The 1994 Kawasaki KDX-200 is a capable off-road motorcycle renowned for its reliable two-stroke engine and agile handling, offering strong performance for enduro and dual-sport applications. Building on Kawasaki's established reputation for performance and innovation in the off-road segment, this model represents a refined iteration of the celebrated KDX lineage. Its design prioritizes robust off-road capability and a competitive spirit, making it a favored choice for riders seeking a potent and versatile machine. This comprehensive service manual provides essential information for the professional technician and experienced DIY mechanic. It covers all aspects of repair and maintenance, including detailed procedures for the engine, transmission, chassis, electrical, and braking systems. The manual offers step-by-step instructions, critical specifications, and troubleshooting guidance to ensure the KDX-200 is maintained in optimal condition, empowering owners to perform routine servicing and complex repairs. 🏷️ Basic Information Identification Make: Kawasaki Model: KDX-200 Year: 1994 Vehicle Type: Off-Road Motorcycle / Dual-Sport Category: Enduro/Off-Road 👋 Introduction Market Position Market Segment: Competitive entry-level to mid-range off-road/enduro motorcycle Competitive Analysis Competitors: Yamaha YZ/WR series, Honda CR/CRF series, Suzuki RM/RMX series, KTM EXC series Key Features Key Selling Points: Reliable two-stroke engine, capable off-road performance, dual-sport potential with proper modification Manual Value Proposition Value For Owner: Empowers owners to perform maintenance and repairs, saving costs and ensuring longevity 📋 Manual Details Coverage Areas Coverage Type: Comprehensive Repair and Service Intended Audience: Professional Technicians and Experienced DIY Mechanics Page Count Page Count: Unknown (PDF document size varies) Manual Type Manual Type: Service Manual / Repair Manual / Workshop Manual Language Language: English Format Format: PDF Download File Format: PDF Print Quality: Full Printable Zoom Capability: YES Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip Compatibility Operating Systems: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine System: Complete overhaul, top-end, bottom-end, cooling, lubrication, ignition, fuel delivery Transmission System: Clutch, gearbox internal components, shifting mechanism, lubrication Chassis System: Frame, suspension (front forks, rear shock), steering, swingarm Electrical System: Wiring diagrams, lighting, charging system, ignition system, component testing Braking System: Front and rear brake assembly, hydraulic system, disc and caliper servicing Fuel System: Carburetor disassembly, cleaning, adjustment, fuel tank, fuel lines Exhaust System: Muffler, header pipe, mounting, maintenance Cooling System: Liquid cooling system components, radiator, water pump, coolant specifications Wheels And Tires: Wheel bearing service, tire installation, spoke tensioning Bodywork: Fairings, fenders, seat, tank removal and installation Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Disassembly: Component-level disassembly and identification Assembly: Reassembly procedures with torque specifications Cleaning: Cleaning procedures for various engine and chassis components Reinstalling: Proper installation of serviced components Troubleshooting: Diagnostic procedures for common faults and issues Rebuilding: Detailed instructions for engine and component rebuilding Adjustments: Carburetor, clutch, brake, and suspension adjustments Technical Depth Depth Level: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds Detail Level: Step-by-step instructions, detailed illustrations/pictures, critical specifications 📊 Manual Specifications File Format File Type: PDF Print Quality Print Capability: Yes Binding Type Binding Type: Digital (N/A for printed) Paper Type Paper Type: Digital (N/A for printed) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, reed valve induction Displacement: 198 cc Bore X Stroke: 66.0 mm x 58.0 mm Compression Ratio: 9.2:1 (typical, check manual for exact) Performance Horsepower: Approx. 35-40 HP (estimated, varies with tuning and condition) Torque: N/A (manual data required) Fuel System Carburetor Type: Mikuni VM29SS (typical) Fuel Type: Unleaded gasoline (91 octane or higher recommended) Fuel Oil Mixture: 50:1 ratio with high-quality 2-stroke oil (manual specification is critical) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet, multi-disc Gear Ratios: Manual data required (typically specified in manual) Transmission Fluid Type: API GL-4, SAE 80W/90 hypoid gear oil (check manual for exact specification) 📐 Dimensions Exterior Length: N/A (manual data required) Width: N/A (manual data required) Height: N/A (manual data required) Weights Dry Weight: Approximately 227 lbs (103 kg) (check manual for exact specification) Wet Weight: N/A (manual data required) Fuel Capacity: Approximately 2.4 US gallons (9.0 L) (check manual for exact specification) 🛡️ Safety Features Ratings Safety Certification: N/A (Motorcycle, not typically rated by consumer safety organizations in the same way as cars) Active Features Braking System: Hydraulic disc front and rear Passive Features Frame Construction: High-tensile steel semi-double cradle frame 💡 Technology Features Infotainment Infotainment System: None (This is a 1994 off-road motorcycle) Driver Assistance Driver Assistance Features: None (This is a 1994 off-road motorcycle) Connectivity Connectivity Options: None (This is a 1994 off-road motorcycle) 🔧 Maintenance Service Intervals Oil Change Frequency: Refer to manual for specific intervals based on usage (e.g., every 5-10 hours of off-road use for gearbox oil). Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions (e.g., every few rides). Spark Plug Replacement: Recommended every 10-20 hours of riding or as per manual's recommendation. Fluid...