🏷️ Basic Information Identification Make: KTM Model: 200 Year: 1999 Product Type: Factory Service Repair Manual 👋 Introduction Market Position Positioning: The KTM 200 from 1999 was positioned as a versatile off-road/enduro or supermoto-style motorcycle, known for its lightweight design and spirited performance, appealing to riders seeking agility and a focused riding experience. Competitive Analysis Competitors: Competed against similar displacement models from Japanese manufacturers like Yamaha (DT200/WR200), Honda (CRF200 variants), and Suzuki (DR200/DRZ200), as well as other European brands offering lightweight dual-sport or off-road machines. Key Features Features: Likely featured a robust two-stroke engine, a capable suspension system suitable for varied terrain, and a minimalist, performance-oriented design characteristic of KTM's off-road heritage. 📋 Manual Details Coverage Areas Primary Coverage: All aspects of repair, maintenance, diagnostics, and troubleshooting for the KTM 200 motorcycle. Page Count Estimated Pages: N/A (PDF Download) Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, inspection, and repair procedures. Includes top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rod, bearings), valve train, cooling system, lubrication system. Fuel System: Carburetor (Mikuni VM series or similar) tuning, cleaning, rebuilding, jetting, float bowl adjustment, fuel lines, fuel pump (if applicable). Ignition System: CDI unit, spark plug, ignition coil, timing checks, troubleshooting electrical faults related to ignition. Transmission: Gearbox disassembly, assembly, inspection of gears, shift drum, shift forks, bearings, clutch operation, clutch plate replacement, clutch cable adjustment. Chassis Frame: Frame inspection, welding repairs (if necessary), headstock bearing replacement, swingarm disassembly and maintenance. Suspension Front: Front fork disassembly, seal replacement, oil level and type specification, spring inspection, damping adjustments. Suspension Rear: Rear shock absorber removal, inspection, linkage maintenance, bearing checks, spring pre-load adjustment. Braking System: Front and rear brake caliper maintenance, piston service, pad replacement, brake fluid flush and bleed, master cylinder service, brake line inspection. Electrical System: Wiring diagrams, battery maintenance, lighting system, horn, starter motor (if applicable), charging system (stator, rectifier/regulator), fuse box. Cooling System: Radiator maintenance, coolant specifications, fan operation (if applicable), hose inspection and replacement. Exhaust System: Exhaust pipe and muffler removal, inspection, gasket replacement. Bodywork Plastics: Fairing removal and installation, seat, fuel tank, fenders, graphics. Procedures Included Routine Maintenance: Oil change intervals and specifications, filter replacement, chain adjustment and lubrication, air filter cleaning/replacement, spark plug replacement, coolant checks. Troubleshooting: Diagnostic flowcharts, common problems and their solutions, electrical system troubleshooting, engine performance issues. Repair Procedures: Step-by-step guides for all major component repairs and replacements. Special Tools: Identification and usage of specialized tools required for specific maintenance or repair tasks. Torque Specifications: Detailed torque values for all critical fasteners and components. Cleaning And Lubrication: Specific guidance on cleaning and lubrication points throughout the motorcycle. Technical Depth Depth: Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Covers complete engine rebuilds, suspension overhauls, and detailed electrical diagnostics. 📊 Manual Specifications File Format Format Details: Searchable PDF document. May include high-resolution diagrams and schematics. Print Quality Quality: Digital, high-resolution for clarity. Printable. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, single-cylinder, two-stroke. Displacement: Approximately 194 cc (exact figure may vary by specific model variant). Bore X Stroke: Refer to manual for exact dimensions, typically around 66 mm x 57 mm for similar displacements. Compression Ratio: Refer to manual for exact specifications, likely in the range of 8.5:1 to 10.5:1. Performance Horsepower: Estimated 25-35 HP (actual figures vary by specific tuning and market). Torque: Refer to manual for exact specifications. Torque delivery is typically strong in the mid-range for this type of engine. Fuel System Carburetor Type: Likely a Mikuni VM series (e.g., VM34 or VM36) or a Keihin equivalent. Fuel Type: Unleaded gasoline with appropriate octane rating (refer to manual). Pre-mix or oil injection system likely. Lubrication Lubrication System: Premix or automatic oil injection system (refer to manual for system type and oil specifications). Cooling System Cooling Method: Liquid Cooling. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh manual transmission. Optional Optional Gearbox: N/A Features Clutch Type: Wet multi-plate clutch. Gear Ratios: Refer to manual for specific gear ratios. Final Drive: Chain drive. Transmission Fluid: Refer to manual for specific fluid type and capacity (typically a dedicated transmission oil or engine oil for wet clutch systems). 📐 Dimensions Exterior Overall Length: Refer to manual for exact dimensions. Overall Width: Refer to manual for exact dimensions. Overall Height: Refer to manual for exact dimensions. Wheelbase: Refer to manual for exact dimensions, typically around 1400-1450 mm. Weights Dry Weight: Approximately 105-115 kg (may vary by specific configuration). Curb Weight: Refer to manual for exact specifications (includes fluids). Fuel Capacity: Approximately 8-10 liters (refer to manual). 🛡️ Safety Features Ratings Safety Certification: Motorcycles are typically certified to relevant roadworthiness standards in their respective markets, but specific crash...