The 200 MXC EGS represents a potent and performance-oriented off-road motorcycle, designed for the rigors of motocross and demanding terrain. Produced between 1999 and 2010, this model exemplifies renowned engineering for off-road competition, featuring a robust chromoly steel trellis frame and typically equipped with high-quality WP Suspension components. Its liquid-cooled, single-cylinder 2-stroke engine, displacing approximately 193cc, delivers a significant power-to-weight ratio, characteristic of a focus on aggressive performance. Known for its agility and capability, the 200 MXC EGS is built for riders who demand precision and power in challenging off-road environments, building upon an extensive legacy in motorsports. This comprehensive Workshop Service Manual, written in English, provides detailed guidance for the maintenance and repair of the 200 MXC EGS models from 1999 through 2010. Spanning 280 pages, it covers all essential aspects of the motorcycle, including in-depth engine and transmission overhauls, fuel and ignition system servicing, suspension and brake system repairs, and electrical diagnostics. The manual includes routine maintenance schedules, troubleshooting guides for common issues, and detailed technical specifications such as torque values and fluid capacities. It is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their 200 MXC EGS. 🏷️ Basic Information Identification Make: KTM Model: 200 MXC EGS Codes Chassis Codes: Specific chassis codes may vary by exact sub-model and year, but typically relate to the 200cc off-road series. Engine Codes: KTM utilizes engine codes that denote displacement and series. The 200cc off-road models will have a specific designation within the LC4 or similar off-road engine family. 👋 Introduction Market Position Segment: Performance off-road/motocross motorcycle. Competitive Analysis Key Competitors: Competitors would have included models from Yamaha (YZ250, WR250), Honda (CR250, XR250), Suzuki (RM250, DR-Z250), and Husqvarna during this era. Key Features Off Road Capability: Designed for closed-course motocross and off-road competition, emphasizing performance and durability. Engine Type: Known for potent 2-stroke performance, offering a high power-to-weight ratio. Suspension Brand: Typically features high-quality WP Suspension components, a hallmark of KTM's performance focus. Frame Design: Chromoly steel trellis frame for strength and rigidity. 📋 Manual Details Coverage Areas Supported Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Total Pages: 280 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, diagnostics, tuning, and repair for the 200cc 2-stroke engine. Transmission: Gearbox operation, maintenance, repair, clutch service, and shift mechanism. Fuel System: Carburetor identification, adjustment, cleaning, rebuilding, fuel tank, fuel lines, and fuel pump (if applicable). Ignition System: CDI unit, ignition coil, spark plug, timing, and troubleshooting. Cooling System: Radiator, coolant, hoses, thermostat (if applicable), and fan operation. Exhaust System: Exhaust pipe, silencer, baffle, and gasket replacement. Suspension: Front fork (WP Suspension typically), rear shock absorber, seals, bushings, oil levels, and adjustment procedures. Brakes: Hydraulic brake systems (front and rear), caliper service, master cylinder, brake pads, rotors, brake fluid specifications, and bleeding procedures. Wheels And Tires: Wheel bearing replacement, rim maintenance, spoke tension, tire fitting, and pressure recommendations. Electrical System: Wiring diagrams, battery maintenance, lighting, horn, starter motor (if electric start), kill switch, and general electrical troubleshooting. Frame And Bodywork: Frame inspection, plastic component removal/installation, seat, handlebars, and controls. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, air filter cleaning, spark plug checks, and general inspection routines. Troubleshooting Guides: Diagnostic flowcharts for common starting, running, and electrical issues. Engine Rebuild: Piston, rings, cylinder, crankshaft, bearings, seals, and gasket replacement. Suspension Rebuild: Fork seal replacement, damper rod service, shock absorber seal head replacement, and spring replacement. Electrical Diagnostics: Testing of CDI, stator, ignition coil, and troubleshooting of lighting and charging circuits. Brake System Service: Pad replacement, rotor inspection, caliper piston service, and brake fluid flush/bleed. Technical Depth Diagnostic Level: Comprehensive diagnostic procedures, including symptom-based troubleshooting and component testing. Repair Complexity: Covers everything from basic adjustments to complete engine and component overhauls. Specifications Detail: Includes detailed torque specifications, clearances, fluid capacities, and electrical resistance values. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, allowing for quick keyword finding. Print Quality Print Capability: Printable for physical reference. Binding Type Binding: Not applicable (Digital download). Paper Type Paper Quality: Not applicable (Digital download). ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, 2-stroke Displacement: Approximately 193cc (exact may vary slightly by specific sub-model or year). Bore X Stroke: Specifics would be detailed in the manual, typically around 62.5 mm x 65 mm. Cooling Method: Liquid-cooled Lubrication: Pre-mix or Autolube (depending on specific variant within the production run). Performance Horsepower: Estimated around 35-40 HP, with variations based on tuning and year. Torque: Torque figures would be detailed in the manual, crucial for off-road grunt. Fuel System Carburetor Type: Typically a Keihin PWK series carburetor (e.g., PWK 38). Fuel Type: Unleaded...