The 200 EGS, produced for the 1999 and 2000 model years, is a performance-oriented enduro motorcycle renowned for its lightweight design, potent 200cc liquid-cooled two-stroke engine, and agile handling. Built upon extensive off-road heritage, this model excels in demanding terrain, offering enthusiasts a machine that prioritizes raw performance and rider engagement. Its capable suspension and robust chassis are engineered to tackle challenging trails, reflecting a commitment to off-road excellence and a competitive standing in the mid-size enduro segment. This comprehensive Service and Repair Manual is your essential guide for the 200 EGS. It covers a wide array of critical areas, including detailed engine overhaul procedures, chassis system maintenance, and electrical system diagnostics. The manual provides step-by-step instructions for routine maintenance tasks, in-depth repair procedures, and valuable troubleshooting guides to address common issues. With technical specifications, torque values, and wiring diagrams, this resource empowers owners and technicians to effectively maintain, diagnose, and repair their 200 EGS, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: KTM Model: 200 EGS Year: 1999, 2000 Engine Variant: 200cc Product Type: Service Repair Manual Codes Engine Code: Likely based on KTM's single-cylinder 2-stroke engine family for this era. 👋 Introduction Market Position Market Segment: KTM's 200 EGS was positioned as a capable off-road and enduro motorcycle, known for its performance-oriented nature and KTM's off-road heritage. Target Audience: Enthusiasts and owners seeking to maintain and repair their KTM 200 EGS, ranging from amateur riders to experienced mechanics. Competitive Analysis Competitors: Competed with other European and Japanese manufacturers in the mid-size enduro segment, such as Yamaha WR200, Honda CR250 (though often higher displacement), and various European brands. Key Features Vehicle Key Features: Lightweight design, potent two-stroke engine, capable suspension, agile handling, focus on off-road performance. Manual Value Proposition Manual Benefit: Provides essential technical knowledge for owners to perform maintenance, diagnostics, and repairs, saving time and money compared to relying solely on professional services. Digital Format Advantage: PDF format offers portability, searchability, and easy access on multiple devices, superior to outdated paper manuals. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English (Presumed based on typical product offerings) Format: PDF Page Count Page Count: Variable, typically 200-400 pages for comprehensive service manuals of this type. Specific count not provided in product data. 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, cylinder head, cylinder, piston, crankshaft, connecting rod, crankcase, lubrication, cooling system, fuel system (carburetor), ignition system, exhaust system, starting system. Chassis Systems: Frame, suspension (front fork, rear shock absorber), steering, wheels, tires, brakes (front and rear), clutch, gearbox, drive chain. Electrical Systems: Wiring diagrams, lighting system, ignition system, battery, charging system, switches, instruments. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake pad replacement. Repair Procedures: Engine disassembly and reassembly, carburetor tuning and rebuilding, suspension component servicing, brake caliper servicing, clutch adjustment and replacement, gearbox inspection and repair. Troubleshooting Guides: Diagnostic procedures for common engine and electrical issues, fault finding charts. Technical Depth Technical Depth: Comprehensive: Covers routine maintenance to complete engine and chassis rebuilds, including detailed specifications and torque values. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Likely text-searchable PDF for easy navigation, assuming it's a professionally produced digital manual. Printability: Printable, allowing users to create hard copies for workshop use. Print Quality Print Quality: Dependent on original source. High-resolution scans or digital creation will ensure clarity of diagrams and text. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder Displacement: 193 cc (approximate, subject to slight variations based on specific EGS variant) Bore X Stroke: Typically around 62.5 mm x 65 mm (exact figures would be in the manual). Compression Ratio: Likely in the range of 8.5:1 to 9.5:1 (check manual for precise value). Performance Horsepower: Estimated 30-35 HP at peak RPM (exact figures in manual). Torque: Estimated 25-30 Nm at peak RPM (exact figures in manual). Fuel System Carburetor: Keihin PWK 35 or similar performance-oriented carburetor. Fuel Type: Unleaded gasoline with appropriate octane rating and 2-stroke oil mixture (premix or separate oil injection system, likely premix for this model). Ignition System Ignition Type: CDI (Capacitor Discharge Ignition), electronic advance. Cooling System Cooling Method: Liquid-cooled Lubrication Lubrication Type: Pre-mix lubrication of fuel and oil, or Autolube system (manual will clarify). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh sequential gearbox. Clutch Type: Wet multi-plate clutch, hydraulically actuated. Features Final Drive: Chain drive (e.g., 520 pitch chain). Gear Ratios: Specific gear ratios will be detailed in the manual, critical for understanding engine RPM at different speeds. 📐 Dimensions Exterior Wheelbase: Approximately 1440-1460 mm (check manual for precise figure). Seat Height: Approximately 900-930 mm (check manual for precise figure). Weights Dry Weight:...