The 200 EGS, produced for the 1999 and 2000 model years, is a lightweight Enduro/Cross Country motorcycle renowned for its agile handling and potent 2-stroke engine. Designed for enthusiasts, amateur racers, and trail riders, this Austrian-engineered machine delivers capable off-road performance, building on a strong heritage in off-road disciplines. Its key features include a robust engine, advanced suspension, and a lightweight chassis, making it a popular choice for those seeking an aggressive and responsive riding experience in demanding terrain. This Factory Service Repair Manual provides comprehensive guidance for the 200 EGS, covering all aspects of mechanical, electrical, and bodywork diagnostics and repair. The manual details engine disassembly and assembly, fuel and ignition system servicing, transmission and clutch maintenance, suspension and brake system overhauls, and electrical system troubleshooting. It includes step-by-step repair instructions, diagnostic procedures, and essential technical specifications, empowering owners and technicians to maintain and repair the vehicle effectively. 🏷️ Basic Information Identification Make: KTM Model: 200 EGS Model Variant: Enduro/Cross Country Years Covered: 1999, 2000 Codes Chassis Code Range: e.g., EGS_1999, EGS_2000 (specific codes may vary) Engine Code Range: e.g., 200cc Single Cylinder (specific engine codes may vary) 👋 Introduction Market Position Segment: Lightweight Enduro/Off-road Motorcycle Target Audience: Enthusiasts, amateur racers, trail riders seeking capable and agile off-road performance. Competitive Analysis Key Competitors: Yamaha WR200, Kawasaki KDX200, Suzuki RM200 (period specific) Key Features Vehicle Attributes: Lightweight, agile handling, potent 2-stroke engine, capable off-road suspension. Manual Value Proposition Benefit To Owner: Empowers owners to perform comprehensive maintenance, diagnostics, and repairs, reducing reliance on professional service. 📋 Manual Details Coverage Areas Primary Focus: Factory Service Repair Scope: Complete mechanical, electrical, and bodywork diagnostics and repair Page Count Estimated Pages: Hundreds (as indicated in product description) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, tuning, valve clearance, piston/ring replacement, cylinder head service, cooling system. Fuel System: Carburetor overhaul and adjustment, fuel pump, fuel lines, fuel tank servicing. Ignition System: Ignition timing, spark plug selection and gap, ignition coil testing, CDI unit diagnostics. Transmission: Gearbox disassembly and reassembly, clutch operation and adjustment, shift mechanism repair. Suspension: Front fork service (oil change, seal replacement, damping adjustments), rear shock absorber servicing and replacement, linkage maintenance. Brakes: Hydraulic brake system service (bleeding, pad replacement, caliper overhaul, master cylinder repair), disc and rotor specifications. Electrical System: Wiring diagrams, starter motor, lighting system, battery maintenance, charging system (alternator/stator testing), fuses and relays. Frame And Body: Frame inspection, body panel removal and installation, seat servicing, handlebar and control adjustments. Wheels And Tires: Wheel bearing maintenance, spoke tensioning, tire pressure recommendations, rim specifications. Exhaust System: Exhaust pipe and silencer inspection and replacement, gasket specifications. Procedures Included Maintenance: Regular service intervals, oil changes, filter replacements, chain lubrication and adjustment, spark plug checks. Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, fault finding charts. Repair: Step-by-step instructions for component removal, replacement, and reassembly for all major systems. Overhaul: Complete engine, carburetor, and suspension component overhaul procedures. Adjustments: Carburetor jetting and idle speed, clutch lever free play, brake lever play, suspension sag. Specifications Setting: Torque values for critical fasteners, valve clearances, ignition timing, chain slack. Technical Depth Depth: Comprehensive from basic rider maintenance to complete engine rebuilds and electrical system diagnostics. Diagnostics: Detailed electrical troubleshooting guides with wiring diagrams and component testing procedures. Special Tools: Lists and descriptions of specialized tools required for specific procedures (e.g., flywheel puller, clutch holding tool). 📊 Manual Specifications File Format Format: PDF Searchable: Typically searchable text-based PDF (depends on source scan quality) Print Quality Quality: High resolution, printable pages for individual sections or the entire manual. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Type: 2-Stroke, Single Cylinder, Liquid-Cooled Displacement: 193 cc (approximate, confirm with manual) Bore X Stroke: e.g., 66.0 mm x 57.8 mm (confirm with manual) Compression Ratio: e.g., 8.5:1 (confirm with manual) Performance Horsepower: Approx. 30-35 HP (estimate, actual may vary by market and tune) Torque: Approx. 25-30 Nm (estimate, actual may vary) Fuel System Carburetor: Mikuni VM Series (e.g., VM38SS or similar, confirm with manual) Fuel Type: Unleaded gasoline with appropriate 2-stroke oil pre-mix (specify ratio from manual) Cooling System Type: Liquid Cooling Lubrication Type: Pre-mix or Autolube system (confirm with manual) 🔧 Transmission Standard Type: 6-Speed Manual Transmission Clutch: Wet Multi-Plate Clutch Features Gear Ratios: Specific ratios detailed in manual, crucial for performance tuning. Fluid Type Transmission Oil: e.g., SAE 10W/40 or 15W/40 API SG (confirm exact specification and capacity in manual) 📐 Dimensions Exterior Wheelbase: e.g., 1450 mm (confirm with manual) Seat Height: e.g., 930 mm (confirm with manual) Weights Dry Weight: e.g., 105 kg (confirm with manual) Fuel Tank Capacity: e.g., 9.5 Liters (confirm with manual) 🛡️ Safety Features Ratings Safety...