Top Banner
2007 Kawasaki KLX200S Illustrated Parts Breakdown
131

2007 Kawasaki KLX200S Service Manual

Apr 08, 2015

Download

Documents

caesarjd

Illustrated Parts Manual
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Page 1: 2007 Kawasaki KLX200S Service Manual

2007 Kawasaki KLX200S

Illustrated Parts Breakdown

Page 2: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/Index.txt

KLX250H7F KLX250S (2007)

AIR CLEANER

BRAKE PEDAL

CABLES

CAMSHAFT(S)/TENSIONER

CARBURETOR

CHASSIS ELECTRICAL EQUIPMENT

CLUTCH

CRANKCASE

CRANKSHAFT

CYLINDER HEAD

CYLINDER HEAD COVER

CYLINDER/PISTON(S)

DECALS (H7F)

ENGINE COVER(S)

ENGINE MOUNT

FENDERS

FOOTRESTS

FRAME

FRAME FITTINGS

FRONT BRAKE

FRONT FORK (H7F)

FRONT HUB

FRONT MASTER CYLINDER

FUEL TANK

GEAR CHANGE DRUM/SHIFT FORK(S)

GEAR CHANGE MECHANISM

GENERATOR

HANDLEBAR

HEADLIGHT(S)

IGNITION SWITCH

IGNITION SYSTEM

LABELS

METER(S)

MUFFLER(S)

OIL PUMP

OPTIONAL PARTS

OWNER'S TOOLS

PUBLICATIONS

RADIATOR

file:///Y|/KLX250S/Index.txt (1 of 2)1/21/2007 5:03:06 PM

mooredan
Rectangle
mooredan
Rectangle
mooredan
Rectangle
Page 3: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/Index.txt

REAR BRAKE

REAR HUB

REAR MASTER CYLINDER

REAR SUSPENSION

SEAT

SHOCK ABSORBER(S)

SIDE COVERS/CHAIN COVER

STAND(S)

STARTER MOTOR

SWINGARM

TAILLIGHT(S)(H7F)

TRANSMISSION

TURN SIGNALS

VALVE(S)

WATER PUMP

WHEELS/TIRES

file:///Y|/KLX250S/Index.txt (2 of 2)1/21/2007 5:03:06 PM

mooredan
Rectangle
mooredan
Rectangle
Page 4: 2007 Kawasaki KLX200S Service Manual
Page 5: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60342.html

Ref # Part # Description Qty Spec #

702 702A0770 TUBE-RUBBER,7X10X70 1

11011 11011-1616 CASE-AIR FILTER 1

11013 11013-1260 ELEMENT-AIR FILTER 1

11061 11061-1056 GASKET,L=535 1

11065 11065-1182 CAP,AIR FILTER 1

13091 13091-1454 HOLDER,ELEMENT 1

13280 13280-1213 HOLDER,ELEMENT 1

14069 14069-1051 BREATHER 1

14073 14073-1588 DUCT,AIR INTAKE 1

14073A 14073-1790 DUCT,AIR FILTER 1

16126 16126-1411 VALVE,AIR SWITCH 1

92002 92002-1719 BOLT,WING 1

92005 92005-1379 FITTING 1

92022 92022-125 WASHER,6.5X20X1.6 1

92037 92037-147 CLAMP,TUBE 4

92066 92066-1211 PLUG,DRAIN 1

92093 92093-1538 SEAL,L=523 1

92151 92151-1239 BOLT,6X12 4

92153 92153-0503 BOLT,6X12 1

92153A 92153-0936 BOLT,FLANGED,6X14 2

92170 92170-1909 CLAMP 2

92171 92171-0643 CLAMP 2

92171A 92171-1441 CLAMP 1

92191 92191-1077 TUBE,4X9X266 1

92191A 92191-1555 TUBE,BREATHER 1

92191B 92191-1556 TUBE,7X10X300 1

92191C 92191-1574 TUBE,CAP-AIR SWITCH 1

92191D 92191-1663 TUBE,AIR SWITCH-AIR FILTER 1

92191E 92191-1686 TUBE 1

file:///Y|/KLX250S/60342.html (1 of 2)1/19/2007 1:36:27 PM

mooredan
Rectangle
mooredan
Rectangle
Page 6: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60342.html

92210 92210-1164 NUT 4

file:///Y|/KLX250S/60342.html (2 of 2)1/19/2007 1:36:27 PM

mooredan
Rectangle
mooredan
Rectangle
mooredan
Rectangle
mooredan
Rectangle
Page 7: 2007 Kawasaki KLX200S Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK

Page 8: 2007 Kawasaki KLX200S Service Manual
mooredan
Rectangle
mooredan
Rectangle
mooredan
Rectangle
mooredan
Rectangle
mooredan
Rectangle
mooredan
Rectangle
Page 9: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60326.html

Ref # Part # Description Qty Spec #

550 550D2525 PIN-COTTER,2.5X25 1

43001 43001-1331 LEVER-BRAKE,PEDAL 1

92022 92022-1561 WASHER,8.5X20X1.6 1

92055 92055-1148 RING-O,OD=18.5 2

92144 92144-1752 SPRING,BRAKE PEDAL RETURN 1

92190 92190-1488 TUBE,13X16X25 1

file:///Y|/KLX250S/60326.html1/19/2007 1:36:32 PM

mooredan
Rectangle
mooredan
Rectangle
Page 10: 2007 Kawasaki KLX200S Service Manual
Page 11: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60351.html

Ref # Part # Description Qty Spec #

222 222C0520 SCREW-CSK-RD-CROS,5X20 1

14090 14090-1309 COVER,THROTTLE CABLE 1

49006 49006-1189 BOOT 1

54001 54001-1198 CABLE-SPEEDMETER 1

54011 54011-0010 CABLE-CLUTCH 1

54012 54012-0072 CABLE-THROTTLE,OPENING 1

54012A 54012-0109 CABLE-THROTTLE,CLOSING 1

92037 92037-1064 CLAMP,CABLE 1

file:///Y|/KLX250S/60351.html1/19/2007 1:24:23 PM

mooredan
Rectangle
mooredan
Rectangle
Page 12: 2007 Kawasaki KLX200S Service Manual
Page 13: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60302.html

Ref # Part # Description Qty Spec #

132 132J0612 BOLT-FLANGED-SMALL,6X12 1

670 670B2018 O RING,18MM 1

12044 12044-1327 CAMSHAFT-VALVE,INTAKE 1

12044A 12044-1365 CAMSHAFT-VALVE,EXHAUST 1

12046 12046-0001 SPROCKET,CAMSHAFT,32T 2

12048 12048-1140 TENSIONER-ASSY 1

12053 12053-1315 GUIDE-CHAIN,FR 1

12053A 12053-1317 GUIDE-CHAIN,UPP 1

12053B 12053-1391 GUIDE-CHAIN,RR 1

14014 14014-1130 PLATE-POSITION 1

92022 92022-1108 WASHER,8.5X13.5X2 1

92055 92055-086 RING-O,18.8X1.9 1

92057 92057-1416 CHAIN,CAM,92RH2010 1

92081 92081-1626 SPRING,DECOMPRESSOR 1

92145 92145-0367 SPRING,TENSIONER 1

92150 92150-1650 BOLT,SOCKET,6X10 4

92151 92151-1135 BOLT,6X35 2

92151A 92151-1154 BOLT,L=30 1

92153 92153-0650 BOLT,TENSIONER 1

file:///Y|/KLX250S/60302.html1/19/2007 1:23:59 PM

mooredan
Rectangle
mooredan
Rectangle
Page 14: 2007 Kawasaki KLX200S Service Manual
Page 15: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60395.html

Ref # Part # Description Qty Spec #

220 220B0408 SCREW-PAN-CROS,4X8 4

11044 11044-1353 BRACKET,THROTTLE CABLE 1

11048 11048-1818 BRACKET 1

13280 13280-1104 HOLDER,NEEDLE JET 1

14041 14041-1061 COVER-COMP,MIXING,INSIDE 1

15003 15003-0081 CARBURETOR-ASSY,CVK34 1

16007 16007-1117 SEAT-SPRING,VALVE 1

16014 16014-1081 SCREW-PILOT AIR 1

16016 16016-0013 PLUNGER,STARTER 1

16017 16017-1439 JET-NEEDLE 1

16021 16021-1183 SCREW-THROTTLE STOP 1

16030 16030-1007 VALVE-FLOAT 1

16031 16031-1077 FLOAT 1

16044 16044-007 CLAMP,FLOAT VALVE 1

16126 16126-1339 VALVE,VACUUM 1

16187 16187-0271 NEEDLE-JET,NFKT 1

21176 21176-1078 SENSOR 1

49019 49019-1097 FILTER-FUEL 1

92005 92005-1290 FITTING 1

92009 92009-1365 SCREW,5X10 1

92009A 92009-1551 SCREW,DRAIN,6X0.75 1

92009B 92009-1781 SCREW 2

92037 92037-1075 CLAMP,FUEL TUBE 1

92037A 92037-1531 CLAMP,TUBE 1

92055 92055-1222 RING-O,FLOAT CHAMBER 1

92055A 92055-1574 RING-O,SENSOR 1

92059 92059-1110 TUBE,3.5X6.5X330 1

92059A 92059-1237 TUBE,6.5X9.5X350 1

92063 92063-1071 JET-MAIN,#118 1

file:///Y|/KLX250S/60395.html (1 of 2)1/19/2007 1:20:03 PM

mooredan
Rectangle
mooredan
Rectangle
Page 16: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60395.html

92063A 92063-1118 JET-MAIN,#115 AR (OPTION)

92064 92064-0012 JET-PILOT,#32 AR (OPTION)

92064A 92064-1209 JET-PILOT,#35 1

92143 92143-1907 COLLAR 1

92144 92144-1538 SPRING,VACUUM VALVE 1

92170 92170-1496 CLAMP,TUBE 1

92190 92190-1560 TUBE,5X8X430 1

92191 92191-1689 TUBE 1

92200 92200-1369 WASHER 2

220A 220D0414 SCREW-PAN-CROS,4X14 3

223 223D0416 SCREW-PAN-WS-CROS,4X16 1

file:///Y|/KLX250S/60395.html (2 of 2)1/19/2007 1:20:03 PM

mooredan
Rectangle
mooredan
Rectangle
Page 17: 2007 Kawasaki KLX200S Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK

