke performance. Kawasaki Top Performance Engine Technology: Includes advanced features for power and reliability within the 2-stroke class. 🔧 Transmission Standard Type: 6-speed constant mesh manual transmission. Features Clutch Type: Wet multi-disc clutch. Final Drive: Chain drive (O-ring sealed). 📐 Dimensions Exterior Wheelbase: Varies by year and model, typically around 56.3 inches (1430 mm). Seat Height: Varies by year and model, typically around 36.2 inches (919 mm). Weights Dry Weight: Varies by year and model, typically in the range of 230-240 lbs (104-109 kg). Capacities Fuel Tank Capacity: Varies by year and model, typically around 2.4 gallons (9.1 liters). 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle, not subject to automotive crash ratings). Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Lighting: Headlight, taillight, brake light, turn signals (depending on trim/region). 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle instrumentation: speedometer, odometer, neutral indicator, high beam indicator). Driver Assistance Driver Assistance Features: N/A (Focus on mechanical and electrical systems, not electronic rider aids). 🔧 Maintenance Service Intervals Oil Change Interval: Recommended based on operating hours or mileage; details in manual. Spark Plug Maintenance: Regular inspection and replacement based on usage; specific plug types and gaps provided in manual. Air Filter Cleaning: Frequent cleaning/replacement recommended for optimal performance, especially in dusty conditions. Fluid Specifications Coolant Type: Ethylene glycol-based antifreeze mixed with distilled water (specific mixture ratio in manual). Transmission Oil Type: API GL-4 or GL-5 gear oil (specific viscosity grade like 75W-90 or 80W-90 recommended in manual). Fork Oil Type: Specific viscosity grade and type (e.g., SAE 10W) as detailed in the manual. 2 Stroke Oil Type: High-quality 2-stroke motorcycle oil meeting JASO FD or FC specifications. Known Issues Common Wear Items: Piston rings, clutch plates, brake pads, wheel bearings, chain and sprockets. Carburetor Maintenance: Requires regular cleaning and adjustment due to fuel volatility and potential for gumming. Technical Tips Engine Decarbonization: Periodic decarbonization of the combustion chamber and exhaust port is beneficial for 2-stroke engines. 📚 Vehicle History Brand Heritage Kawasaki Offroad Legacy: Kawasaki has a strong heritage in off-road and motocross racing, with the KDX line being a prominent part of its dual-sport and trail offerings. Model Evolution Kdx Line Development: The KDX series evolved from earlier models, focusing on a balance of trail riding capability and off-road performance, with displacement increases leading to the KDX220. Production Production Period: The KDX200 and KDX220 were produced for an extended period, with the models covered by this manual representing a significant evolution of the platform. Market Segment Category: Dual-sport / Off-road trail motorcycle. 🏆 Awards & Recognition Recognitions Industry Recognition: The KDX series generally received positive reviews for its off-road prowess and versatility during its production run, often praised for its balance of power and handling. Ratings...