🏷️ Basic Information Identification Make: KTM Model: 200 EGS Model Years Covered: 1999, 2000 👋 Introduction Market Position Segment: Off-road, Enduro Target Audience: Enthusiasts and mechanics servicing the KTM 200 EGS. Competitive Analysis Competitors At Time: Yamaha WR200, Kawasaki KDX200, Suzuki TS200R. Key Features Vehicle Reputation: Known for its potent two-stroke power and agile handling in off-road conditions. Manual Value: Essential resource for maintaining peak performance and longevity of a classic off-road KTM. 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Service Manual Language: English Format: PDF Download Completeness: Comprehensive All Models/Engines/Trim/Transmissions Page Count: Estimated 300-400 pages (typical for a comprehensive workshop manual). 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, diagnostics, and repair for the 200cc two-stroke engine. Fuel System: Carburetor adjustment, cleaning, rebuilding, fuel pump and line service. Ignition System: Ignition timing, coil testing, spark plug specifications, CDI unit diagnostics. Cooling System: Radiator, hoses, thermostat, coolant specifications and maintenance. Transmission: Clutch operation, gearbox disassembly, assembly, gear inspection, and lubrication. Suspension: Front fork disassembly, seal replacement, oil levels, rear shock absorber service and adjustments. Brakes: Hydraulic brake system bleeding, pad replacement, caliper service, master cylinder inspection. Electrical System: Wiring diagrams, component testing, battery maintenance, lighting, stator and rectifier service. Chassis And Frame: Frame inspection, headstock bearing service, swingarm maintenance. Exhaust System: Muffler and pipe maintenance, gasket replacement. Wheel And Tire: Wheel bearing service, spoke tensioning, tire pressure recommendations, and wheel balancing. Bodywork And Fairings: Removal and installation procedures for plastic panels, seat, and fuel tank. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain adjustment, brake adjustments. Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting guides. Repair: Step-by-step instructions for component overhaul and replacement. Diagnostics: Methods for identifying and resolving issues across all major vehicle systems. Electrical Troubleshooting: Detailed troubleshooting flowcharts for electrical faults. Suspension Tuning: Guidance on adjusting suspension settings for various terrain and riding styles. Carburetor Rebuilding: Step-by-step instructions for full carburetor overhaul and jetting changes. Technical Depth Depth: Detailed, from basic maintenance to complete engine and component rebuilds. Torque Specifications: Precise torque values for all critical fasteners and engine components. Clearances: Specifications for valve clearances (if applicable to 2-stroke port timing), piston ring gap, and other critical tolerances. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick information retrieval. Printability: Printable for hard copy reference. Print Quality Image Resolution: High-resolution images and diagrams for clarity. 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: 64 mm x 60 mm Cooling Method: Liquid-cooled Power Output: Approx. 30-35 HP (Varies by tune and specific model variant) Torque Output: Approx. 25-28 Nm (Varies by tune and specific model variant) Spark Plug Type: NGK BR8ES (or equivalent, check manual for precise fitment) Performance Compression Ratio: Approx. 7.5:1 Fuel Delivery: Keihin PWK 35 carburetor Fuel System Fuel Type: Unleaded gasoline with 2-stroke oil mix (ratio specified in manual) Fuel Tank Capacity: Approx. 9-11 Liters (Varies slightly by model year/submodel) 🔧 Transmission Standard Transmission Type: 6-speed manual Clutch Type: Wet, multi-plate Features Gear Ratios: Specific gear ratios detailed within the manual for optimal performance tuning. Transmission Fluid: Specific ATF or manual transmission fluid type and capacity listed in manual. 📐 Dimensions Exterior Wheelbase: Approx. 1450 mm (57.1 inches) Seat Height: Approx. 920 mm (36.2 inches) Weights Dry Weight: Approx. 115-120 kg (253-265 lbs) Wet Weight: Approx. 125-130 kg (275-287 lbs) (with fluids) 🛡️ Safety Features Ratings Safety Ratings: N/A (Off-road motorcycle, not subjected to typical automotive crash testing standards). Active Features Braking System: Hydraulic disc brakes front and rear for effective stopping power. Passive Features Frame Construction: Chromoly steel frame for strength and rigidity. 💡 Technology Features Infotainment Infotainment System: N/A (Minimalist off-road design). Driver Assistance Driver Assistance Features: N/A (Focus on rider input and control). Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 10-15 hours of use or annually, whichever comes first (refer to manual for exact specification). Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions (typically every 5-10 hours). Spark Plug Replacement: Every 20-30 hours of use or as per manual recommendations. Chain And Sprocket Maintenance: Regular cleaning, lubrication, and tension adjustment (check after every ride). Fluid Specifications Engine Oil Type: Fully synthetic 2-stroke premix oil, specific API/JASO rating detailed in manual. Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors, specific mixture ratio detailed in manual. Brake Fluid Type: DOT 4 hydraulic brake fluid. Transmission Fluid Type: Specified ATF or dedicated manual transmission fluid (refer to manual for exact type and quantity). Known Issues Common Wear Items: Piston rings, clutch plates, crank seals, suspension seals, and carburetor jets are common wear items for this era of two-stroke. Carburetor Tuning: Can be sensitive to altitude and temperature changes, requiring...