Page 18: 2007 Kawasaki KLX200S Service Manual
Page 19: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60294.html

Ref # Part # Description Qty Spec #

11012 11012-1589 CAP,BUNGEE CORD HOOK 1

26004 26004-1089 FUSE-ASSY 1

26006 26006-1002 FUSE,10A,L=30 3

26011 26011-1592 WIRE-LEAD,BATTERY(-) 1

26011A 26011-1609 WIRE-LEAD,BATTERY(+) 1

26012 26012-0068 BATTERY,FTX7L-BS,12V6AH 1

26031 26031-0372 HARNESS,MAIN 1

27002 27002-1086 RELAY-ASSY 1

27002A 27002-1101 RELAY-ASSY,TURN SIGNAL 1

27003 27003-0029 HORN 1

49018 49018-1052 DIODE 1

92037 92037-1163 CLAMP,SPEED,L=58 5

92072 92072-1237 BAND,L=250 2

92072A 92072-1288 BAND,L=215 1

92072B 92072-1293 BAND,L=140 4

92150 92150-1689 BOLT,FLANGED,6X14 1

92170 92170-1114 CLAMP,L=150 1

92171 92171-1437 CLAMP 1

92171A 92171-1438 CLAMP 1

file:///Y|/KLX250S/60294.html1/19/2007 1:24:19 PM

mooredan
Rectangle
mooredan
Rectangle
Page 20: 2007 Kawasaki KLX200S Service Manual
Page 21: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60385.html

Ref # Part # Description Qty Spec #

13086 13086-1072 WHEEL-CLUTCH 1

13087 13087-1150 HUB-CLUTCH 1

13088 13088-1125 PLATE-FRICTION 7

13089 13089-1085 PLATE-CLUTCH 1

13089A 13089-1094 PLATE-CLUTCH,T=1.6 5

13089B 13089-1116 PLATE-CLUTCH,T=2.0 AR

13089C 13089-1117 PLATE-CLUTCH,T=1.2 AR

13091 13091-1134 HOLDER,CLUTCH PUSHER 1

13091A 13091-1683 HOLDER,CLUTCH SPRING 1

13095 13095-1352 HOUSING-COMP-CLUTCH 1

13114 13114-1068 PUSHER-CLUTCH 1

13236 13236-1259 LEVER-COMP 1

92015 92015-1581 NUT,16MM 1

92022 92022-1356 WASHER,16.3X29X1.75 1

92022A 92022-1974 WASHER,JUDDER SPRING 1

92022B 92022-1993 WASHER,JUDDER SPRING SEAT 1

92026 92026-1496 SPACER,20.3X36X2.0 2

92045 92045-1236 BEARING-BALL,627 1

92143 92143-1959 COLLAR 1

92145 92145-1095 SPRING 6

92151 92151-1218 BOLT,5X35 6

92200 92200-1197 WASHER,7X12.5X0.8 1

file:///Y|/KLX250S/60385.html1/19/2007 1:20:11 PM

mooredan
Rectangle
mooredan
Rectangle
Page 22: 2007 Kawasaki KLX200S Service Manual
Page 23: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60380.html

Ref # Part # Description Qty Spec #

172 172G0680 BOLT-STUD,6X80 1

11061 11061-0222 GASKET,10.5X16X2 1

14001 14001-5363 SET-CRANKCASE 1

14067 14067-006 FITTING,BREATHER 1

92001 92001-1829 BOLT,W/WASHER,6X14 2

92022 92022-1415 WASHER,10.2X18X1.0,SK5 1

92037 92037-1318 CLAMP,HARNESS 1

92042 92042-007 PIN,DOWEL,6.3X8X14 8

92045 92045-036 BEARING-BALL,#6905 1

92045A 92045-1041 BEARING-BALL,TMB204 JR 1

92045B 92045-1287 BEARING-BALL,TMB203LU 1

92045C 92045-1288 BEARING-BALL,TMB205LU 1

92045D 92045-1346 BEARING-BALL,TMB302JR2 2

92045E 92045-1347 BEARING-BALL,TMB306JR2 1

92045F 92045-1348 BEARING-BALL,3TM-6207CJR2 1

92045G 92045-1414 BEARING-BALL,DG204012 1

92049 92049-1577 SEAL-OIL,TC32457 1

92066 92066-0070 PLUG,DRAIN 1

92143 92143-1263 COLLAR 1

92150 92150-1803 BOLT,RETURN SPRING 1

92150A 92150-1874 BOLT,SOCKET,6X50 1

92150B 92150-1875 BOLT,SOCKET,6X35 1

92151 92151-1234 BOLT,6X50 6

92153 92153-0018 BOLT,FLANGED,6X70 2

92190 92190-1493 TUBE 1

file:///Y|/KLX250S/60380.html1/19/2007 1:20:14 PM

mooredan
Rectangle
mooredan
Rectangle
Page 24: 2007 Kawasaki KLX200S Service Manual
Page 25: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60334.html

Ref # Part # Description Qty Spec #

13031 13031-1386 CRANKSHAFT-COMP 1

13041 13041-0001 BALANCER 1

13097 13097-1385 GEAR-PRIMARY SPUR,30T 1

13101 13101-1253 GEAR-ASSY,BALANCER 1

92015 92015-1581 NUT,16MM 1

92022 92022-1356 WASHER,16.3X29X1.75 1

92033 92033-029 RING-SNAP,18MM 1

92038 92038-1057 KEY 1

file:///Y|/KLX250S/60334.html1/19/2007 1:36:04 PM

mooredan
Rectangle
mooredan
Rectangle
Page 26: 2007 Kawasaki KLX200S Service Manual
Page 27: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60323.html

Ref # Part # Description Qty Spec #

11060 11060-1318 GASKET,HEAD COVER 1

14090 14090-1477 COVER,HEAD 1

92055 92055-1352 RING-O,HEAD COVER BOLT 3

92153 92153-1343 BOLT,FLANGED,6X22.5 3

file:///Y|/KLX250S/60323.html1/19/2007 1:36:29 PM

mooredan
Rectangle
mooredan
Rectangle
Page 28: 2007 Kawasaki KLX200S Service Manual
Page 29: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60321.html

Ref # Part # Description Qty Spec #

11002 11002-1382 HEAD-ASSY-CYLINDER 1

11004 11004-1249 GASKET-HEAD 1

11009 11009-1105 GASKET,10X14.5X1.5 2

11009A 11009-1344 GASKET,8.2X14X1.0 5

11060 11060-1886 GASKET,AIR SUCTION VALVE 2

11065 11065-1190 CAP 1

12021 12021-1115 VALVE-ASSY-REED 1

16065 16065-1283 HOLDER-CARBURETOR 1

39193 39193-1018 PIPE-OIL 1

49002 49002-1126 GUIDE-VALVE AR

49054 49054-1053 THERMOSTAT 1

92001 92001-1105 BOLT,FLANGED,6X38 6

92001A 92001-1872 BOLT,6X46 2

92004 92004-1217 STUD,8X22 2

92005 92005-1258 FITTING 1

92033 92033-1247 RING-SNAP 4

92037 92037-1304 CLAMP,ID=53,BLACK 1

92042 92042-007 PIN,DOWEL,6.3X8X14 2

92043 92043-4009 PIN,10.1X12X14 2

92055 92055-1255 RING-O 1

92150 92150-1368 BOLT,10X165 4

92150A 92150-1552 BOLT,6X135 2

92151 92151-1133 BOLT,6X12 3

92151A 92151-1937 BOLT,6X22 2

92153 92153-0651 BOLT,BANJO,8X20 2

92153A 92153-1342 BOLT,FLANGED,8X10 1

92153B 92153-1344 BOLT,SOCKET,6X16 2

92153C 92153-1345 BOLT,BANJO,10X23 1

92160 92160-1523 DAMPER,6.3X15X14 1

file:///Y|/KLX250S/60321.html (1 of 2)1/19/2007 1:36:17 PM

mooredan
Rectangle
mooredan
Rectangle
Page 30: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60321.html

92200 92200-1042 WASHER,10.5X19X2.3 4

file:///Y|/KLX250S/60321.html (2 of 2)1/19/2007 1:36:17 PM

mooredan
Rectangle
mooredan
Rectangle
Page 31: 2007 Kawasaki KLX200S Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK

Page 32: 2007 Kawasaki KLX200S Service Manual
Page 33: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60332.html

Ref # Part # Description Qty Spec #

11005 11005-1982 CYLINDER-ENGINE 1

11060 11060-1740 GASKET,CYLINDER BASE 1

13001 13001-1433 PISTON-ENGINE 1

13002 13002-1073 PIN-PISTON 1

13008 13008-1149 RING-SET-PISTON 1

52014 52014-1084 ELBOW 1

92033 92033-1054 RING-SNAP 2

92043 92043-4009 PIN,10.1X12X14 2

92055 92055-055 RING-O,19.5X1.5 1

92151 92151-1423 BOLT,6X14 2

file:///Y|/KLX250S/60332.html1/19/2007 1:36:06 PM

mooredan
Rectangle
mooredan
Rectangle
Page 34: 2007 Kawasaki KLX200S Service Manual
Page 35: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60336.html

Ref # Part # Description Qty Spec #

56052 56052-0948 MARK,RR FENDER,KAWASAKI 1

56052A 56052-0956 MARK,SIDE COVER,KLX250 2

56052B 56052-0965 MARK,SHROUD,KAWASAKI 2

56052C 56052-0968 MARK,HEAD LAMP COVER,KAWASAKI 1

56067 56067-1315 PATTERN,SHROUD,LH 1

56067A 56067-1316 PATTERN,SHROUD,RH 1

56067B 56067-1317 PATTERN,HEAD LAMP COVER,LH 1

56067C 56067-1318 PATTERN,HEAD LAMP COVER,RH 1

file:///Y|/KLX250S/60336.html1/19/2007 1:35:59 PM

mooredan
Rectangle
mooredan
Rectangle
Page 36: 2007 Kawasaki KLX200S Service Manual
Page 37: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60304.html

