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1994 Kdx 200 Service Manual Free Download
When reference is made in KAWASAKI KDX200 KDX-200 BIKE 1989-1994 WORKSHOP MANUAL to a brand name, number, or specific tool, an equivalent product may be used in place of the recommended item. All information, illustrations and specifications contained in KAWASAKI KDX200 KDX-200 BIKE 1989-1994 WORKSHOP MANUAL are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice.
KAWASAKI KDX200 KDX-200 BIKE 1989-1994 WORKSHOP MANUAL includes pictures and easy to follow directions on what tools are needed and how the repair is performed. Just imagine how much you can save by doing simple repairs yourself. You can save anywhere from hundreds if not thousands of dollars in repair bills by using this KAWASAKI KDX200 KDX-200 BIKE 1989-1994 WORKSHOP MANUAL. Many people buy this manual just to have it around for when the inevitable happens. Sooner or later, maintenance will need to be performed. Be prepared for it when it happens by simply purchasing this service manual for later use! See below for a list of items that most of our manuals cover. Some manuals actually cover more items that are not even listed!
KAWASAKI KDX200 KDX-200 BIKE 1989-1994 WORKSHOP MANUAL COVERED:
Cheery Cherry Punch
Removing the outboard drive
Location and Signal Assignment
METHODS OF TOWING MACHINE
Determining the piston class
Captain Control Panel
Adjustment Record Play
Arrangement of the console to truck adaptor connectors
Spiral spring setting
Wind screen wiper
Oil Cooler and Filter Housing
Travel Motor Hose Installation
Kdx 200 For Sale Craigslist
Total Pages: 656
Size: 21.28Mb
FORMAT: PDF / WINRAR
LANGUAGE: English
Compatibility:Win95/98/ME/XP/vista/7/8/10/Linux/MAC
Also can be used on any devices that runs IOS / Android
Delivery:Instant Download!! To assist filing of revised information, each sub-section is numbered from page 1. Individual items are to be overhauled in the sequence in which they appear in the Manual. Items numbered in the illustrations are referred to in the text.
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- 2List of Abbreviations
- 3Quick Reference Guide
- 4Foreword
- 6General Information
- 6Table of Contents
- 7Before Servicing
- 9Model Identification
- 9KDX200-H1 Left Side View
- 9KDX200-H1 Right Side View
- 10General Specifications
- 12Periodic Maintenance Chart
- 13Kips Mechanism
- 13Technical Information-KIPS (Kawasaki Integrated Power Valve System)
- 14Operation at Low Engine Speed
- 15Operation at MID to High Engine Speed
- 16Torque and Locking Agent
- 16Basic Torque for General Fasteners
- 19Special Tools and Sealant
- 24Cable, Wire, and Hose Routing
- 28Fuel System
- 29Exploded View
- 31Specifications
- 32Throttle Grip and Cable
- 32Free Play Inspection/Adjustment
- 33Installation
- 33Cable Lubrication
- 33Cable Inspection
- 34Carburetor
- 34Idle Speed Inspection
- 34Idle Speed Adjustment
- 34Service Fuel Level Inspection
- 35Service Fuel Level Adjustment
- 36Removal
- 37Fuel Inspection
- 37Disassembly
- 38Assembly
- 38Carburetor Cleaning
- 39Carburetor Inspection
- 41Air Cleaner
- 41Housing Removal/Installation
- 41Element Removal/Installation
- 41Element Cleaning and Inspection
- 43Fuel Tank
- 43Fuel Tap Removal
- 43Fuel Tap Installation
- 44Fuel Tap Inspection
- 44Fuel Tank and Tap Cleaning
- 45Reed Valve
- 45Inspection
- 46Cooling System
- 49Coolant Level Inspection
- 49Coolant Deterioration Inspection
- 50Coolant Change
- 50Coolant Draining
- 50Coolant Filling
- 51Recommended Coolant
- 52Cooling System Pressure Testing
- 53Cooling System Flushing
- 54Water Pump
- 54Cover Removal/Installation
- 54Impeller Removal/Installation
- 54Impeller Inspection
- 55Shaft Removal
- 55Shaft Installation
- 55Water Pump Inspection
- 55Mechanical Seal Replacement
- 56Mechanical Seal Inspection
- 57Radiator
- 58Cap Inspection
- 58Filler Neck Inspection
- 59Cooling Hoses, Breather Hose Installation
- 59Cooling Hoses, Breather Hose Inspection
- 60Engine Top End
- 64Cylinder Head
- 64Cylinder Compression Measurement
- 65Warp Inspection
- 66Cylinder Removal
- 66Cylinder Installation
- 67Piston Removal
- 67Piston Installation
- 68Cylinder Wear Inspection
- 69Piston Diameter Measurement
- 69Piston/Cylinder Clearance
- 69Piston Ring, Piston Ring Groove Inspection
- 70Piston Ring End Gap Inspection
- 71Exhaust Valve (KIPS)
- 73Muffler (Expansion Chamber, Silencer)
- 73Spark Arrester Cleaning
- 75Clutch
- 79Clutch Cable
- 79Clutch Lever Free Play Check
- 79Clutch Lever Free Play Adjustment
- 80Clutch Release Lever Angle Inspection, Adjustment
