🏷️ 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 mechanical performance) Connectivity Connectivity Features: None Lighting Tech Headlight Type: Halogen (bulb type specified in manual) 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific interval based on usage (typically 15-25 hours of riding) Air Filter Cleaning: Regular cleaning recommended, especially in dusty conditions (every few rides) Spark Plug Check: Inspect and clean/replace every 50-100 hours Top End Rebuild: Recommended around 100-150 hours for optimal performance Fluid Specifications Engine Oil Type: Fully synthetic 2-stroke engine oil (e.g., Motorex, Castrol) Coolant Type: Ethylene glycol-based antifreeze coolant (50/50 mix with distilled water) Brake Fluid Type: DOT 4 Known Issues Common Wear Items: Piston rings, clutch plates, reed valves, suspension seals, wheel bearings Potential Problems: Carburetor jetting sensitivity to altitude and temperature, 2-stroke specific maintenance requirements Technical Tips Carburetor Tuning: Crucial for optimal performance, manual provides guidance on jetting and adjustment Suspension Setup: SAG and damping adjustments vital for off-road performance 📚 Vehicle History Brand Heritage Manufacturer: KTM Sportmotorcycle AG, Austria Model Evolution Lineage: Part of KTM's established off-road and enduro lineage, evolving from earlier EXC models Production Manufacturing Location: Austria Production Era: Late 1990s,...