Ref # Part # Description Qty Spec #

11053 11053-1656 BRACKET 1

11060 11060-1324 GASKET,CLUTCH COVER INNER 1

11060A 11060-1325 GASKET,CLUTCH COVER OUTER 1

11060B 11060-1326 GASKET,GENERATOR COVER 1

11060C 11060-1327 GASKET,TRANSMISSION COVER 1

11060D 11060-1641 GASKET,CAP 1

11065 11065-0103 CAP,GENERATOR COVER 1

12053 12053-1337 GUIDE-CHAIN 1

13151 13151-1096 SWITCH-COMP 1

13271 13271-1567 PLATE 1

14014 14014-1062 PLATE-POSITION 1

14026 14026-0027 COVER-CHAIN 1

14031 14031-0042 COVER-GENERATOR 1

14032 14032-0058 COVER-CLUTCH,OUTER 1

14032A 14032-0059 COVER-CLUTCH,INNER 1

14044 14044-1078 HOLDER-CABLE 1

14091 14091-0020 COVER 1

16115 16115-1053 CAP-OIL FILLER 1

16130 16130-1001 VALVE-ASSY-RELIEF 1

49063 49063-1055 SEAL-MECHANICAL,WATER 1

52005 52005-1009 GAUGE,OIL LEVEL 1

55020 55020-1736 GUARD 1

92009 92009-1571 SCREW,5X16 2

92015 92015-1193 NUT,FLANGED,6MM 1

92022 92022-1488 WASHER,8.2X14X1.0 1

92027 92027-1885 COLLAR,6.5X10.5X4.5 1

92045 92045-1246 BEARING-BALL,6901 1

92046 92046-1010 BEARING-NEEDLE,HK1210 1

92046A 92046-1148 BEARING-NEEDLE,HK1312 1

file:///Y|/KLX250S/60304.html (1 of 2)1/19/2007 1:20:55 PM

mooredan
Rectangle
mooredan
Rectangle
Page 38: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60304.html

92046B 92046-1230 BEARING-NEEDLE 1

92049 92049-1191 SEAL-OIL 1

92049A 92049-1228 SEAL-OIL,SC 12X22X5 1

92049B 92049-1262 SEAL-OIL,AG0353-F0 1

92049C 92049-1559 SEAL-OIL 1

92055 92055-012 RING-O 1

92055A 92055-091 RING-O 1

92055B 92055-1146 RING-O,20X2 1

92055C 92055-1619 RING-O,27.7X2.4 1

92066 92066-1397 PLUG 1

92066A 92066-1404 PLUG 1

120 120P0610 BOLT-SOCKET,6X10 1

610 610A0408 ROLLER,4X8 4

92066B 92066-1411 PLUG,RCA297 1

92150 92150-1406 BOLT,5X8 4

92151 92151-1131 BOLT,6X40 6

92151A 92151-1133 BOLT,6X12 2

92151B 92151-1134 BOLT,6X30 3

92151C 92151-1252 BOLT,FLANGED-SMALL,6X20 4

92151D 92151-1311 BOLT,6X18 3

92151E 92151-1930 BOLT,FLANGED-SMALL,6X25 12

92153 92153-0018 BOLT,FLANGED,6X70 2

92153D 92153-0695 BOLT,6X16 2

92153E 92153-0844 BOLT,6X30 1

92153H 92153-1342 BOLT,FLANGED,8X10 1

92153I 92153-1351 BOLT,FLANGED,6X35 1

92161 92161-1182 DAMPER 1

92170 92170-1785 CLAMP 1

92172 92172-0223 SCREW,6X16 1

file:///Y|/KLX250S/60304.html (2 of 2)1/19/2007 1:20:55 PM

mooredan
Rectangle
mooredan
Rectangle
Page 39: 2007 Kawasaki KLX200S Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK

Page 40: 2007 Kawasaki KLX200S Service Manual
Page 41: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60318.html

Ref # Part # Description Qty Spec #

32029 32029-1855 BRACKET-ENGINE,FR 2

32029A 32029-1886 BRACKET-ENGINE,HEAD,LH 1

32029B 32029-1887 BRACKET-ENGINE,HEAD,RH 1

92001 92001-1499 BOLT,FLANGED,10X44 1

92002 92002-1674 BOLT,10X90 3

92150 92150-1168 BOLT,FLANGED,8X40 2

92150A 92150-1642 BOLT,FLANGED,10X120 1

92210 92210-1080 NUT,LOCK,FLANGED,10MM 5

file:///Y|/KLX250S/60318.html1/19/2007 1:36:23 PM

mooredan
Rectangle
mooredan
Rectangle
Page 42: 2007 Kawasaki KLX200S Service Manual
Page 43: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60293.html

Ref # Part # Description Qty Spec #

132 132G0625 BOLT-FLANGED-SMALL,6X25 4

35004 35004-1319-290 FENDER-FRONT,L.GREEN 1

35019 35019-0004 FLAP,RR FENDER,FR 1

35019A 35019-0040 FLAP,RR FENDER 1

35022 35022-0001-290 FENDER-COMP-REAR,FR,L.GREEN 1

35022A 35022-0003-290 FENDER-COMP-REAR,RR,L.GREEN 1

92022 92022-1690 WASHER,6.5X24X2 4

92027 92027-1936 COLLAR 4

92027A 92027-4015 COLLAR 2

92071 92071-024 GROMMET 3

92071A 92071-1210 GROMMET 2

92075 92075-1690 DAMPER 4

92143 92143-1196 COLLAR 4

92143A 92143-1353 COLLAR 4

92150 92150-1339 BOLT,FLANGED,6X20 4

92150A 92150-1340 BOLT,6X14 4

92150B 92150-1506 BOLT,FLANGED,6X16 2

file:///Y|/KLX250S/60293.html1/19/2007 1:19:58 PM

mooredan
Rectangle
mooredan
Rectangle
Page 44: 2007 Kawasaki KLX200S Service Manual
Page 45: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60377.html

Ref # Part # Description Qty Spec #

130 130P1020 BOLT-FLANGED,10X20 1

550 550D2515 PIN-COTTER,2.5X15 2

34003 34003-1401-458 HOLDER-STEP,RH,P.SILVER 1

34028 34028-1361 STEP,FR,LH 1

34028A 34028-1362 STEP,FR,RH 1

34028B 34028-1376 STEP,RR,LH 1

34028C 34028-1377 STEP,RR,RH 1

92043 92043-115 PIN,8X35.5 2

92144 92144-1685 SPRING,STEP RETURN,RH 1

92144A 92144-1749 SPRING,STEP RETURN,LH 1

92150 92150-1584 BOLT,SOCKET,8X34 2

92200 92200-0089 WASHER,8.5X16X1.2 2

92200A 92200-1042 WASHER,10.5X19X2.3 2

92200B 92200-1133 WASHER,SPRING 2

92210 92210-1080 NUT,LOCK,FLANGED,10MM 1

file:///Y|/KLX250S/60377.html1/19/2007 1:20:17 PM

mooredan
Rectangle
mooredan
Rectangle
Page 46: 2007 Kawasaki KLX200S Service Manual
Page 47: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60329.html

Ref # Part # Description Qty Spec #

130 130G0840 BOLT-FLANGED,8X40 1

132 132L0612 BOLT-FLANGED-SMALL,6X12 3

186 186B0620 BOLT-UPSET-WP,6X20 1

11053 11053-1242 BRACKET 1

12053 12053-0001 GUIDE-CHAIN 1

13091 13091-1875 HOLDER 1

32059 32059-1117 BRACKET-SWITCH,BRAKE 1

32097 32097-0001 CASE-BATTERY 1

55020 55020-1456 GUARD,ENGINE 1

92015 92015-1078 NUT,FLANGED,6MM 1

92022 92022-1561 WASHER,8.5X20X1.6 2

92027 92027-1670 COLLAR,CHAIN ROLLER 1

92066 92066-1034 PLUG,FRAME END,12X13 2

92122 92122-1153 ROLLER,CHAIN GUIDE 1

92150 92150-1340 BOLT,6X14 2

92150A 92150-1435 BOLT,6X12 4

92150B 92150-1481 BOLT,FLANGED,6X22 3

92160 92160-1396 DAMPER 2

92160A 92160-1565 DAMPER 1

92170 92170-1423 CLAMP,HARNESS 1

92170A 92170-1944 CLAMP,HARNESS 1

92172 92172-0004 SCREW,6X14 1

file:///Y|/KLX250S/60329.html1/19/2007 1:35:51 PM

mooredan
Rectangle
mooredan
Rectangle
Page 48: 2007 Kawasaki KLX200S Service Manual
Page 49: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60316.html

Ref # Part # Description Qty Spec #

11012 11012-1762 CAP,STEERING STEM 1

32160 32160-0149-458 FRAME-COMP,P.SILVER 1

92015 92015-1546 NUT,25MM,T=12 1

92047 92047-017 RACE,ROLLER,32005JR RS 1

92116 92116-1069 BEARING-ROLLER,HI-CAP32006JRRS 1

file:///Y|/KLX250S/60316.html1/19/2007 1:36:34 PM

mooredan
Rectangle
mooredan
Rectangle
Page 50: 2007 Kawasaki KLX200S Service Manual
Page 51: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60371.html

Ref # Part # Description Qty Spec #

14079 14079-1097 HOLDER-ASSY,FRONT CALIPER 1

32085 32085-1361 STOPPER,PAD 1

41080 41080-0080-CM DISC,FR,SILVER 1

43048 43048-1064 PISTON-CALIPER 2

43049 43049-1060 PACKING,PISTON SEAL 2

43049A 43049-1061 PACKING,PISTON SEAL 2

43056 43056-1055 BREATHER 1

43057 43057-1001 CAP-BREATHER 1

43080 43080-5119 CALIPER-SUB-ASSY,FR,LH 1

43082 43082-1225 PAD-ASSY-BRAKE 1

49006 49006-1088 BOOT,CALIPER 1

49006A 49006-1242 BOOT,CALIPER 1

92144 92144-1721 SPRING,PAD 1

92150 92150-1691 BOLT,HANGER 1

92150A 92150-1692 BOLT,PLUG 1

92150B 92150-1811 BOLT,DISC PLATE,8X15 4

92153 92153-0517 BOLT,SOCKET,8X40 2

file:///Y|/KLX250S/60371.html1/19/2007 1:20:32 PM

mooredan
Rectangle
mooredan
Rectangle
Page 52: 2007 Kawasaki KLX200S Service Manual
Page 53: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60346.html

