The KTM 200 EGS, produced for the 1999 and 2000 model years, represents a formidable entry in the lightweight, two-stroke enduro motorcycle segment. Renowned for its agile handling, impressive power-to-weight ratio, and robust off-road capability, this Austrian-engineered machine is built for demanding terrain. Its design emphasizes pure performance, featuring a liquid-cooled, 193 cc single-cylinder engine with a Nikasil-coated cylinder and typically a V-Force reed block, delivering approximately 32-35 horsepower. The 6-speed manual gearbox, coupled with a hydraulic clutch and advanced WP suspension components, ensures precise control and responsiveness in challenging conditions. This comprehensive workshop manual serves as an indispensable resource for the maintenance, repair, and optimal performance of your KTM 200 EGS. Covering over 300 pages of detailed information in English, it provides step-by-step instructions for engine overhauls, transmission servicing, fuel system adjustments, ignition system diagnostics, and suspension tuning. It also includes thorough guidance on brake systems, electrical schematics, frame and bodywork procedures, and essential troubleshooting charts for common issues. This manual is designed to empower both professional mechanics and experienced enthusiasts with the knowledge required to keep the 200 EGS in peak operating condition. 🏷️ Basic Information Identification Make: KTM Model: 200 EGS Years Covered: 1999, 2000 Product Name: KTM 200 EGS 1999 2000 Service Repair Workshop Manual PDF Download 👋 Introduction Market Position Category: Off-road / Enduro Motorcycle Target Audience: Enthusiasts and professionals working on the KTM 200 EGS Competitive Analysis Competitors Segment: Lightweight 2-stroke enduro bikes of the late 90s Key Features Vehicle Strengths: Agile handling, strong power-to-weight ratio, off-road capability Manual Benefit: Empowers owners and technicians with comprehensive knowledge for maintenance and repair 📋 Manual Details Coverage Areas Primary Focus: Service, Repair, Workshop Page Count Estimated Pages: 300+ Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, diagnostics Transmission: Gearbox inspection, repair, clutch service, shift mechanism Fuel System: Carburetor service (model specific), fuel pump, fuel lines, tank inspection Ignition System: Ignition timing, spark plugs, CDI unit, wiring diagrams Cooling System: Radiator, fan, coolant hoses, thermostat, fluid checks Lubrication System: Oil pump, oil filter, oil passages, 2-stroke oil injection system Exhaust System: Muffler, expansion chamber, exhaust seals, decarbonizing Suspension: Front fork (WP USD), rear shock absorber, linkage, seals, oil levels Brakes: Hydraulic brake system, front and rear calipers, master cylinders, brake fluid, pads, discs Wheels And Tires: Wheel bearing service, spoke tensioning, tire pressure, tire types Electrical System: Wiring diagrams, battery maintenance, lighting, switches, fuses, horn Frame And Bodywork: Frame inspection, plastic panel removal/installation, seat, handlebars Procedures Included Maintenance: Scheduled maintenance, pre-ride checks, chain adjustment, filter cleaning Troubleshooting: Diagnostic charts, common problems and solutions, fault finding Repair: Step-by-step repair instructions for all major components Rebuilds: Engine and gearbox rebuild procedures, top-end overhaul Adjustments: Carburetor jetting, ignition timing, clutch cable, throttle cable Disassembly Assembly: Detailed instructions for removing and installing parts Wiring Diagrams: Detailed electrical system schematics for troubleshooting and repair Special Tools: Lists and descriptions of required special tools for specific procedures Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts Diagnostic Focus: Detailed diagnostic flowcharts and symptom-based troubleshooting Specification Detail: Includes precise torque values, clearances, fluid capacities, and electrical specifications 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval Print Quality Print Readability: High-resolution scans for clear text and diagrams Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, single-cylinder Displacement: 193 cc Bore X Stroke: 66 mm x 58 mm Cooling Method: Liquid-cooled Lubrication: Automatic oil injection system (pre-mix capability also available) Performance Horsepower Est: ~32-35 hp (variant dependent) Torque Est: ~25-28 Nm (variant dependent) Fuel System Carburetor Type: Dell'Orto PHBH 30 / Keihin PWK 35 (model year dependent) Fuel Type: Unleaded gasoline (minimum 95 RON) with 2-stroke oil mix Engine Components Cylinder Design: Nikasil coated cylinder Reed Valve System: V-Force reed block (typical) 🔧 Transmission Standard Transmission Type: 6-speed manual gearbox Clutch Type: Wet multi-plate clutch (hydraulic actuation) Features Gear Ratios: Detailed ratios provided in manual Fluid Requirements Transmission Oil Type: API GL-4 or GL-5, SAE 75W/90 or 80W/90 (specific viscosity recommended in manual) Clutch Fluid Type: DOT 4 Brake Fluid 📐 Dimensions Exterior Wheelbase: Approx. 1470 mm (57.9 in) Seat Height: Approx. 950 mm (37.4 in) Weights Dry Weight: Approx. 118 kg (260 lbs) Fuel Tank Capacity: Approx. 9.5 Liters (2.5 US gal) 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle, no official crash ratings) Active Features Braking System: Hydraulic disc brakes (front and rear) Suspension Design: WP Upright Front Forks, WP Monoshock Rear Suspension with Linkage Passive Features Lighting: Headlight, taillight, brake light, turn signals 💡 Technology Features Infotainment Infotainment System: N/A (Minimalist off-road design) Driver Assistance Electronic Aids: None (Pure...