- 81Lubrication and Inspection
- 82Clutch Cover
- 83Right Engine Cover
- 85Exhaust Advancer Assembly
- 86Clutch Removal
- 88Friction and Steel Plates Wear/Warp Inspection
- 88Spring Free Length Measurement
- 88Friction Plate/Clutch/Housing Finger Damage
- 89Clutch Hub Spline Inspection
- 90External Shift Mechanism
- 91Primary Gear
- 92Kickstarter
- 93Kick Idle Gear Removal
- 93Kick Idle Gear Installation
- 94Engine Removal/Installation
- 96Engine Removal
- 97Engine Installation
- 98Crankshaft/Transmission
- 102Transmission Oil
- 102Level Inspection
- 102Change
- 104Crankcase
- 104Splitting
- 107Crankshaft, Connecting Rod
- 108Crankshaft Bearing Check
- 108Connecting Rod Big End Radial Clearance
- 108Connecting Rod Big End Seizure
- 108Connecting Rod Big End Side Clearance
- 109Crankshaft Runout
- 109Crankshaft Alignment
- 110Transmission
- 110Shaft Removal/Installation
- 110Shaft Disassembly/Assembly
- 111Shift Drum and Fork Installation
- 111Shift Fork Bending
- 111Shift Fork/Gear Groove Wear
- 112Shift Fork Guide Pin/Shift Drum Groove Wear
- 112Gear Dog, Gear Dog Hole, and Dog Recess Damage
- 112Ball Bearing Wear
- 113Wheels/Tires
- 116Wheels (Rims)
- 116Front Wheel Removal
- 116Front Wheel Installation
- 117Rear Wheel Removal
- 118Rear Wheel Installation
- 119Spoke Inspection
- 119Rim Inspection
- 119Rim Runout (With Tire Installed)
- 119Axle Inspection
- 120Air Pressure Inspection/Adjustment
- 120Standard Tire
- 122Hub Bearings (Wheel Bearings)
- 124Trip Meter Gear Housing
- 124Gear Housing Disassembly/Assembly
- 124Gear Housing Lubrication
- 125Final Drive
- 128Drive Chain
- 128Slack Inspection
- 128Slack Adjustment
- 129Wear Inspection
- 129Lubrication
- 131Engine Sprocket Removal
- 131Engine Sprocket Installation
- 131Rear Sprocket Removal/Installation
- 133Brakes
- 137Brake Lever, Brake Pedal
- 137Lever Play Adjustment
- 137Pedal Position Adjustment
- 137Pedal Removal
- 138Pedal Installation
- 139Brake Fluid Recommendation
- 141Bleeding the Brake Line
- 143Front Caliper Removal
- 143Front Caliper Installation
- 143Rear Caliper Removal
- 144Rear Caliper Installation
- 146Front Brake Pad Removal
- 146Front Brake Pad Installation
- 146Rear Brake Pad Removal
- 147Rear Brake Pad Installation
- 148Front Master Cylinder Removal
- 148Front Master Cylinder Installation
- 148Rear Master Cylinder Removal
- 149Rear Master Cylinder Installation
- 149Front Master Cylinder Disassembly
- 149Rear Master Cylinder Disassembly
- 150Inspection (Visual Inspection)
- 151Brake Disc
- 152Brake Hose
- 152Removal/Installation
- 153Suspension
- 157Front Fork
- 157Air Pressure Adjustment
- 157Compression Damping Adjustment
- 157Fork Oil Level Adjustment
- 160Fork Oil Change
- 161Fork Spring Replacement
- 164Inner Tube Inspection
- 164Spring Inspection
- 165Rear Shock Absorber
- 165Rebound Damping Adjustment
- 165Spring Adjustment
- 168Spring Replacement
- 168Disassembly (Oil Change)
- 170Assembly (Oil Filling)
- 172Scrapping
- 173Swingarm Removal/Installation
- 173Swingarm Bearing Removal
- 174Swingarm Bearing Installation
- 174Swingarm Pivot Check
- 174Swingarm Bearing, Sleeve Inspection
- 175Tie-Rod Removal
- 175Tie-Rod Installation
- 175Rocker Arm Removal
- 176Rocker Arm/Tie-Rod Bearing Removal/Installation
- 176Uni-Trak Link Pivot Check
- 176Rocker Arm/Tie-Rod Bearing Inspection
- 176Rocker Arm/Tie-Rod Sleeve Inspection
- 177Steering
- 180Steering Inspection
- 180Steering Adjustment
- 181Stem, Stem Bearing Removal
- 182Stem, Stem Bearing Installation
- 184Steering Maintenance
- 184Stem Bearing Lubrication
- 184Stem Bearing Wear, Damage
- 184Stem Warp
- 185Frame
- 188Seat Removal
- 189Electrical System
- 192Parts Location
- 193KDX200-H1 Wiring Diagram
- 195Precautions
- 196Electrical Wiring
- 197Flywheel Magneto Removal/Installation
- 198Ignition Coil Arcing Distance Inspection
- 198Ignition Coil Resistance Inspection
- 198Spark Plug Cleaning and Inspection
- 199Spark Plug Gap Inspection
- 199Exciter Coil Inspection
- 199Ignition Circuit
- 200CDI Unit Removal
- 200CDI Unit Inspection
- 200CDI Unit Resistance
- 201CDI Unit Troubleshooting
- 202Lighting System
- 202Headlight Vertical Adjustment
- 202Headlight Bulb Replacement
- 202Headlight Unit Installation
- 203Taillight Bulb Replacement
- 203Regulator Removal
- 203Regulator Inspection
- 204Regulator Internal Resistance
- 204Lighting Coil Inspection
- 205Trip Meter
- 205Meter Mounting Inspection
- 206Appendix
- 207Troubleshooting Guide
- 211General Lubrication
- 212Nut, Bolt, and Fastener Tightness
- 212Tightness Inspection
- 213Unit Conversion Table
- 213Units of Temperature