Ref # Part # Description Qty Spec #

11009 11009-1592 GASKET,FORK CYLINDER BOLT 2

11012 11012-1381 CAP,FORK CYLINDER 2

13070 13070-1263-RZ GUIDE,FORK,LH,WHITE 1

13070A 13070-1264-RZ GUIDE,FORK,RH,WHITE 1

44008 44008-1028-JS PIPE-FORK OUTER,BRONZE 2

44013 44013-1387 PIPE-FORK INNER,LH 1

44013A 44013-1388 PIPE-FORK INNER,RH 1

44018 44018-1056 PISTON-FORK,INNER PIPE 2

44022 44022-1327 CYLINDER-FORK 2

44026 44026-1686 SPRING-FRONT FORK,K=3.55N/MM 2

44028 44028-1081 GUIDE-FORK SPRING 2

44028A 44028-1084 GUIDE-FORK SPRING 2

44029 44029-1149 SEAT-FORK SPRING 2

44037 44037-1390 HOLDER-FORK UNDER 1

44039 44039-1242 HOLDER-FORK UPPER 1

44063 44063-1056 HOLDER-FRONT AXLE 1

44070 44070-1683-JS DAMPER-ASSY,FORK,LH,BRONZE 1

44070A 44070-1684-JS DAMPER-ASSY,FORK,RH,BRONZE 1

49116 49116-1168 VALVE-ASSY,FORK 2

55020 55020-0196-RZ GUARD,FORK,LH,WHITE 1

55020A 55020-0199-RZ GUARD,FORK,RH,WHITE 1

92009 92009-1568 SCREW 2

92015 92015-1653 NUT,STEERING STEM,22MM 1

92015A 92015-1839 NUT 2

92022 92022-1299 WASHER 2

92022A 92022-1873 WASHER,STEERING STEM 1

92028 92028-1581 BUSHING 2

92033 92033-1077 RING-SNAP 2

92049 92049-1373 SEAL-OIL 2

file:///Y|/KLX250S/60346.html (1 of 2)1/19/2007 1:36:08 PM

mooredan
Rectangle
mooredan
Rectangle
Page 54: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60346.html

92055 92055-1156 RING-O 2

92055A 92055-1333 RING-O,FORK,AIR TUBE 2

92055B 92055-1441 RING-O,2.8X6.6X1.9 2

92055C 92055-1502 RING-O,FORK VALVE 2

92072 92072-1267 BAND 1

92072A 92072-1283 BAND 1

92093 92093-1342 SEAL,FORK OUTER TUBE 2

92143 92143-1643 COLLAR,FORK 2

92150 92150-1340 BOLT,6X14 5

92150A 92150-1434 BOLT,FLANGED,5X40 4

92150B 92150-1446 BOLT,FLANGED,8X40 2

92150C 92150-1516 BOLT,FLANGED,8X40 4

92152 92152-0315 COLLAR,8X12.7X4 5

92210 92210-1070 NUT,FLANGED,6MM 4

file:///Y|/KLX250S/60346.html (2 of 2)1/19/2007 1:36:08 PM

mooredan
Rectangle
mooredan
Rectangle
Page 55: 2007 Kawasaki KLX200S Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK

Page 56: 2007 Kawasaki KLX200S Service Manual
Page 57: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60401.html

Ref # Part # Description Qty Spec #

480 480J2400 CIRCLIP-TYPE-C,24MM 1

481 481J3500 CIRCLIP-TYPE-C,35MM 1

601 601B6202UG BEARING-BALL,#6202UG 2

41034 41034-1243 DRUM-ASSY,FRONT BRAKE 1

41060 41060-1143 GEAR-METER SCREW,25T 1

41060A 41060-1144 GEAR-METER SCREW,8T 1

41068 41068-0013 AXLE,FR 1

41078 41078-1095 CASE-ASSY-METER GEAR 1

92022 92022-1511 WASHER,5X9.5X0.8 1

92027 92027-1958 COLLAR,15.2X22.2X75 1

92027A 92027-1959 COLLAR,L=12 1

92049 92049-1176 SEAL-OIL,MH20354.5 1

92049A 92049-1399 SEAL-OIL,SDD 50 62 7 1

92087 92087-1060 BUSHING-METER GEAR 1

92200 92200-1137 WASHER,24X31X0.8 1

file:///Y|/KLX250S/60401.html1/19/2007 1:20:05 PM

mooredan
Rectangle
mooredan
Rectangle
Page 58: 2007 Kawasaki KLX200S Service Manual
Page 59: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60370.html

Ref # Part # Description Qty Spec #

132 132G0630 BOLT-FLANGED-SMALL,6X30 1

311 311L0600 NUT-HEX 1

27010 27010-0025 SWITCH,BRAKE 1

43015 43015-0040 CYLINDER-ASSY-MASTER,FR 1

43020 43020-1065 PISTON-COMP-BRAKE 1

43022 43022-1010 STOPPER-BRAKE,PISTON 1

43026 43026-1074 CAP-BRAKE 1

43028 43028-1061 DIAPHRAGM 1

43034 43034-1016 HOLDER-BRAKE,MASTER CYLINDER 1

43060 43060-1100 PIPE-BRAKE,FR 1

43095 43095-0163 HOSE-BRAKE,FR 1

46092 46092-1175 LEVER-GRIP,FRONT BRAKE 1

49006 49006-1040 BOOT,DUST 1

49016 49016-1044 COVER-SEAL,MASTER CYLINDER 1

49091 49091-0001 WASHER-SEAL,10.1X14.5X1.5 4

92002 92002-1323 BOLT,SCREW,4X12 1

92002A 92002-1893 BOLT,ADJUST 1

92002B 92002-1894 BOLT 2

92009 92009-1458 SCREW,4MM 2

92015 92015-1642 NUT,ADJUST 1

92022 92022-1814 WASHER 1

92143 92143-1408 COLLAR,6.5X9.5X17 1

92144 92144-1103 SPRING,RETURN 1

92153 92153-0627 BOLT,OIL,L=23 2

92153A 92153-0790 BOLT,LEVER SET 1

file:///Y|/KLX250S/60370.html1/19/2007 1:20:34 PM

mooredan
Rectangle
mooredan
Rectangle
Page 60: 2007 Kawasaki KLX200S Service Manual
Page 61: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60357.html

Ref # Part # Description Qty Spec #

132 132G0635 BOLT-FLANGED-SMALL,6X35 1

132A 132L0608 BOLT-FLANGED-SMALL,6X8 2

220 220B0308 SCREW-PAN-CROS,3X8 2

220A 220D0510 SCREW-PAN-CROS,5X10 2

43049 43049-1091 PACKING,TAP VALVE 1

49019 49019-1057 FILTER-FUEL,"RES" 1

49019A 49019-1077 FILTER-FUEL,"ON" 1

51001 51001-1715-H8 TANK-COMP-FUEL,EBONY 1

51023 51023-1322 TAP-ASSY,FUEL 1

51049 51049-1134 CAP-TANK,FUEL 1

53044 53044-1209 TRIM,L=490 1

92022 92022-1690 WASHER,6.5X24X2 1

92022A 92022-1977 WASHER,5.1X10X1.0 2

92037 92037-147 CLAMP,TUBE 4

92055 92055-1386 RING-O,ID=9.5 1

92055A 92055-1387 RING-O,11.5X1.5 1

92055B 92055-1419 RING-O,TAP LEVER 1

92055C 92055-1552 RING-O,ID=9 2

92059 92059-1888 TUBE 1

92075 92075-1123 DAMPER,RUBBER 2

92075A 92075-281 DAMPER 1

92143 92143-1353 COLLAR 2

92143A 92143-1459 COLLAR,6.8X10X24.5 1

92153 92153-0502 BOLT,6X20 2

92160 92160-1254 DAMPER,FUEL TANK,RR 1

92160A 92160-1328 DAMPER,FUEL TANK 2

92170 92170-1834 CLAMP,TUBE 2

92190 92190-1486 TUBE,"ON" 1

92191 92191-1138 TUBE,7X12X600 2

file:///Y|/KLX250S/60357.html1/19/2007 1:20:40 PM

mooredan
Rectangle
mooredan
Rectangle
Page 62: 2007 Kawasaki KLX200S Service Manual
Page 63: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60298.html

Ref # Part # Description Qty Spec #

610 610A0408 ROLLER,4X8 2

13091 13091-1856 HOLDER,CHANGE DRUM 1

13140 13140-1216 FORK-SHIFT,5TH&TOP 1

13140A 13140-1217 FORK-SHIFT,2ND&3RD 1

13140B 13140-1218 FORK-SHIFT,LOW&4TH 1

13141 13141-1198 DRUM-CHANGE 1

13280 13280-1214 HOLDER 1

49047 49047-1056 ROD-SHIFT,L=106.7 1

49047A 49047-1057 ROD-SHIFT,L=71.7 1

92043 92043-1523 PIN 1

92144 92144-1245 SPRING 1

92151 92151-1471 BOLT,SOCKET,6X45 1

file:///Y|/KLX250S/60298.html1/19/2007 1:24:08 PM

mooredan
Rectangle
mooredan
Rectangle
Page 64: 2007 Kawasaki KLX200S Service Manual
Page 65: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60306.html

Ref # Part # Description Qty Spec #

172 172G0612 BOLT-STUD,6X12 1

311 311G0600 NUT-HEX,6MM 1

480 480J1300 CIRCLIP-TYPE-C,13MM 1

13156 13156-1480 LEVER-CHANGE,PEDAL 1

13161 13161-1214 LEVER-COMP-CHANGE SHAFT 1

13236 13236-1209 LEVER-COMP,NEUTRAL POSITION 1

92022 92022-1496 WASHER,13.3X20X1 1

92022A 92022-1827 WASHER,6X12.8X1.2 1

92026 92026-1217 SPACER 1

92081 92081-076 SPRING,CHANGE LEVER 1

92081A 92081-1129 SPRING,TENSION 1

92143 92143-1148 COLLAR 1

92144 92144-1695 SPRING 1

92151 92151-1252 BOLT,FLANGED-SMALL,6X20 1

92152 92152-1075 COLLAR 1

file:///Y|/KLX250S/60306.html1/19/2007 1:21:02 PM

mooredan
Rectangle
mooredan
Rectangle
Page 66: 2007 Kawasaki KLX200S Service Manual
Page 67: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60292.html

