1986 KDX 200 Manual

The 1986 KDX 200 is a versatile two-stroke enduro motorcycle featuring a 198cc air-cooled engine, 6-speed transmission, Uni-Trak rear suspension system, front disc brake, and rear drum brake. Designed for both trail riding and competitive enduro use, this manual covers maintenance, specifications, operation, and troubleshooting procedures to ensure optimal performance and longevity.

Features at a Glance

Key components: 198cc two-stroke engine, 6-speed transmission, Uni-Trak rear suspension, front disc brake, rear drum brake, Mikuni carburetor.

Feature	Description
Engine Type	198cc air-cooled two-stroke single
Transmission	6-speed constant mesh
Suspension Front	Telescopic fork
Suspension Rear	Uni-Trak system
Brakes Front	Hydraulic disc
Brakes Rear	Mechanical drum
Carburetor	Mikuni VM32SS
Fuel Capacity	2.6 gallons (10 liters)
Weight	224 lbs (102 kg) dry
Seat Height	34.6 inches (880 mm)

Installation & Assembly

Unpack and inspect all components. Ensure proper assembly before operation.

1. Handlebar installation: Mount handlebars to triple clamp, tighten bolts to specification.
2. Wheel assembly: Install front and rear wheels, check axle nut torque.
3. Control cables: Route throttle, clutch, and brake cables properly.
4. Fluid checks: Add engine oil, transmission fluid, and brake fluid as required.

WARNING! Motorcycle is heavy; use proper lifting techniques. Ensure all fasteners are properly torqued.

First-Time Setup

Complete pre-ride inspection and setup before initial operation.

1. Fuel mixture: Prepare 32:1 fuel/oil mixture using recommended two-stroke oil.
2. Tire pressure: Set to 15 psi front, 15 psi rear for standard conditions.
3. Suspension adjustment: Set sag and damping to rider weight and conditions.
4. Control adjustment: Adjust lever positions and cable free play.

CAUTION! Always wear proper protective gear. Break in engine gradually during first hours of operation.

Specifications

• Engine: 198cc air-cooled two-stroke single
• Bore x Stroke: 66.0 x 58.0 mm
• Compression Ratio: 7.7:1
• Carburetion: Mikuni VM32SS
• Ignition: CDI electronic
• Transmission: 6-speed constant mesh
• Final Drive: Chain 520-112 links
• Suspension Travel Front: 10.2 inches (260 mm)
• Suspension Travel Rear: 10.6 inches (270 mm)
• Brakes Front: Single disc 240mm
• Brakes Rear: Drum 130mm
• Wheelbase: 56.7 inches (1440 mm)

Controls and Operation

Familiarize yourself with all controls before riding.

Left Handlebar: Clutch lever, horn button, turn signal switch, high/low beam switch.

Right Handlebar: Front brake lever, throttle grip, engine stop switch, start button.

Operation: Start with choke when cold, allow warm-up before riding. Use proper shifting technique - clutch in for all gear changes. Avoid lugging engine at low RPM.

Maintenance Procedures

Regular maintenance is essential for optimal performance and safety.

1. Pre-ride inspection: Check tires, controls, lights, fluid levels.
2. Chain adjustment: Maintain 1.2-1.6 inches (30-40mm) free play.
3. Air filter service: Clean every 100 miles or after dusty conditions.
4. Spark plug: Check and clean every 200 miles, replace as needed.
5. Brake service: Check pad wear, fluid level, and lever free play.

Tip: Keep maintenance log to track service intervals.

Engine Service

Two-stroke engine requires specific maintenance procedures.

1. Top end service: Inspect piston and rings every 50 hours of operation.
2. Cylinder inspection: Check for scoring and proper cross-hatch pattern.
3. Reed valve: Inspect for cracks or damage during top end service.
4. Carburetor cleaning: Disassemble and clean every 6 months or 500 miles.
5. Power valve: Clean and inspect during major service intervals.
6. Cooling system: Check for leaks, ensure radiator fins are clean.
7. Exhaust system: Remove and clean carbon buildup regularly.

WARNING! Always use proper fuel/oil mixture. Never run engine without adequate lubrication.

Electrical System

CDI ignition system provides reliable spark with minimal maintenance.

Battery: 12V 4Ah maintenance-free. Charging system: AC magneto. Lighting: 35W headlight, 21W/5W tail/brake light. Troubleshooting: Check spark first, then coil resistance, stator output, and CDI unit.

Care & Storage

Proper storage prevents damage during periods of non-use.

Drain fuel system or add stabilizer. Remove battery and store charged. Clean and lubricate entire motorcycle. Inflate tires to maximum pressure. Store in dry, covered location.

CAUTION! Do not store with fuel in carburetor. Protect from moisture and temperature extremes.

Regulatory Information

Manufactured to meet applicable DOT and EPA standards for off-road motorcycles. Designed for off-road use only - not legal for highway operation in most states. Always obey local riding regulations and land use laws. For support, contact Kawasaki Motors Corp., U.S.A. or authorized dealers.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Fouled plug, stale fuel	Replace spark plug; drain old fuel; check compression.
Poor performance	Clogged air filter, carb issues	Clean air filter; service carburetor; check reed valve.
Transmission issues	Low oil, worn clutch	Check oil level; adjust clutch; inspect gears.
Electrical failure	Bad connections, stator	Check all connections; test stator output; verify ground.
Brake problems	Worn pads, air in system	Replace pads; bleed brakes; adjust lever.

Reset: For electrical issues, disconnect battery for 30 seconds to reset CDI.

Service: Contact authorized Kawasaki dealer for major repairs and parts.