1998 - 2004 Kawasaki Kdx 200 Service Workshop Repair Manual

Kawasaki KDX200/KDX220 service manual 1995-2006 This manual is comprised of a base manual for the Kawasaki KDX200, along with a supplement manual to make it relevant for the KDX220. Kawasaki service manuals sometimes utilize this build-on-earlier models method when two models are similar to each other. Use the links below or the bookmarks to the left to get to the manual that covers your model. Kawasaki KDX200 base manual Kawasaki KDX220 supplement manual

Kawasaki KDX200 Motorcycle Service Manual © Kawasaki Heavy Industries. ltd . 1994 First Edition (1) : Jut 15, 1994 (M)

LIST OF ABBREVIATIONS A ampere(s) Ib pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound{s) per square inch "C degree(s) Celsius , revolution DC direct current 'pm revolution(s) per minute F farad(s) TOC top dead center "F degree(s) Fahrenheit TIA total indicator reading ft foot. feet V volt(s) 9 gram(s) W watt(s) h hour(s) n ohm(s) L liter(s) Read OWNER'S MANUAL before operating.

This quick referen ce gui de wi t! assi st you in locating a desired topic or procedure. • Bood the pages back to match the black tab of the des ired chapter number with the black tab on the edge at each table of c ontents page. • Refer to the sectional table of con toots for the exact pages to locate the specific topic required. Quick Reference Guide General Information Fuel System Cooling System Engine Top End Clutch Engine Removal/Installation CrankshaftlTransmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix I 1 1 I 2 1 I 3 1 I 4 1 I 5 I I 6 1 I 7 1 I 8 1 9 1 101 111 121 131 14. 151

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However, It contains enough detail and basic Information to make It useful to the owner who deSires to perlorm his own baSIC maintenance and repair work_ A basic knowledge of mechanics, the proper use of tools. and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient expertence or doubts his ability to do the work, all adjustments. maintenance. and repair should be carried out only by qualified mechanics. In order to periorm the work efficiently and to avoid castly mistakes, read the text. thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substi - tute tools may adversely affect safe operation We recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. To get the longest life out of your Motorcycle: e Follow the Periodic Maintenance Chart in the Service Manual. e Be alert for problems and non -scheduled mamte- nance. .U se proper tools and genuine Kawasaki Motorcy- cle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki Motorcy- cles are introduced by the Special Tool Catalog or Manual. Genuine parts provided as spare parts are listed in the Parts Catalog . .Follow the procedures in this manual carefully. Don't take shortcuts. e Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use this Manual In preparing this manual. we divided the product Into ItS major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own compre- hensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section. Whenever you see these WARNING and CAUTION symbols, heed their instructions I Always follow safe operating and maintenance practices. .. WARNING This warning symbol identifies special instructions or procedures which. if not correctly followed. could rasult In personal Injury. or loss of life. CAlJT10N This caution symbol identifies spaciel instructions or procedures which. if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distingUIsh different types of information.

NOTE o This note symbol indicates points of particular interest (Of more efficient and convenient operation . • Indicates a procedural step or work to be done. Otndicales a procedural sub-step or how to do the work of the procedural step it follows. II also precedes the text of a NOTE. *lndicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-slep it follows. In most chapters an exploded "jew illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil. grease or a locking agent during assembly.

GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ......................................................................................................... 1·2 Model Identification .................................................................................................... 1 -4 General Speci fications ... ............................................................ ... ............................ .. 1-5 Periodic Maintenance Chart ....................................................................................... 1- 7 Technical Information - KIPS (Kawasaki Integrated Power Valve System) ...... .... .. 1-8 Torque and Locking Agent ........................................................ ...............................1·" Special Tools and Sealant ................................................................................... .. . .. 1·14 Cable, Wire, and Hose Routing .. ..................................................................... , .... , ... 1 ·19

1-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs. diagrams, notes, cautions, warnings, and detaJled descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations. a certain amount of basic knowledg e is also required for successful work. Especially note the following ; (1) Dirt Before removal and disassembly, clean the motorcycle, Any dirt entering the engme or other parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before Installing a new part clean off any dust or metal filings. (2) Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. But if this Service Manual has installation or assembly procedures, follow them . (3) Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them an in their holes and tighten them to a snug fit. Then tighten them evenly in a cross panern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them_ Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. (4) Torque When torque values are given in this Service Manual, use them. Either too linle or too much torque may lead to serious damage. Use a good quality, reliable tOfque wrench. (5) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic -faced mallet. Use an impact driver for sc rews (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (8) Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign maner and perfectly smooth to avoid oil or compression leaks. (9) Liquid Gasket. Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block. engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock'n Seal (B lu e). (10) Press A part installed using a press or driver, such as a wheel bea ring (hub bearing), sho uld first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (11) Bait Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones, as removal generally damages bearing. Install bearings with the marked side facing out applying pressure evenly with a suitable driver. Only press on the race that forms the press fit with the base component to avoid damaging the bearings. This prevents severe stress on the balls or needles and races, and prevent races and balls or needles from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft.

GENERAL INFORMATION 1-3 (12) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal. until the face of the seal is even with the end of the hole. Before a shaft passes through a seal. apply a little high temperature grease on the lips to reduce rubber to metal friction. (13) Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circtips and retaining rings, take care to compress or expand them only enough to install them and no more. (14) Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (15) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulfide grease (MOS2 ) in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants. (16) Electrical Wires All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color. (17) Replacement Parts Wire (cross-section) Red Wire Strands Yellow Red Name of Wire Color Yellow/Red When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (18) Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (19) Specifications Specification terms are defined as follows: "Standards H show dimensions or performances which brand-new parts or systems have. "Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

1-4 GENERAL INFORMATION Model Identification K0X200-H1 Left Side View K0X200-H1 Right Side View

1998 - 2004 Kawasaki Kdx 200 Service Workshop Repair Manual

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