Ref # Part # Description Qty Spec #

120 120P0530 BOLT-SOCKET,5X30 3

220 220B0512 SCREW-PAN-CROS,5X12 2

510 510A3100 KEY-WOODRUFF 1

21003 21003-1386 STATOR 1

21007 21007-1273 ROTOR,MAGNETO 1

21066 21066-1093 REGULATOR-VOLTAGE 1

92150 92150-1708 BOLT,12X50 1

92151 92151-1930 BOLT,FLANGED-SMALL,6X25 2

92170 92170-1346 CLAMP 1

file:///Y|/KLX250S/60292.html1/19/2007 1:24:05 PM

mooredan
Rectangle
mooredan
Rectangle
Page 68: 2007 Kawasaki KLX200S Service Manual
Page 69: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60307.html

Ref # Part # Description Qty Spec #

220 220C0525 SCREW-PAN-CROS,5X25 2

220A 220C0530 SCREW-PAN-CROS,5X30 2

220B 220F0514 SCREW-PAN-CROSS,5X14 2

11036 11036-1297 BRACKET-A,LEVER HOLDER 1

13070 13070-1274 GUIDE,THROTTLE CABLE 1

13091 13091-1718 HOLDER,MIRROR 1

14079 14079-1125 HOLDER-ASSY,CLUTCH CABLE 1

32099 32099-1146 CASE,THROTTLE,UPP 1

32099A 32099-1147 CASE,THROTTLE,LWR 1

46003 46003-1383-458 HANDLE,P.SILVER 1

46012 46012-0010-458 HOLDER-HANDLE,UPP,P.SILVER 1

46019 46019-1093 GRIP-ASSY,THROTTLE 1

46055 46055-009 SCREW,CABLE ADJUST,8MM 1

46056 46056-006 NUT,CABLE ADJUST 1

46075 46075-1149 GRIP,LH 1

46076 46076-1219 LEVER-ASSY-GRIP,CLUTCH 1

46091 46091-1690 HOUSING-ASSY-CONTROL,LH 1

46091A 46091-1733 HOUSING-ASSY-CONTROL,RH 1

46092 46092-1159 LEVER-GRIP,CLUTCH 1

56001 56001-1285 MIRROR-ASSY 2

59441 59441-0001-290 COVER-HANDLE,RH,L.GREEN 1

59441A 59441-0002-290 COVER-HANDLE,LH,L.GREEN 1

92001 92001-1034 BOLT,FLANGED,6X10 2

92002 92002-1880 BOLT,LEVER SET 1

92009 92009-1699 SCREW,5X16 2

92015 92015-1603 NUT,LOCK,FLANGED,6MM 2

92037 92037-1621 CLAMP,LEVER HOLDER 1

92072 92072-1293 BAND,L=140 4

92150 92150-1389 BOLT,5X20 2

file:///Y|/KLX250S/60307.html (1 of 2)1/19/2007 1:20:52 PM

mooredan
Rectangle
mooredan
Rectangle
Page 70: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60307.html

92153 92153-1519 BOLT,FLANGED,8X30 4

92170 92170-1255 CLAMP,BRAKE HOSE 1

92210 92210-0006 NUT,LOCK,6MM 1

file:///Y|/KLX250S/60307.html (2 of 2)1/19/2007 1:20:52 PM

mooredan
Rectangle
mooredan
Rectangle
Page 71: 2007 Kawasaki KLX200S Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK

Page 72: 2007 Kawasaki KLX200S Service Manual
Page 73: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60317.html

Ref # Part # Description Qty Spec #

132 132G0825 BOLT-FLANGED-SMALL,8X25 2

186 186B0614 BOLT-UPSET-WP,6X14 1

220 220B0508 SCREW-PAN-CROS,5X8 2

11054 11054-0054 BRACKET,HEAD LAMP 1

23005 23005-1052 BODY-COMP-HEAD LAMP 1

23005B 23005-5060-266 BODY-COMP-HEAD LAMP,S.WHITE 1

23007 23007-1372 LENS-COMP,HEAD LAMP 1

23014 23014-005 SPRING,FOCUS ADJUSTING 1

23020 23020-018 NUT,4MM,FOCUS ADJUST 1

49016 49016-1037 COVER-SEAL,SOCKET 1

49016A 49016-1160 COVER-SEAL,HEAD LAMP 1

92002 92002-1262 BOLT,UPSET-WP,6X22 2

92009 92009-1065 SCREW,4X48 1

92009A 92009-1286 SCREW,6X10,WHITE 2

92015 92015-1354 NUT,5MM 2

92027 92027-1134 COLLAR,L=14 2

92069 92069-1002 BULB,12V 60/55W,H4 1

92075 92075-209 DAMPER 2

92143 92143-1353 COLLAR 2

92150 92150-1435 BOLT,6X12 3

92160 92160-1007 DAMPER 2

92172 92172-0004 SCREW,6X14 4

file:///Y|/KLX250S/60317.html1/19/2007 1:36:12 PM

mooredan
Rectangle
mooredan
Rectangle
Page 74: 2007 Kawasaki KLX200S Service Manual
Page 75: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60303.html

Ref # Part # Description Qty Spec #

411 411E0600 WASHER-PLAIN,6MM 2

11053 11053-1720 BRACKET,REFLECTOR,RR 2

11054 11054-0367 BRACKET,REFLECTOR,FR,LH 1

11054A 11054-0368 BRACKET,REFLECTOR,FR,RH 1

21007 21007-5052 ROTOR,LOCK,TANK CAP 1

27005 27005-0025 SWITCH-ASSY-IGNITION 1

27008 27008-1220 KEY-LOCK,BLANK 1 (OPTION)

27010 27010-0045 SWITCH,SIDE STAND 1

27010A 27010-1489 SWITCH,REAR BRAKE 1

27016 27016-5291 LOCK-ASSY,HELMET 1

27045 27045-5320 SWITCH-ASSY 1

28012 28012-016 REFLECTOR-REFLEX,FR 2

28012A 28012-1067 REFLECTOR-REFLEX 2

28012B 28012-1077 REFLECTOR-REFLEX 1

46123 46123-0002 SPRING-COMP,REAR BRAKE SWITCH 1

92009 92009-1459 SCREW,5X20 2

92009A 92009-1753 SCREW,6X30 1

92015 92015-1259 NUT,FLANGED,5MM 2

92151 92151-1946 BOLT,TORX,6X22 2

92210 92210-0007 NUT,FLANGED,5MM 3

file:///Y|/KLX250S/60303.html1/19/2007 1:20:58 PM

mooredan
Rectangle
mooredan
Rectangle
Page 76: 2007 Kawasaki KLX200S Service Manual
Page 77: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60313.html

Ref # Part # Description Qty Spec #

21119 21119-1579 IGNITER 1

21121 21121-1230 COIL-IGNITION 1

21130 21130-1002 CAP-SPARK PLUG 1

21131 21131-005 GROMMET,HIGH TENSION 1

92070 92070-0019 PLUG-SPARK,CR8E(NGK) 1

92070A PLUG-SPARK,U27ESR-N(ND) AR (LOCAL PROCUREMENT ITEM) (OPTION)

92070B PLUG-SPARK,U24ESR-N(ND) 1 (LOCAL PROCUREMENT ITEM)

92070C 92070-1209 PLUG-SPARK,CR7E(NGK) AR (OPTION)

92070D 92070-1266 PLUG-SPARK,CR9E(NGK) AR (OPTION)

92071 92071-1124 GROMMET,PLUG CAP 1

92151 92151-1311 BOLT,6X18 2

92172 92172-0241 SCREW-PAN-WS-CROS,6X10 2

file:///Y|/KLX250S/60313.html1/19/2007 1:24:11 PM

mooredan
Rectangle
mooredan
Rectangle
Page 78: 2007 Kawasaki KLX200S Service Manual
Page 79: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60335.html

Ref # Part # Description Qty Spec #

56031 56031-1845 LABEL-MANUAL,DAILY SAFETY 1

56033 56033-0100 LABEL-MANUAL,DAILY SAFETY 1 [CN]

56033A 56033-0101 LABEL-MANUAL,CHAIN 1 [CN]

56033B 56033-0102 LABEL-MANUAL,CHAIN 1

56033C 56033-0167 LABEL-MANUAL,OIL&OIL FILTER 1

56037 56037-1612 LABEL-SPECIFICATION,TIRE&LOAD 1

56040 56040-1007 LABEL-WARNING,BREAK IN CAUTION 1 [US]

56040A 56040-1314 LABEL-WARNING,MAXIMUM LOAD 1

56040B 56040-1327 LABEL-WARNING,MAXIMUM LOAD 1 [CN]

56053 56053-0151 LABEL-SPECIFICATION,TIRE&LOAD 1 [CN]

file:///Y|/KLX250S/60335.html1/19/2007 1:36:15 PM

mooredan
Rectangle
mooredan
Rectangle
Page 80: 2007 Kawasaki KLX200S Service Manual
Page 81: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60337.html

Ref # Part # Description Qty Spec #

322 322C0500 NUT-CAP 3

14090 14090-1303 COVER,METER HOUSING 1

23008 23008-0043 SOCKET-ASSY,METER 1 [US]

23008A 23008-1506 SOCKET-ASSY,METER 1 [CN]

25005 25005-1536 SPEEDOMETER,KPH 1 [CN]

25005A 25005-1541 SPEEDOMETER,MPH 1 [US]

25008 25008-1194 BRACKET-METER 1

25009 25009-004 WASHER,5.2X16X1.2 3

25015 25015-1321 TACHOMETER,X1000R/MIN 1

25023 25023-1203 COVER-METER CASE,UPP 1

92009 92009-1172 SCREW,2X6,BLACK 1

92009A 92009-1503 SCREW,TAPPING,4X14 3

92069 92069-1068 BULB,12V 3W,T6.5 2 [US]

92069 92069-1068 BULB,12V 3W,T6.5 3 [CN]

92069A 92069-1070 BULB,12V 1.7W,T6.5 5 [CN]

92069A 92069-1070 BULB,12V 1.7W,T6.5 6 [US]

92077 92077-1059 KNOB,METER 1

92160 92160-1460 DAMPER 3

file:///Y|/KLX250S/60337.html1/19/2007 1:36:01 PM

mooredan
Rectangle
mooredan
Rectangle
Page 82: 2007 Kawasaki KLX200S Service Manual
Page 83: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60356.html

