🏷️ Basic Information Identification Make: Kawasaki Model: KDX200 Year: 1990 Vehicle Type: All-Terrain Vehicle (ATV) Codes Chassis Code: KDX200-E1 👋 Introduction Market Position Vehicle Segment: Sport/Off-Road ATV Competitive Analysis Competitors 1990: Yamaha YZ250/Warrior, Honda TRX250R/FourTrax, Suzuki LT250R/LT-F250 Key Features Vehicle Positioning: Known for its lightweight, agile handling and powerful two-stroke engine, a favorite for trail riding and amateur racing. Manual Value Proposition: Provides dealership-level service information, empowering owners and independent mechanics for comprehensive maintenance and repair. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics Page Count Estimated Page Count: Estimated 200-300 pages (typical for this era's comprehensive manuals) Manual Type Type: Digital Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: General Information, Fuel System, Cooling System, Engine Top End, Engine Right Side, Engine Removal/Installation, Engine Bottom End Transmission Drivetrain Systems: Transmission, Wheels/Tires, Final Drive Chassis Systems: Brakes, Suspension, Steering Electrical Systems: Electrical System Auxiliary Systems: Appendix (likely includes torque settings, fluid capacities, wiring diagrams) Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug maintenance, chain adjustment, brake pad replacement, suspension adjustments Repair Procedures: Engine rebuilds (top and bottom end), transmission overhauls, brake caliper overhauls, carburetor tuning/rebuilding, electrical component testing/replacement Troubleshooting Procedures: Diagnostic guides for common issues, electrical fault finding Technical Depth Depth: Comprehensive: From basic user maintenance to full engine and component overhauls. Diagrams: Detailed step-by-step diagrams and illustrations 📊 Manual Specifications File Format Requirements: Adobe PDF Reader, WinZip (for potential archive extraction) Compatibility: All versions of Windows & Mac Features: Zoom In/Out capability Print Quality Printability: Likely printable pages, optimized for clarity Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, Reed Valve Displacement: 198 cc Bore X Stroke: 66.0 x 58.0 mm (typical for KDX200 of this era) Compression Ratio: 7.8:1 (typical) Carburetor: Keihin PWK33 (typical for this model) Ignition: CDI (Capacitor Discharge Ignition) Performance Horsepower Estimated: Approx. 28-30 HP (at crankshaft, estimated for stock configuration) Torque Estimated: Approx. 19-21 lb-ft (at crankshaft, estimated for stock configuration) Fuel System Fuel Type: Unleaded gasoline, 91 octane (AKI) or higher recommended Fuel Mixture: 2-stroke oil pre-mix (typically 50:1 or 40:1 ratio specified in manual) Cooling System Cooling Method: Liquid-cooled Coolant Type: Ethylene glycol-based antifreeze with corrosion inhibitors (specified in manual) Coolant Capacity: Approx. 1.2 Liters (refer to manual for exact capacity) 🔧 Transmission Standard Type: 6-speed constant mesh Clutch Type: Wet, multi-plate Features Gear Ratios: Specific ratios detailed in the manual, crucial for performance tuning. Transmission Oil Type: API GL-4 SAE 80W or 90W gear oil (refer to manual for exact specification and capacity) 📐 Dimensions Exterior Length: Approx. 75.6 inches (1920 mm) (refer to manual for exact) Width: Approx. 45.5 inches (1155 mm) (refer to manual for exact) Height: Approx. 44.1 inches (1120 mm) (refer to manual for exact) Weights Dry Weight: Approx. 249 lbs (113 kg) (refer to manual for exact) Fuel Capacity: Approx. 2.6 US gallons (9.8 Liters) (refer to manual for exact) 🛡️ Safety Features Ratings Safety Standards: ATV safety standards of the era, with emphasis on rider responsibility and safe operating practices. Active Features Braking System: Hydraulic disc brakes front and rear, providing effective stopping power. Suspension System: Long-travel independent front suspension and a Uni-Trak rear suspension system for handling rough terrain. 💡 Technology Features Infotainment Infotainment Features: N/A (Basic ATV design of the era focused on performance and utility, not infotainment). Driver Assistance Driver Assistance Features: N/A (No electronic driver assistance systems in this model). 🔧 Maintenance Service Intervals Oil Change Interval: Recommended every 20-40 hours of operation or annually (refer to manual for precise intervals). Air Filter Cleaning: Inspect and clean every 5-10 hours of operation, depending on riding conditions. Spark Plug Replacement: Recommended every 100-200 hours of operation or as needed based on inspection. Fluid Specifications Engine Oil: 2-stroke engine oil, SAE 10W-30 (for oil injection system, refer to manual for exact specification). Brake Fluid: DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for exact specification). Known Issues Common Wear Items: Piston rings, clutch plates, chain and sprockets, wheel bearings, brake pads, and fork seals are common wear items on ATVs of this age and type. Carburetor Issues: Carburetor jetting and cleaning are crucial for optimal performance, especially after periods of storage or if using incorrect fuel mixtures. 📚 Vehicle History Brand Heritage Kawasaki Atv Legacy: Kawasaki has a strong history in off-road performance vehicles, including a significant presence in the ATV market with models like the Bayou and the sport-oriented KDX line. Model Evolution Kdx200 Series: The KDX200 was a popular model in Kawasaki's ATV lineup, known for its performance and off-road capabilities, evolving through various iterations from the mid-1980s. Production Production Period: The KDX200 was produced...