1986 Kawasaki KDX 200 Manual PDF

The 1986 Kawasaki KDX 200 is a legendary two-stroke enduro motorcycle featuring a 198cc liquid-cooled engine, 6-speed transmission, Uni-Trak rear suspension, and front disc brake. This comprehensive manual covers all aspects of ownership, maintenance, and repair for this classic off-road machine. Below are key sections covering specifications, maintenance procedures, troubleshooting, and technical data.

1. Features at a Glance 2. Specifications 3. Maintenance Schedule 4. Engine Service 5. Fuel System 6. Electrical System 7. Chassis & Suspension 8. Brakes 9. Troubleshooting 10. Technical Data 11. Parts Catalog

Features at a Glance

Key components: Liquid-cooled two-stroke engine, 6-speed transmission, Uni-Trak rear suspension, front disc brake, aluminum swingarm.

Feature	Description
Engine Type	Liquid-cooled, single-cylinder two-stroke
Displacement	198cc
Bore x Stroke	66.0 x 58.0 mm
Compression Ratio	7.7:1
Carburetor	Keihin PWK 34mm
Transmission	6-speed constant mesh
Final Drive	Chain
Suspension Front	Telescopic fork
Suspension Rear	Uni-Trak system
Brakes Front	Single disc
Brakes Rear	Drum
Dry Weight	229 lbs (104 kg)

Specifications

Engine: 198cc liquid-cooled two-stroke single
Power Output: Approximately 32 hp
Fuel Capacity: 2.6 gallons (10 liters)
Oil Capacity: Transmission oil 0.8 liters
Ignition System: CDI electronic ignition
Starting System: Kick starter
Frame Type: Semi-double cradle steel
Wheelbase: 56.3 inches (1430 mm)
Seat Height: 36.2 inches (920 mm)
Ground Clearance: 12.2 inches (310 mm)

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

After each ride: Clean air filter, check tire pressure, inspect chain tension
Every 15 hours: Change transmission oil, check spark plug
Every 30 hours: Clean carburetor, check brake pads
Every 60 hours: Top end rebuild, suspension service
Annually: Wheel bearing inspection, frame bolt torque check

WARNING! Always use proper safety equipment and follow torque specifications.

Engine Service

Two-stroke engine maintenance procedures.

Top End Rebuild: Remove cylinder, inspect piston and rings, measure cylinder wear
Carburetor Cleaning: Disassemble Keihin PWK, clean jets, check float height
Cooling System: Check radiator, replace coolant annually
Exhaust System: Clean power valve, repack silencer
Transmission: Drain and refill with recommended oil

CAUTION! Engine must be cool before disassembly. Use proper gaskets and seals.

Fuel System

Keihin PWK 34mm carburetor specifications and maintenance.

Component	Specification
Main Jet	#158 (standard)
Pilot Jet	#48
Needle	R1170N (clip position 3)
Float Height	16mm
Air Screw	1.5 turns out

Fuel Mix: 32:1 premium gasoline to two-stroke oil

Electrical System

CDI ignition, lighting, and charging system details.

Spark Plug: NGK BR8ES, gap 0.6-0.7mm
Battery: 12V 4Ah (if equipped with lighting)
Stator Output: 70W AC
Ignition Timing: Fixed at 1.8mm BTDC
Lighting: Headlight 35W/35W, taillight 5W

Tip: Keep electrical connections clean and dielectric grease applied.

Chassis & Suspension

Frame, suspension tuning, and wheel maintenance.

Front Fork: Oil capacity 375ml per leg, 10WT oil
Rear Shock: Nitrogen pressure 142 psi, sag setting 100mm
Swingarm: Grease bearings annually
Wheel Bearings: Inspect for play every 60 hours
Chain: DID 520, tension 1.2-1.6 inches free play

WARNING! Always support motorcycle properly when working on suspension.

Brakes

Front disc and rear drum brake maintenance.

Component	Specification
Front Disc	Diameter 240mm, thickness 3.5mm
Front Pads	Wear limit 1.5mm
Rear Drum	Diameter 150mm, wear limit 151mm
Brake Fluid	DOT 4
Brake Lever Free Play	2-3mm

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Fouled plug, stale fuel	Replace spark plug, drain old fuel
Poor performance	Clogged air filter, exhaust restriction	Clean air filter, decarbonize exhaust
Transmission noise	Low oil, worn gears	Check oil level, inspect transmission
Overheating	Low coolant, radiator blockage	Check coolant level, clean radiator fins
Electrical failure	Bad connections, failed stator	Check wiring, test stator output

Technical Data

Torque Specifications: Cylinder head nuts 20 Nm, spark plug 25 Nm
Fluid Capacities: Coolant 1.1L, transmission oil 0.8L
Bearing Sizes: Front wheel 6302, rear wheel 6304
Electrical: Resistance values for stator and ignition coil testing
Tire Pressures: Front 12 psi, rear 10 psi (off-road)

Parts Catalog

Genuine Kawasaki part numbers for common replacement items.

Part	Part Number
Piston Kit	13001-1093
Piston Rings	13048-1093
Cylinder	11001-1093
Air Filter	11009-1093
Spark Plug	BR8ES (NGK)
Front Brake Pads	43081-1093
Chain	92052-1093

Service: Contact authorized Kawasaki dealer for genuine parts