Ref # Part # Description Qty Spec #

461 461S0600 WASHER-SPRING,6MM 3

11060 11060-1203 GASKET,EXHAUST PIPE 1

11061 11061-1055 GASKET,EXHAUST PIPE CONNECTING 1

18088 18088-0033 PIPE-EXHAUST 1

18091 18091-0238 BODY-COMP-MUFFLER 1

49107 49107-0062 COVER-EXHAUST PIPE 1

92015 92015-1402 NUT,8MM 2

92022 92022-1488 WASHER,8.2X14X1.0 1

92065 92065-096 GASKET 1

92153 92153-0578 BOLT,6X8 3

92153A 92153-1308 BOLT,FLANGED,8X16 3

92153B 92153-1347 BOLT,SOCKET,6X12 1

92153C 92153-1348 BOLT,SOCKET,8X14 1

92161 92161-0336 DAMPER 2

92171 92171-0631 CLAMP 1

file:///Y|/KLX250S/60356.html1/19/2007 1:20:43 PM

mooredan
Rectangle
mooredan
Rectangle
Page 84: 2007 Kawasaki KLX200S Service Manual
Page 85: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60333.html

Ref # Part # Description Qty Spec #

220 220B0610 SCREW-PAN-CROS,6X10 3

220A 220B0625 SCREW-PAN-CROS,6X25 1

220B 220B0630 SCREW-PAN-CROS,6X30 2

670 670D2010 O RING 1

11065 11065-0102 CAP,OIL FILTER 1

13216 13216-1193 GEAR-COMP,OIL PUMP 1

16082 16082-1163 PUMP-ASSY-OIL 1

16142 16142-1123 COVER-PUMP 1

16154 16154-1130 ROTOR-PUMP 1

49065 49065-1058 FILTER-OIL 1

52010 52010-1053 ELEMENT-OIL FILTER 1

92033 92033-1327 RING-SNAP,6MM 1

92042 92042-007 PIN,DOWEL,6.3X8X14 2

92055 92055-074 RING-O,OD=13 1

92055A 92055-1577 RING-O,52.6X2.4 1

92144 92144-1761 SPRING 1

92153 92153-0695 BOLT,6X16 2

92200 92200-1591 WASHER,8.5X12X1.0 1

file:///Y|/KLX250S/60333.html1/19/2007 1:35:57 PM

mooredan
Rectangle
mooredan
Rectangle
Page 86: 2007 Kawasaki KLX200S Service Manual
Page 87: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60390.html

Ref # Part # Description Qty Spec #

132 132G0616 BOLT-FLANGED-SMALL,6X16 1

480 480J1600 CIRCLIP-TYPE-C,16MM 2

600 600A0800 BALL-STEEL,1/4" 1

11060 11060-1324 GASKET,CLUTCH COVER INNER 1

11060A 11060-1328 GASKET,PUMP COVER 1

13061 13061-1397 BOSS,KICK PEDAL 1

13064 13064-0034 LEVER-ASSY-KICK,PEDAL 1

13066 13066-1088 SHAFT-KICK 1

13070 13070-011 GUIDE,KICK SPRING 1

13078 13078-1052 RATCHET 1

13206 13206-1062 GUIDE-KICK 1

49006 49006-1287 BOOT 1

59051 59051-1131 GEAR-SPUR,KICK,29T 1

59051A 59051-1400 GEAR-SPUR,28T 1

92022 92022-118 WASHER,18.5X23X1.2 1

92022A 92022-269 WASHER,12.3X20X0.5 1

92022B 92022-315 WASHER,16.8X22X0.5 2

92025 92025-1451 SHIM,T=0.7 2

92033 92033-029 RING-SNAP,18MM 1

92050 92050-078 SEAL-OIL 1

92081 92081-020 SPRING,KICK PEDAL 1

92081A 92081-122 SPRING,RATCHET 1

92082 92082-003 SPRING,KICKSTARTER 1

92153 92153-1350 BOLT,SOCKET,8X25 1

92172 92172-0222 SCREW,6X27 1

99999 99999-0073 KIT.,KICK STARTER 1 (OPTION)

file:///Y|/KLX250S/60390.html1/19/2007 1:20:08 PM

mooredan
Rectangle
mooredan
Rectangle
Page 88: 2007 Kawasaki KLX200S Service Manual
Page 89: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60375.html

Ref # Part # Description Qty Spec #

56007 56007-1383 TOOL-KIT 1

56008 56008-006 BAG,TOOL 1

56019A 56019-120 THREE BOND TB1211,HT/RS,WHITE 1

92104 92104-002 GASKET-LIQUID,TUBE,100G,SILVER 1

92107 92107-1051 TOOL-DRIVER,#2PHILLIPS&SLOT 1

92110 92110-1144 TOOL-WRENCH,HOOK 1

92110A 92110-1152 TOOL-WRENCH,OPEN END,10X12 1

92110B 92110-1153 TOOL-WRENCH,OPEN END,14X17 1

92110C 92110-1160 TOOL-WRENCH,BOX,8&10MM 1

92110D 92110-1172 TOOL-WRENCH,BOX,16MM 1

92111 92111-1051 TOOL-BAR,BOX END WRENCH 1

92112 92112-1001 TOOL-PLIERS 1

file:///Y|/KLX250S/60375.html1/19/2007 1:20:23 PM

mooredan
Rectangle
mooredan
Rectangle
Page 90: 2007 Kawasaki KLX200S Service Manual
Page 91: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60353.html

Ref # Part # Description Qty Spec #

99987-1421 O/M KLX250H 1

99931-1458-01 A&P KLX250H 1

99924-1165-03 S/M KLX250D/H 1

99924-1240-56 S/M SUPP KLX250H 1

file:///Y|/KLX250S/60353.html1/19/2007 1:20:46 PM

mooredan
Rectangle
mooredan
Rectangle
Page 92: 2007 Kawasaki KLX200S Service Manual
Page 93: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60350.html

Ref # Part # Description Qty Spec #

11009 11009-1145 GASKET,RESERVOIR TANK CAP 1

11009A 11009-1152 GASKET,DRAIN BOLT 1

11012 11012-1084 CAP 1

14037 14037-0047-RZ SCREEN,RH,WHITE 1

14037A 14037-1099-RZ SCREEN,WHITE 1

27002 27002-1051 RELAY-ASSY 1

27010 27010-1180 SWITCH,FAN 1

27010A 27010-1199 SWITCH,WARNING 1

39061 39061-1193 RADIATOR-ASSY,LH 1

39061A 39061-1303 RADIATOR-ASSY,RH 1

39062 39062-1535 HOSE-COOLING,HEAD-RADIATOR 1

39062A 39062-1536 HOSE-COOLING,RADIATOR,L-R 1

39062B 39062-1563 HOSE-COOLING,PUMP-CYLINDER 1

39062C 39062-1564 HOSE-COOLING,RADIATOR-PUMP 1

39062D 39062-1613 HOSE-COOLING,RESERVOIR 1

39062E 39062-1891 HOSE-COOLING,5X9X370 1

43078 43078-0001 RESERVOIR 1

49085 49085-1066 CAP-ASSY-PRESSURE 1

49131B 49131-5097-290 SHROUD-ENGINE,LH,L.GREEN 1

49131C 49131-5098-290 SHROUD-ENGINE,RH,L.GREEN 1

59502 59502-1139 FAN-ASSY 1

92002 92002-1682 BOLT,RADIATOR DRAIN 1

92015 92015-1487 NUT 4

92027 92027-194 COLLAR,L=11.1 6

92037 92037-1163 CLAMP,SPEED,L=58 1

92037A 92037-1589 CLAMP,COOLING HOSE 8

92037B 92037-1712 CLAMP 3

92075 92075-1982 DAMPER,IGNITION 1

92075A 92075-209 DAMPER 6

file:///Y|/KLX250S/60350.html (1 of 2)1/19/2007 1:24:35 PM

mooredan
Rectangle
mooredan
Rectangle
Page 94: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60350.html

92143 92143-1196 COLLAR 2

92150 92150-1186 BOLT,6X12 3

92152 92152-1235 COLLAR 4

92153 92153-0502 BOLT,6X20 7

92153A 92153-0503 BOLT,6X12 6

92153B 92153-0936 BOLT,FLANGED,6X14 2

92153C 92153-0950 BOLT,FLANGED,6X22 1

92153D 92153-1008 BOLT,FLANGED WP,6X25 1

92153E 92153-1354 BOLT,FLANGED,6X10 1

92153F 92153-1457 BOLT,FLANGED,6X30 1

92170 92170-1357 CLAMP 1

92170A 92170-1419 CLAMP 1

file:///Y|/KLX250S/60350.html (2 of 2)1/19/2007 1:24:35 PM

mooredan
Rectangle
mooredan
Rectangle
Page 95: 2007 Kawasaki KLX200S Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK

Page 96: 2007 Kawasaki KLX200S Service Manual
Page 97: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60374.html

Ref # Part # Description Qty Spec #

14079 14079-1105 HOLDER-ASSY,REAR CALIPER 1

32085 32085-1386 STOPPER,PAD 1

41080 41080-0050-CM DISC,RR,SILVER 1

43048 43048-1068 PISTON-CALIPER 1

43049 43049-1060 PACKING,PISTON SEAL 1

43049A 43049-1061 PACKING,PISTON SEAL 1

43056 43056-1055 BREATHER 1

43057 43057-1001 CAP-BREATHER 1

43080 43080-5120 CALIPER-SUB-ASSY,RR 1

43082 43082-1173 PAD-ASSY-BRAKE 1

49006 49006-1088 BOOT,CALIPER 1

49006A 49006-1242 BOOT,CALIPER 1

55020 55020-1488-RZ GUARD,RR CALIPER,WHITE 1

92043 92043-1507 PIN,HANGER 1

92043A 92043-1508 PIN 1

92144 92144-1819 SPRING,PAD 1

92150 92150-1340 BOLT,6X14 2

92150A 92150-1692 BOLT,PLUG 1

92150B 92150-1811 BOLT,DISC PLATE,8X15 6

file:///Y|/KLX250S/60374.html1/19/2007 1:20:29 PM

mooredan
Rectangle
mooredan
Rectangle
Page 98: 2007 Kawasaki KLX200S Service Manual
Page 99: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60301.html

