The Kawasaki KDX200E / KDX250D online service manual features detailed full-color photographs and wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran Kawasaki dealer trained technician.

1989 Kawasaki KDX200E1
1990 Kawasaki KDX200E2
1991 Kawasaki KDX200E3
1992 Kawasaki KDX200E4
1993 Kawasaki KDX200E5
1994 Kawasaki KDX200E6

Please note that while this manual is based on the KDX200E there are many similarities to the KDX250.

1991 Kawasaki KDX250D1
1992 Kawasaki KDX250D2
1993 Kawasaki KDX250D3
1994 Kawasaki KDX250D4
1995 Kawasaki KDX250D5

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Quick Reference – Bolt and Nut Torque and Size Specification, General Torque Specifications, Specifications for the KDX200E 1989-1994, Torque Conversions, VIN and Engine Number Location

External Components – Component Location, Foot Pegs, Front Fender, Fuel Tank, Radiator Shrouds, Rear Fender, Seat, Side Covers

Periodic Maintenance – Air Filter Servicing, Brake Fluid, Brake Bleeding, Brakes Hoses, Clutch Adjustment, Compression Check, Drive Chain, Engine Coolant Hoses, Engine Idle Speed, Throttle Free Play, Transmission Oil, Tires, Wheel Lacing and Truing

Fuel System – Specification Charts, Carburetor Removal and Installation, Carburetor Disassembly and Reassembly, Float Height, Fuel Valve

Cooling System – Coolant Replacement, Radiator, Water Pump

Exhaust System – Expansion Chamber and Silencer

Engine – Magneto, Clutch, Output Shaft Seal Replacement, Top End Disassembly, Top End Inspection, Top End Reassembly, Kick Starter and Shift Mechanism, Engine Removal, Bottom End Disassembly, Transmission, Bottom End Reassembly, Engine Installation

Final Drive – Component Inspection, Chain Replacement, Sprocket Replacement

Front Wheel – Runout, Removal, Bearings, Installation

Front Brakes – Brake Disc, Brake Pads, Brake Caliper, Brake Master Cylinder

Front Suspension – Fork Adjustment, Fork Oil Service, Fork Removal, Fork Seal Replacement, Fork Disassembly, Fork Inspection, Fork Reassembly, Fork Installation

Steering – Steering Removal, Assembly and Installation

Rear Wheel – Runout, Removal, Bearings, Installation

Rear Brakes – Brake Adjustment, Brake Pads, Brake Disc, Brake Caliper, Brake Master Cylinder

Rear Suspension – Shock Adjustment, Shock Removal and Installation, Shock Rebuild, Swing Arm Removal, Swing Arm Bearings, Swing Arm Installation

Electrical System – Electrical Specifications, Ignition Timing, Lighting, Sparkplug Inspection, Wiring Diagrams

Troubleshooting - Common problems and remedies