This manual covers the 200 EGS, a versatile off-road motorcycle produced for the 1999 and 2000 model years. Known for its potent two-stroke engine and agile handling, the 200 EGS is a capable machine for enduro riding, often compared favorably against competitors like the Yamaha WR200 and Kawasaki KDX200. The heritage in off-road racing is evident in the 200 EGS's design, offering a blend of performance and reliability for enthusiasts and riders seeking a classic off-road experience. This workshop repair service manual is an essential resource for maintaining the peak performance and longevity of this iconic model. This comprehensive English-language workshop repair service manual provides detailed guidance for the maintenance, troubleshooting, and repair of the 200 EGS. It covers all major systems, including the 193cc liquid-cooled two-stroke engine, fuel system, ignition, transmission, suspension, brakes, and electrical components. The manual offers step-by-step instructions for routine maintenance, component overhauls, and diagnostics, complete with technical specifications, torque values, and clearances. Its thorough coverage and clear explanations make it an indispensable tool for owners, mechanics, and technicians dedicated to preserving the optimal condition and functionality of their 1999-2000 200 EGS. 🏷️ 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...