Ref # Part # Description Qty Spec #

410 410B0800 WASHER-PLAIN-SMALL,8MM 6

550 550D3025 PIN-COTTER,3.0X25 1

11012 11012-1581 CAP,AXLE 2

41034 41034-1216 DRUM-ASSY,REAR BRAKE 1

41068 41068-0014 AXLE,RR 1

42041 42041-1421 SPROCKET-HUB,42T 1

92015 92015-1432 NUT,8MM 6

92015A 92015-1770 NUT,LOCK,20MM 1

92033 92033-1041 RING-SNAP,42MM 1

92045 92045-1239 BEARING-BALL,6004X8JRLLX2/3A 2

92049 92049-1203 SEAL-OIL,BJNC2 25425 2

92057 92057-1367 CHAIN,DRIVE,EK520LV-OX106L 1

92058 92058-1070 JOINT-CHAIN,DRIVE,EK 1

92143 92143-1259 COLLAR,RR AXLE,L=22 1

92143A 92143-1402 COLLAR,RR BRAKE DRUM,L=105 1

92143B 92143-1840 COLLAR,RR AXLE,RH,L=20 1

92150 92150-1978 BOLT,SOCKET,8X28 6

92200 92200-1146 WASHER,20.2X36X2 1

file:///Y|/KLX250S/60301.html1/19/2007 1:24:02 PM

mooredan
Rectangle
mooredan
Rectangle
Page 100: 2007 Kawasaki KLX200S Service Manual
Page 101: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60373.html

Ref # Part # Description Qty Spec #

221 221B0610 SCREW-CSK-CROS,6X10 4

550 550D2015 PIN-COTTER,2.0X15 1

13070 13070-1144 GUIDE,HOSE 2

13159 13159-1056 CONNECTOR 1

43010 43010-1068 ROD-ASSY-BRAKE 1

43016 43016-1149 CYLINDER-MASTER 1

43020 43020-1094 PISTON-COMP-BRAKE 1

43026 43026-1075 CAP-BRAKE 1

43028 43028-1067 DIAPHRAGM 1

43059 43059-1767 HOSE-BRAKE,RR MASTER CYLINDER 1

43078 43078-1189 RESERVOIR 1

43095 43095-0164 HOSE-BRAKE,RR 1

49091 49091-0001 WASHER-SEAL,10.1X14.5X1.5 4

55020 55020-1489 GUARD,RR BRAKE RESERVOIR HOSE 1

92009 92009-1596 SCREW,4X40 2

92022 92022-1028 WASHER,8.5X13X1 1

92022A 92022-1601 WASHER,CIRCRIP 1

92033 92033-1186 RING-SNAP,20.5MM 1

92037 92037-1710 CLAMP 2

92043 92043-0004 PIN 1

92055 92055-1251 RING-O,MASTER CYLINDER 1

92153 92153-0502 BOLT,6X20 1

92153A 92153-0627 BOLT,OIL,L=23 2

92172 92172-0107 SCREW,6X14 4

file:///Y|/KLX250S/60373.html1/19/2007 1:20:26 PM

mooredan
Rectangle
mooredan
Rectangle
Page 102: 2007 Kawasaki KLX200S Service Manual
Page 103: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60354.html

Ref # Part # Description Qty Spec #

13107 13107-1330 SHAFT,ARM,14MM 1

39007 39007-1230 ARM-SUSP,UNI TRAK 1

42036 42036-1245 SLEEVE,15X22X57 2

42036A 42036-1248 SLEEVE,10X16X19 1

42036B 42036-1318 SLEEVE,17X25X57 1

46102 46102-1360 ROD,SUSPENSION 2

92001 92001-1499 BOLT,FLANGED,10X44 1

92015 92015-1407 NUT,14MM 1

92046 92046-1162 BEARING-NEEDLE,F-2220 4

92046A 92046-1192 BEARING-NEEDLE,16BM2212 1

92046B 92046-1228 BEARING-NEEDLE,BM2520 2

92049 92049-0069 SEAL-OIL 2

92049A 92049-1254 SEAL-OIL,MHA22 28 5.7F 4

92049B 92049-1426 SEAL-OIL,MF025N1 2

92150 92150-1711 BOLT,FLANGED,10X40 1

92150A 92150-1812 BOLT,ROD,12X90 2

92210 92210-0348 NUT,LOCK,FLANGED,12MM 2

file:///Y|/KLX250S/60354.html1/19/2007 1:20:49 PM

mooredan
Rectangle
mooredan
Rectangle
Page 104: 2007 Kawasaki KLX200S Service Manual
Page 105: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60314.html

Ref # Part # Description Qty Spec #

132 132G0830 BOLT-FLANGED-SMALL,8X30 2

411 411B0800 WASHER-PLAIN,8MM 2

53029 53029-1146 CARRIER 1

53066 53066-0095-336 SEAT-ASSY,DUAL,W/BAND,GRN/BLK 1

56008 56008-1074-MA BAG,TOOL,BLACK 1

92015 92015-1078 NUT,FLANGED,6MM 2

92015A 92015-1143 NUT,8MM 2

92150 92150-1340 BOLT,6X14 2

file:///Y|/KLX250S/60314.html1/19/2007 1:24:16 PM

mooredan
Rectangle
mooredan
Rectangle
Page 106: 2007 Kawasaki KLX200S Service Manual
Page 107: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60348.html

Ref # Part # Description Qty Spec #

11012 11012-1391 CAP,VALVE AIR 1

13070 13070-1165 GUIDE,SPRING 1

43078 43078-1094 RESERVOIR,SHOCKABSORBER 1

45014 45014-5020 SHOCKABSORBER 1

92002 92002-1955 BOLT,DRAIN 1

92015 92015-1703 NUT,SPRING ADJUST 1

92015A 92015-1704 NUT,SPRING ADJUST LOCK 1

92033 92033-1209 RING-SNAP 1

92033A 92033-1228 RING-SNAP,SHOCKABSORBER 1

92055 92055-1383 RING-O 1

92092 92092-1062 BUSHING-RUBBER,SHOCKABSORBER 1

92145 92145-1161-8V SPRING,SHOCK,K=54N/MM,I.SILVER 1

file:///Y|/KLX250S/60348.html1/19/2007 1:24:32 PM

mooredan
Rectangle
mooredan
Rectangle
Page 108: 2007 Kawasaki KLX200S Service Manual
Page 109: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60368.html

Ref # Part # Description Qty Spec #

36001 36001-0078-266 COVER-SIDE,LH,S.WHITE 1

36001A 36001-0079-266 COVER-SIDE,RH,S.WHITE 1

36014 36014-0003 CASE-CHAIN 1

39156 39156-1345 PAD,SIDE COVER,RH 1

39156A 39156-1346 PAD,SIDE COVER,RH 1

39156B 39156-1349 PAD,SIDE COVER,LH 1

92075 92075-1138 DAMPER,8MM 4

92075A 92075-1658 DAMPER 1

92150 92150-1435 BOLT,6X12 2

92152 92152-0334 COLLAR 4

92153 92153-0502 BOLT,6X20 4

file:///Y|/KLX250S/60368.html1/19/2007 1:20:37 PM

mooredan
Rectangle
mooredan
Rectangle
Page 110: 2007 Kawasaki KLX200S Service Manual
Page 111: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60315.html

Ref # Part # Description Qty Spec #

34024A 34024-1311-458 STAND-SIDE,P.SILVER 1

92003 92003-157 BOLT,SIDE STAND 1

92015 92015-1188 NUT,LOCK,10MM,BLACK 1

92145 92145-0116 SPRING,SIDE STAND 1

file:///Y|/KLX250S/60315.html1/19/2007 1:35:47 PM

mooredan
Rectangle
mooredan
Rectangle
Page 112: 2007 Kawasaki KLX200S Service Manual
Page 113: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60328.html

Ref # Part # Description Qty Spec #

13091 13091-1883 HOLDER,SWITCH 1

13194 13194-1091 CLUTCH-ONEWAY 1

13216 13216-1148 GEAR-COMP,ONEWAY CLUTCH 1

21017 21017-017 GROMMET,STARTER TERMINAL 1

21025 21025-011 WASHER,9.1X18X0.2 AR

21039 21039-1062 BRUSH,CARBON 1

21040 21040-1057 SPRING-BRUSH 2

21163 21163-1256 STARTER-ELECTRIC 1

26006 26006-1051 FUSE,20A-Y 1

26011 26011-1604 WIRE-LEAD 1

27010 27010-1336 SWITCH 1

39076 39076-1069 LIMITER,STARTER IDLER GEAR 1

42034 42034-1181 COUPLING 1

59051 59051-1304 GEAR-SPUR,IDLE 1

92002 92002-1778 BOLT,SOCKET,6X16 6

92015 92015-1476 NUT,STARTER MOTOR 2

92022 92022-1132 WASHER,9.1X18X0.8 1

92022A 92022-1458 WASHER,LOCK,T=2.0 2

92022B 92022-1649 WASHER,10.2X20X0.5 4

92022C 92022-1781 WASHER,27.2X44X1.0 1

92026 92026-1450 SPACER 1

92055 92055-1276 RING-O 1

92055A 92055-1370 RING-O,4.5X2.0 3

92055B 92055-1381 RING-O,STARTER MOTOR 2

92150 92150-1838 BOLT,STARTER MOTOR 2

92151 92151-1134 BOLT,6X30 2

92172 92172-0234 SCREW-PAN-WS-CROS,5X10 2

file:///Y|/KLX250S/60328.html1/19/2007 1:36:20 PM

mooredan
Rectangle
mooredan
Rectangle
Page 114: 2007 Kawasaki KLX200S Service Manual
Page 115: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60338.html

