KTM 200 EGS 1999-2010 Factory Service Repair Manual

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Art.-Nr: 78388

Stichworte: 1999 200 EGS 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 KTM Misc Motorcycle Motorcycles

Produktvarianten

Beschreibung

The KTM 200 EGS, produced between 1999 and 2010, is a distinguished dual-sport and enduro motorcycle celebrated for its lightweight agility and potent low-to-mid range torque, making it exceptionally capable off-road. Built with renowned engineering quality and a strong racing pedigree, this model offers a pure riding experience focused on performance and rider control. Its robust steel trellis frame and advanced suspension systems contribute to excellent handling and terrain absorption, cementing its reputation as a reliable and engaging machine for adventurous riders. This comprehensive Factory Service Repair Manual provides essential technical information for the KTM 200 EGS, covering all variants produced from 1999 to 2010. The manual details a wide array of systems, including the engine, fuel, ignition, cooling, transmission, chassis, suspension, brakes, wheels, and electrical systems. It offers in-depth procedures for scheduled maintenance, engine rebuilds, suspension overhauls, brake system servicing, electrical diagnostics, and carburetor tuning, alongside troubleshooting guides and critical technical specifications. This resource is invaluable for owners and technicians seeking to maintain, repair, and optimize the performance and longevity of their KTM 200 EGS.

🏷️ Basic Information

Identification

Make:

Model:

200 EGS

Product Name:

KTM 200 EGS 1999-2010 Factory Service Repair Manual PDF Download

Codes

Model Code General:

200 EGS

👋 Introduction

Market Position

Segment:

Dual-sport/Enduro, popular for its off-road capability and relative simplicity.

Competitive Analysis

Competitors:

Yamaha WR250R, Honda CRF250X, Kawasaki KLX250S, Husqvarna TE250.

Key Features

Vehicle Strengths:

Lightweight, agile, strong low-to-mid range torque for off-road riding, reliable KTM engineering.

Manual Value Proposition:

Provides essential factory-level technical data for owners to maintain and repair their KTM 200 EGS, crucial for an off-road focused machine.

📋 Manual Details

Coverage Areas

Model Years Covered:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Engine Variants Covered:

All 200 EGS variants

Page Count

Estimated Page Count:

Approx. 500-800 pages (typical for a comprehensive factory manual)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, inspection, assembly, troubleshooting, torque specifications, valve adjustment, piston/cylinder, crankshaft, gearbox integration.

Fuel System:

Carburetor (likely Mikuni VM or similar) overhaul, jetting, fuel pump, fuel lines, tank maintenance.

Ignition System:

CDI, stator, ignition coil, spark plug specifications, timing, troubleshooting.

Cooling System:

Liquid cooling system, radiator, water pump, hoses, thermostat, coolant specifications, bleeding procedures.

Transmission:

Clutch operation, gearbox disassembly, inspection, assembly, gear ratios, lubrication, troubleshooting.

Chassis Frame:

Frame inspection, steering head bearing service, swingarm pivot, suspension mounting points.

Suspension Front:

Upside-down forks (likely WP), disassembly, seal replacement, oil type and level, damping adjustments, spring rates.

Suspension Rear:

Monoshock (likely WP PDS or similar), linkage system, shock absorber servicing, adjustment, spring preload, damping.

Brakes Front:

Hydraulic disc brake system, caliper overhaul, master cylinder service, brake pad replacement, fluid type (DOT 4), bleeding procedures, rotor specifications.

Brakes Rear:

Hydraulic disc brake system, caliper overhaul, master cylinder service, brake pad replacement, fluid type (DOT 4), bleeding procedures, rotor specifications.

Wheels Tires:

Wheel bearing service, spoke tensioning, tire fitment, recommended pressures, wheel specifications.

Electrical System:

Wiring diagrams, battery maintenance, lighting systems, starter motor, charging system, fuses, relays, troubleshooting common electrical faults.

Exhaust System:

Exhaust pipe removal/installation, muffler repacking (if applicable), gasket replacement.

Bodywork Plastic:

Fairing removal/installation, seat, tank cover, fender service, fastener torque values.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacement, chain adjustment/lubrication, spark plug replacement, air filter cleaning/replacement, valve clearance checks.

Troubleshooting:

Diagnostic flowcharts for common problems, symptom-based troubleshooting guides.

Engine Rebuild:

Complete engine teardown, rebuild procedures, part specifications, honing, piston ring installation.

Suspension Overhaul:

Fork seal replacement, shock absorber rebuild, bushings and bearings.

Brake System Service:

Bleeding, caliper and master cylinder repair, pad and rotor replacement.

Electrical Diagnostics:

Fault finding for lighting, charging, and ignition systems using wiring diagrams.

