The 200 EGS is a performance-oriented off-road motorcycle, produced for the 1999 through 2010 model years. Known for its lightweight construction and powerful 2-stroke, liquid-cooled single-cylinder engine, this model is designed for agility and responsiveness in demanding terrain. It features a robust steel trellis frame and suspension components, contributing to its excellent handling characteristics. The 200 EGS is well-suited for trail riding, enduro events, and general recreational off-road use, embodying a heritage in off-road racing. This comprehensive service repair manual provides detailed guidance for the maintenance, servicing, and repair of the 200 EGS. It covers essential areas including engine service, transmission overhaul, fuel system components, ignition, cooling, and exhaust systems. Furthermore, the manual includes procedures for routine maintenance, disassembly and reassembly of major components, troubleshooting common issues, and identifying necessary special tools. This resource is invaluable for owners and technicians seeking to ensure the optimal performance and longevity of their 200 EGS motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 200 EGS Engine Model Designation: Likely a variant of the KTM 200 LC2 or similar 2-stroke engine Vehicle Type: Off-road Motorcycle / Enduro Generation Applicable Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Codes Vin Code: Typically begins with 'VBK' for KTM, followed by model and year indicators. 👋 Introduction Market Position Segment: Lightweight, performance-oriented off-road motorcycle, popular for trail riding and entry-level enduro competitions. Competitive Analysis Competitors: Models from manufacturers like Husqvarna, Yamaha (YZ250), Suzuki (RM250), Honda (CR250R), Kawasaki (KX250) in similar displacement classes. Key Features Engine Type: 2-stroke, single-cylinder, liquid-cooled; known for its power-to-weight ratio and aggressive performance. Chassis Design: Lightweight steel trellis frame, WP suspension components (often high-quality for its class), strong braking performance. Intended Use: Trail riding, enduro, motocross, recreational off-road riding. 📋 Manual Details Coverage Areas Primary Coverage: Engine Service and Repair Secondary Coverage: General maintenance, troubleshooting, and component replacement Page Count Estimated Page Count: Varies, but typical service manuals for this era and coverage are 200-400 pages. Manual Type Type: Service Repair Manual Language Language: English (presumed based on product title) Format Format: PDF 📖 Manual Coverage Systems Covered Engine Internal: Cylinder head, piston, rings, connecting rod, crankshaft, bearings, seals, gaskets, lubrication system. Fuel System: Carburetor (model specific, e.g., Dell'Orto PHBH/PHBL), fuel pump (if applicable), fuel lines, fuel tank, petcock. Ignition System: CDI unit, ignition coil, spark plug, stator, rotor, wiring. Cooling System: Liquid cooling system components: radiator, water pump, thermostat, hoses, coolant. Exhaust System: Expansion chamber, silencer, associated gaskets and mounting hardware. Transmission Internal: Gearbox, clutch (primary and secondary), shift mechanism, bearings, seals. Electrical System: Wiring diagrams, lighting system, battery, charging system (alternator/stator), starter motor (if equipped). Chassis Components: Suspension (forks and rear shock), brakes (front and rear caliper, master cylinders, lines), wheels, steering head bearings. Procedures Included Routine Maintenance: Oil change intervals, spark plug replacement, air filter cleaning/replacement, chain maintenance, coolant checks. Disassembly Reassembly: Complete engine teardown and reassembly, transmission overhaul, suspension servicing, brake system bleeding/overhaul. Troubleshooting: Diagnostic procedures for common engine, electrical, and mechanical faults. Inspection Adjustments: Valve clearance (if applicable, though unlikely for 2-stroke), carburetor tuning, clutch adjustment, chain slack adjustment. Special Tools: Identification of required special tools for specific repair procedures. Technical Depth Depth: Comprehensive service and repair, suitable for experienced DIY mechanics and professional workshops. Diagnostic Level: Detailed troubleshooting guides for performance issues, starting problems, and abnormal noises. Rebuild Scope: Covers full engine rebuilds, including piston and cylinder servicing, crankshaft and con-rod replacement. 📊 Manual Specifications File Format Compatibility: Viewable on any device with a PDF reader (PC, Mac, tablet, smartphone). Searchability: Typically includes searchable text for quick information retrieval. Print Quality Resolution: High resolution, ensuring clarity of diagrams and text. Binding Type Binding: Not applicable for PDF format. If a physical copy, typically wire-bound or saddle-stitched for durability. Paper Type Paper Quality: Not applicable for PDF format. If a physical copy, typically heavy-duty, matte-finish paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, Liquid-cooled, Single-cylinder Displacement: ~193 cc (exact capacity may vary slightly by specific sub-model or year) Bore X Stroke: Commonly around 62.5 mm x 65 mm, but requires manual verification for specific model. Compression Ratio: Typically around 12.5:1 to 13.5:1, dependent on exact engine tuning. Performance Horsepower: Estimated 30-35 HP (at crankshaft), power output can vary significantly with tuning and exhaust. Torque: Estimated 22-26 Nm (at crankshaft), torque characteristics are peaky for a 2-stroke. Fuel System Carburetor Type: Likely Dell'Orto PHBH 30 or similar size carburetor. Fuel Type: Unleaded gasoline (RON 95 or higher recommended), mixed with 2-stroke engine oil (typically 1:30 or 1:40 ratio). Reed Valve System: Standard for 2-stroke performance enhancement. Lubrication System: Pre-mix fuel or separate oil injection system (Autolube). 🔧 Transmission Standard Type: 6-speed manual transmission Optional Type: N/A (Standard 6-speed manual) Features Clutch Type: Wet multi-plate clutch Gear Ratios: Specific ratios...