1987 Kawasaki KDX200 Manual

The 1987 Kawasaki KDX200 is a versatile two-stroke enduro motorcycle featuring a 198cc liquid-cooled engine, 6-speed transmission, Uni-Trak rear suspension, and front disc brake. This manual covers safety guidelines, technical specifications, maintenance procedures, troubleshooting, and operational instructions for proper care and operation of your KDX200.

1. Features at a Glance 2. Installation & Assembly 3. First-Time Setup 4. Specifications 5. Controls and Operation 6. Maintenance Procedures 7. Engine Service 8. Electrical System 9. Care & Storage 10. Regulatory Information 11. Troubleshooting

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 liquid-cooled single cylinder two-stroke
Transmission	6-speed constant mesh
Suspension Front	Air-adjustable telescopic fork
Suspension Rear	Uni-Trak swingarm with adjustable shock
Brakes Front	Hydraulic disc
Brakes Rear	Mechanical drum
Carburetor	Mikuni VM34SS
Fuel Capacity	2.6 gallons (10 liters)
Oil Capacity	1.1 quarts (1.0 liter)
Weight	229 lbs (104 kg) dry

Installation & Assembly

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

Handlebar installation: Align handlebar with top clamp, tighten bolts to specification.
Front wheel assembly: Install wheel with spacers, tighten axle nut to 65-80 Nm.
Controls setup: Install clutch and brake levers, adjust free play.
Fuel system: Connect fuel lines, check for leaks.

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.

Fluid levels: Check engine oil, coolant, and brake fluid.
Tire pressure: Set to 15 psi front, 15 psi rear for off-road use.
Suspension adjustment: Set sag and adjust damping for rider weight.
Fuel mixture: Use 32:1 fuel/oil ratio for break-in period.

CAUTION! Always wear proper protective gear. Complete break-in procedure before aggressive riding.

Specifications

Engine: 198cc liquid-cooled two-stroke single
Bore x Stroke: 66.0 x 58.0 mm
Compression Ratio: 7.7:1
Transmission: 6-speed, wet multi-plate clutch
Final Drive: Chain, 13T/47T sprockets
Frame: Semi-double cradle, steel
Wheelbase: 56.3 inches (1430 mm)
Seat Height: 35.6 inches (905 mm)
Ground Clearance: 12.2 inches (310 mm)
Fuel System: Mikuni VM34SS carburetor

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, engine stop switch, start button.

Instrumentation: Speedometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators.

Starting Procedure: Turn fuel on, pull choke, shift to neutral, pull clutch, press start button.

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

Pre-ride inspection: Check tires, controls, lights, fluid levels.
Chain adjustment: Maintain 1.2-1.6 inches (30-40 mm) free play.
Air filter service: Clean every 200 miles or after dusty conditions.
Spark plug: Replace every 1,000 miles or as needed.

Tip: Keep maintenance records for reference and resale value.

Engine Service

Two-stroke engine requires specific maintenance procedures.

Top end rebuild: Inspect piston and cylinder every 100 hours.
Carburetor adjustment: Main jet 155, pilot jet 48, needle clip position 3.
Crankcase seals: Replace if engine shows air leak symptoms.
Cooling system: Check radiator cap (1.1 kg/cm²), flush coolant annually.
Exhaust system: Clean power valve mechanism regularly.
Transmission oil: Change every 15 hours or 500 miles.
Reed valve: Inspect for cracks or damage during service.
Ignition timing: Set to 1.8mm BTDC at 5,000 RPM.

WARNING! Use proper tools and follow torque specifications. Engine components are precision items.

Electrical System

CDI ignition system with 6-volt electrical components.

Battery: 6N6-3B maintenance-free, 6V 5Ah. Charging system: AC magneto. Bulbs: Headlight 25/25W, brake/tail 21/5W, turn signals 10W.

Care & Storage

Proper storage prevents deterioration during periods of non-use.

Drain fuel system or add stabilizer. Remove battery and store charged. Clean and lubricate chain. Inflate tires to maximum pressure. Cover motorcycle to protect from dust and moisture.

CAUTION! Store in dry, well-ventilated area. Do not store near heat sources or flammable materials.

Regulatory Information

Manufactured to meet applicable DOT and EPA standards for 1987 model year. Kawasaki Heavy Industries, Ltd. Copyright © 1987 Kawasaki Motors Corp., U.S.A. For technical support, contact authorized Kawasaki dealership or Kawasaki Consumer Relations at 1-800-661-RIDE.

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; inspect carburetor jets; check reed valve.
Overheating	Low coolant, lean mixture	Check coolant level; inspect for leaks; adjust carburetor.
Transmission issues	Worn clutch, low oil	Adjust clutch cable; change transmission oil; inspect plates.
Electrical problems	Bad connections, weak battery	Check all connections; test battery; inspect stator.

Service Intervals: Oil change every 15 hours, air filter every 200 miles, top end inspection every 100 hours.

Support: 1-800-661-RIDE; www.kawasaki.com