Carburetor Tuning:

Adjustment, cleaning, jetting recommendations for altitude and conditions.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and component overhauls, including detailed diagnostics and specifications.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text within the PDF for efficient information retrieval.

Print Quality

Print Readability:

High quality, allowing for clear printing of diagrams and text.

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Quality:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, liquid-cooled

Displacement:

Approx. 193-198cc (specific for 200 EGS)

Bore X Stroke:

Specifications will be detailed in the manual.

Compression Ratio:

Specifications will be detailed in the manual.

Performance

Horsepower Est:

Approx. 25-30 HP (varies by specific year/tune)

Torque Est:

Approx. 18-20 lb-ft (varies by specific year/tune)

Fuel System

Fuel Delivery:

Carburetor (likely Mikuni VM series, e.g., VM30 or VM34)

Recommended Fuel:

Unleaded gasoline, 91-95 octane (RON+MON)/2

Lubrication

Oil Type:

Refer to manual for specific KTM recommended oil (typically JASO MA certified 10W-50 or 10W-40 motorcycle oil).

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-plate clutch

Features

Gear Ratios:

Specific gear ratios are provided in the manual.

Final Drive:

Chain drive (likely 520 pitch)

Transmission Oil:

Refer to manual for specific KTM transmission oil specifications.

📐 Dimensions

Exterior

Overall Length:

Specifications vary by year, details in manual.

Overall Width:

Specifications vary by year, details in manual.

Overall Height:

Specifications vary by year, details in manual.

Weights

Dry Weight:

Approx. 230-240 lbs (104-109 kg) - specific details in manual.

Curb Weight:

N/A (Typically not quoted for off-road bikes, refer to manual for wet weight details).

Fuel Tank Capacity:

Approx. 2.5-3 gallons (9-12 liters) - specific details in manual.

Wheelbase:

Specifications vary by year, details in manual.

Seat Height:

Specifications vary by year, details in manual.

🛡️ Safety Features

Ratings

Safety Standards:

N/A (Motorcycle safety ratings are not standardized like automobiles; manual covers mechanical safety aspects).

Active Features

Braking System:

Dual hydraulic disc brakes for enhanced stopping power and control.

Suspension Performance:

WP suspension designed for optimal handling and absorption of off-road terrain.

Passive Features

Frame Design:

Steel trellis frame for rigidity and rider feedback.

Ergonomics:

Designed for rider control and comfort during demanding off-road use.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Minimalistic design focused on off-road functionality; no complex infotainment systems).

Driver Assistance

Assistance Features:

N/A (No electronic rider aids like ABS or traction control on this model).

Connectivity

Connectivity Options:

Instrumentation

Dashboard:

Analog speedometer and tachometer, basic indicator lights (neutral, turn signals, oil pressure). Digital elements minimal or absent.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual; typically every 2,000-3,000 km or 6 months for regular use.

Air Filter Cleaning:

Refer to manual; frequency dependent on riding conditions (e.g., every 500-1000 km or more frequently in dusty conditions).

Chain Maintenance:

Refer to manual; lubrication and adjustment as needed, typically every 500-1000 km.

Valve Clearance Check:

Refer to manual; typically every 4,000-6,000 km.

Fluid Specifications

Engine Oil Viscosity:

10W-50 or 10W-40 (JASO MA certified motorcycle oil recommended).

Brake Fluid:

DOT 4 recommended for hydraulic brake systems.

Coolant:

Ethylene glycol-based antifreeze with corrosion inhibitors, typically a 50/50 mix with distilled water.

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, wheel bearings, fork seals, brake pads due to off-road use.

Carburetor Performance:

May require periodic cleaning and jetting adjustments for optimal performance across different conditions.

Suspension Maintenance:

Regular servicing of forks and shock is critical for consistent performance and longevity.

📚 Vehicle History

Brand Heritage

Heritage:

KTM AG is an Austrian manufacturer renowned for its off-road motorcycles, known for performance and racing pedigree.

Model Evolution

Evolution Context:

The 200 EGS represents KTM's strategy of offering accessible, lightweight, and capable dual-sport machines with strong off-road bias, building on their enduro heritage.

Production

Manufacturing Origin:

Austria (primary)

Production Run:

The 200 EGS was produced for a significant period, encompassing the years 1999 through 2010, indicating a popular and well-received model.

🏆 Awards & Recognition

Recognitions

Motorcycle Reviews:

While specific awards for the 200 EGS might be scarce, KTM models from this era generally received praise for their off-road prowess and build quality.

Ratings

Reliability Perception:

Generally perceived as reliable when properly maintained, consistent with KTM's reputation for robust off-road machinery.