Ref # Part # Description Qty Spec #

132 132G0616 BOLT-FLANGED-SMALL,6X16 1

132A 132G0660 BOLT-FLANGED-SMALL,6X60 2

220 220B0608 SCREW-PAN-CROS,6X8 4

221 221B0650 SCREW-CSK-CROS,6X50 2

11012 11012-1259 CAP,SWING ARM 4

12053 12053-1268 GUIDE-CHAIN,RR,OUTSIDE 1

12053A 12053-1270 GUIDE-CHAIN,DRIVE,RR,INSIDE 1

12053B 12053-1323 GUIDE-CHAIN,DRIVE,RR,OUTSIDE 1

12053C 12053-1324 GUIDE-CHAIN,DRIVE,RR,INSIDE 1

12053D 12053-1328 GUIDE-CHAIN,DRIVE,FR 1

33001 33001-1564-458 ARM-COMP-SWING,P.SILVER 1

33032 33032-0006 SHAFT-SWING ARM 1

33040 33040-1113 ADJUSTER-CHAIN 2

39092 39092-0001 PIN-HAIR 2

42036 42036-1064 SLEEVE,SWING ARM 2

92009 92009-1686 SCREW,SET,10X29 2

92015 92015-1078 NUT,FLANGED,6MM 3

92015A 92015-1407 NUT,14MM 1

92043 92043-1590 PIN,6X45 2

92046 92046-1128 BEARING-NEEDLE,TA2030Z 2

92143 92143-1156 COLLAR 4

file:///Y|/KLX250S/60338.html1/19/2007 1:36:10 PM

mooredan
Rectangle
mooredan
Rectangle
Page 116: 2007 Kawasaki KLX200S Service Manual
Page 117: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60330.html

Ref # Part # Description Qty Spec #

11009 11009-1371 GASKET,TAIL LAMP 1

11045 11045-1387 BRACKET,LICENSE 1

14025 14025-1725 COVER,LICENSE LAMP 1

23016 23016-1116 LAMP-ASSY,LICENSE PLATE 1

23025 23025-0037 LAMP-TAIL 1

23026 23026-1053 LENS,TAIL LAMP 1

23026A 23026-1064 LENS,LICENSE LAMP 1

23035 23035-1066 REFLECTOR-LAMP,LICENSE 1

39184 39184-0007 BRACKET-ASSY,TAIL LAMP 1

92002 92002-1831 BOLT,TAPPING,5X25 2

92009 92009-1297 SCREW,TAPPING,4X20 2

92009A 92009-1378 SCREW,TAPPING,4X20 2

92015 92015-1367 NUT,FLANGED,6MM 3

92015A 92015-1899 NUT,6MM 2

92022 92022-1581 WASHER,5.5X20X1.2 2

92027 92027-1920 COLLAR,L=14.1 3

92069 92069-1055 BULB,12V 5W 1

92069A 92069-1093 BULB,12V 27/8W 1

92075 92075-1870 DAMPER 2

92143 92143-1047 COLLAR,5.8X9X10.5 2

92153 92153-0684 BOLT,6X16 2

92160 92160-1167 DAMPER 3

92160A 92160-1406 DAMPER,TAIL LAMP 1

file:///Y|/KLX250S/60330.html1/19/2007 1:35:54 PM

mooredan
Rectangle
mooredan
Rectangle
Page 118: 2007 Kawasaki KLX200S Service Manual
Page 119: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60297.html

Ref # Part # Description Qty Spec #

13127 13127-1223 SHAFT-TRANSMISSION INPUT,10T 1

13128 13128-1253 SHAFT-TRANSMISSION OUTPUT 1

13129 13129-1603 GEAR,INPUT 5TH,20T 1

13129A 13129-1650 GEAR,OUTPUT 3RD,27T 1

13129B 13129-1653 GEAR,OUTPUT TOP,19T 1

13144 13144-1314 SPROCKET-OUTPUT,14T 1

13260 13260-1385 GEAR,INPUT 2ND,15T 1

13260A 13260-1386 GEAR,OUTPUT 2ND,30T 1

13260B 13260-1595 GEAR,INPUT TOP,21T 1

13260C 13260-1596 GEAR,OUTPUT 5TH,21T 1

13260D 13260-1897 GEAR,INPUT 3RD&4TH,18T&20T 1

13260E 13260-1898 GEAR,OUTPUT 4TH,25T 1

13260F 13260-1901 GEAR,OUTPUT LOW,30T 1

92015 92015-1963 NUT,20MM 1

92022 92022-159 WASHER,25.3X30X0.5 1

92022A 92022-198 WASHER,22.3X27X0.5 1

92022B 92022-252 WASHER,20.5X25.5X0.5 1

92022C 92022-255 WASHER,17.3X28X1 1

92024 92024-038 WASHER,TOOTHED,22.5X31X0.5 2

92024A 92024-039 WASHER,TOOTHED,22.5X27X0.5 2

92025 92025-1451 SHIM,T=0.7 1

92026 92026-079 SPACER,30X38X1.0 1

92028 92028-1016 BUSHING,OUTPUT GEAR 1

92033 92033-025 RING-SNAP,20X25.5X1.2 3

92033A 92033-026 RING-SNAP,24MM 3

92033B 92033-029 RING-SNAP,18MM 1

92055 92055-1293 RING-O,21.5X1.5 1

92152 92152-1350 COLLAR 1

92152A 92152-1357 COLLAR,20X28X8.5 1

file:///Y|/KLX250S/60297.html (1 of 2)1/19/2007 1:24:13 PM

mooredan
Rectangle
mooredan
Rectangle
Page 120: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60297.html

92200 92200-1065 WASHER 1

file:///Y|/KLX250S/60297.html (2 of 2)1/19/2007 1:24:13 PM

mooredan
Rectangle
mooredan
Rectangle
Page 121: 2007 Kawasaki KLX200S Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK

Page 122: 2007 Kawasaki KLX200S Service Manual
Page 123: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60339.html

Ref # Part # Description Qty Spec #

11009 11009-1128 GASKET,TURN SIGNAL LAMP LENS 4

11012 11012-1367 CAP 2

23037 23037-0027 LAMP-ASSY-SIGNAL,FR 2

23037A 23037-0070 LAMP-ASSY-SIGNAL,RR 2

23048 23048-1076 LENS-SIGNAL LAMP 4

23058 23058-002 WASHER,PLAIN,4MM 8

92015 92015-1428 NUT,FLANGED,10MM 4

92069 92069-055 BULB,12V 32CP(23W) 4

92172 92172-0124 SCREW,TAPPING,4X30 8

file:///Y|/KLX250S/60339.html1/19/2007 1:36:25 PM

mooredan
Rectangle
mooredan
Rectangle
Page 124: 2007 Kawasaki KLX200S Service Manual
Page 125: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60376.html

Ref # Part # Description Qty Spec #

12004 12004-1111 VALVE-INTAKE 2

12005 12005-0029 VALVE-EXHAUST 2

12009 12009-1069 RETAINER-VALVE SPRING 4

12011 12011-1053 COLLET 8

12032 12032-1058 TAPPET 4

16007 16007-1163 SEAT-SPRING 4

49078 49078-1094 SPRING-ENGINE VALVE,OUTER 4

49078A 49078-1114 SPRING-ENGINE VALVE,INNER 4

92049 92049-1349 SEAL-OIL,VSB 4.3 7.5 5.3 8.3 4

92180 92180-1014 SHIM,T=2.50 AR

92180A 92180-1016 SHIM,T=2.55 AR

92180B 92180-1018 SHIM,T=2.60 AR

92180C 92180-1020 SHIM,T=2.65 AR

92180D 92180-1022 SHIM,T=2.70 AR

92180E 92180-1024 SHIM,T=2.75 AR

92180F 92180-1026 SHIM,T=2.80 AR

92180G 92180-1028 SHIM,T=2.85 AR

92180H 92180-1030 SHIM,T=2.90 AR

92180I 92180-1032 SHIM,T=2.95 AR

92180J 92180-1034 SHIM,T=3.00 AR

92180K 92180-1036 SHIM,T=3.05 AR

92180L 92180-1038 SHIM,T=3.10 AR

92180M 92180-1040 SHIM,T=3.15 AR

92180N 92180-1042 SHIM,T=3.20 AR

92180O 92180-1044 SHIM,T=3.25 AR

92180P 92180-1046 SHIM,T=3.30 AR

92180Q 92180-1048 SHIM,T=3.35 AR

92180R 92180-1050 SHIM,T=3.40 AR

92180S 92180-1052 SHIM,T=3.45 AR

file:///Y|/KLX250S/60376.html (1 of 2)1/19/2007 1:20:20 PM

mooredan
Rectangle
mooredan
Rectangle
Page 126: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60376.html

92180T 92180-1054 SHIM,T=3.50 AR

file:///Y|/KLX250S/60376.html (2 of 2)1/19/2007 1:20:20 PM

mooredan
Rectangle
mooredan
Rectangle
Page 127: 2007 Kawasaki KLX200S Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK

Page 128: 2007 Kawasaki KLX200S Service Manual
Page 129: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60349.html

Ref # Part # Description Qty Spec #

670 670B1506 O RING,6MM 1

11060 11060-1328 GASKET,PUMP COVER 1

16142 16142-0022 COVER-PUMP 1

59256 59256-1063 IMPELLER 1

92015 92015-1078 NUT,FLANGED,6MM 1

92151 92151-1199 BOLT,6X65 1

92151A 92151-1930 BOLT,FLANGED-SMALL,6X25 2

file:///Y|/KLX250S/60349.html1/19/2007 1:24:29 PM

mooredan
Rectangle
mooredan
Rectangle
Page 130: 2007 Kawasaki KLX200S Service Manual
Page 131: 2007 Kawasaki KLX200S Service Manual

file:///Y|/KLX250S/60352.html

Ref # Part # Description Qty Spec #

11012 11012-1670 CAP,BEAD STOPPER 2

41009 41009-0027 TIRE,FR,3.00-21 51P,D603F(D) 1

41009A 41009-0028 TIRE,RR,4.60-18 63P,D603(D) 1

41022 41022-0004 TUBE-TIRE,120/80-18(D) 1

41022A 41022-1244 TUBE-TIRE,80/100-21(D) 1

41023 41023-1144 BAND-RIM,21XWM1.60-1.85(D) 1

41023A 41023-1145 BAND-RIM,18XWM/MT 1.85-2.15(D) 1

41025 41025-1364-WA RIM,FR,1.60X21,SILVER 1

41025B 41025-1366-WA RIM,RR,2.15X18,SILVER 1

41029 41029-0004 SPOKE-INNER,FR,228MMX165D 36

41029A 41029-0005 SPOKE-INNER,RR,RH,193MMX165D 18

41029B 41029-0006 SPOKE-INNER,RR,LH,189MMX160D 18

41032 41032-0003 NIPPLE-SPOKE,8X9X20(+) 36

41032A 41032-1075 NIPPLE-SPOKE 36

file:///Y|/KLX250S/60352.html1/19/2007 1:24:26 PM

mooredan
Rectangle
mooredan
Rectangle