Kawasaki KDX200 1983 - 1988 Clymer Owners Service & Repair Manual covers Kawasaki KDX200 dual-sport bike 1983 to 1988.
● QUICK REFERENCE DATA
● GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Engine operation / Washing the bike / Torque specifications / Fasteners / Lubricants / RTV Gasket sealant / Threadlock / Parts replacement / Optional parts / Basic hand tools / Precision measureing tools / Special tools / Fabricating tools / Expendable supplies / Mechanic's tips / Safety / Specifications
Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Engine starting trouble / Engine / Engine performance / Engine noises / Excessive vibration / Fuel system / Two-stroke pressure testing / Clutch /Transmission / Ignition system / Front suspension and steering / Brakes
● LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-checks / Tyres and wheels / Lubricants / Cleaning solvent / Engine lubrication / Periodic lubrication / Oil level check / Fork oil change / Periodic maintenance / Engine tune-up / Valve clearance adjustment / Air filter / Suspension adjustment / Storage / Specifications
● ENGINE TOP END
Engine principles / Engine lubrication / Engine cooling / Cleanliness / Servicing engine in frame / Cylinder head / Cylinder / Piston, wrist pin and piston rings / Break-in procedure / Reed valve assembly / Specifications
● ENGINE LOWER END
Servicing engine in frame / Engine / Engine sprocket / Crankcase and crankshaft / Specifications
● CLUTCH, KICKSTARTER AND EXTERNAL SHIFT MECHANISM
Clutch cover (1983-1985) / Clutch cover (1986-on) / Clutch / Primary drive gear / Clutch cable / Clutch release mechanism / Kickstarter / External shift mechanism / Specifications
● TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation / Transmission / Transmission overhaul / Internal shift mechanism / Specifications
● FUEL AND EXHAUST SYSTEMS
Air cleaner / Carburetor operation / Carburetor service (1983-1987) / Carburetor fuel level adjustment / Fuel tank / Fuel shutoff valve / Exhaust system / Exhaust system decarbonizing / Exhaust system repair / Specifications
● ELECTRICAL SYSTEM
Capacitor discharge system / Magneto / Capacitor discharge ignition unit / Ignition coil / Spark plug / Engine kill switch / Lighting system / Enduro timer case / Wiring diagrams / Specifications
● FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Tyre changing / Tyre repairs / Handlebar / Steering head / Front fork / Specifications
● REAR SUSPENSION
Rear wheel / Rear hub / Drive sprocket / Drive chain / Tyre changing and Tyre repairs / Uni-trax rear suspension / Uni-trax shock absorber (1983-1985) / Uni-trax shock absorber (1986-on) / Uni-trax linkage / Swing arm / Swing arm bearing / Specifications
Drum brakes / Front brake cable / Front disc brake (1986-on) / Front brake pad replacement / Front caliper / Front master cylinder / Front brake hose replacement / Front brake disc / Bleeding the system / Specifications
● WIRING DIAGRAMS
Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.
General information on Repair Manuals
Please note that workshop manuals are usually written for models sold in a specific country.
Differences in specification can exist between models sold in different countries and items such as engines can vary.
Please check that the manual will cover your model before purchase and if you are unsure please contact us first.