Market Segment:
KTM's 200 EGS was positioned as a capable off-road and enduro motorcycle, known for its performance-oriented nature and KTM's off-road heritage.
Target Audience:
Enthusiasts and owners seeking to maintain and repair their KTM 200 EGS, ranging from amateur riders to experienced mechanics.
Competitors:
Competed with other European and Japanese manufacturers in the mid-size enduro segment, such as Yamaha WR200, Honda CR250 (though often higher displacement), and various European brands.
Vehicle Key Features:
Lightweight design, potent two-stroke engine, capable suspension, agile handling, focus on off-road performance.
Manual Benefit:
Provides essential technical knowledge for owners to perform maintenance, diagnostics, and repairs, saving time and money compared to relying solely on professional services.
Digital Format Advantage:
PDF format offers portability, searchability, and easy access on multiple devices, superior to outdated paper manuals.
Engine Systems:
Engine overhaul, cylinder head, cylinder, piston, crankshaft, connecting rod, crankcase, lubrication, cooling system, fuel system (carburetor), ignition system, exhaust system, starting system.
Chassis Systems:
Frame, suspension (front fork, rear shock absorber), steering, wheels, tires, brakes (front and rear), clutch, gearbox, drive chain.
Electrical Systems:
Wiring diagrams, lighting system, ignition system, battery, charging system, switches, instruments.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake pad replacement.
Repair Procedures:
Engine disassembly and reassembly, carburetor tuning and rebuilding, suspension component servicing, brake caliper servicing, clutch adjustment and replacement, gearbox inspection and repair.
Troubleshooting Guides:
Diagnostic procedures for common engine and electrical issues, fault finding charts.
Technical Depth:
Comprehensive: Covers routine maintenance to complete engine and chassis rebuilds, including detailed specifications and torque values.
File Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable PDF for easy navigation, assuming it's a professionally produced digital manual.
Printability:
Printable, allowing users to create hard copies for workshop use.
Print Quality:
Dependent on original source. High-resolution scans or digital creation will ensure clarity of diagrams and text.
Binding Type:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF)
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
Displacement:
193 cc (approximate, subject to slight variations based on specific EGS variant)
Bore X Stroke:
Typically around 62.5 mm x 65 mm (exact figures would be in the manual).
Compression Ratio:
Likely in the range of 8.5:1 to 9.5:1 (check manual for precise value).
Horsepower:
Estimated 30-35 HP at peak RPM (exact figures in manual).
Torque:
Estimated 25-30 Nm at peak RPM (exact figures in manual).
Carburetor:
Keihin PWK 35 or similar performance-oriented carburetor.
Fuel Type:
Unleaded gasoline with appropriate octane rating and 2-stroke oil mixture (premix or separate oil injection system, likely premix for this model).
Ignition Type:
CDI (Capacitor Discharge Ignition), electronic advance.
Cooling Method:
Liquid-cooled
Lubrication Type:
Pre-mix lubrication of fuel and oil, or Autolube system (manual will clarify).
Transmission Type:
6-speed constant mesh sequential gearbox.
Clutch Type:
Wet multi-plate clutch, hydraulically actuated.
Final Drive:
Chain drive (e.g., 520 pitch chain).
Gear Ratios:
Specific gear ratios will be detailed in the manual, critical for understanding engine RPM at different speeds.
Wheelbase:
Approximately 1440-1460 mm (check manual for precise figure).
Seat Height:
Approximately 900-930 mm (check manual for precise figure).
Dry Weight:
Approximately 105-115 kg (dry, without fluids).
Fuel Tank Capacity:
Typically around 9-11 liters (check manual for precise figure).
Front Wheel Size:
21 inches
Rear Wheel Size:
18 inches
Front Tire Specification:
e.g., 80/100-21 (check manual for precise fitment).
Rear Tire Specification:
e.g., 100/100-18 (check manual for precise fitment).
Safety Ratings:
Motorcycles of this era did not typically undergo standardized crash safety ratings like cars. Safety is inherent in design and rider skill.
Braking System:
Hydraulic disc brakes front and rear. Specific caliper and rotor sizes and piston counts detailed in manual.
Suspension Performance:
Long-travel, adjustable suspension (e.g., WP Suspension components) designed for off-road terrain compliance and rider control.
Frame Construction:
Chromoly steel frame, providing rigidity and impact absorption.
Infotainment System:
Basic motorcycle instrumentation: speedometer, odometer, possibly engine hour meter. No advanced infotainment features.
Driver Assistance Features:
None. This is a performance-oriented off-road machine with no electronic rider aids beyond basic ignition and lighting systems.
Connectivity Features:
None.
Lighting System:
Standard halogen headlight and taillight/brake light assembly.
Oil Change Interval:
Typically every 10-15 hours of riding for off-road use, or as specified by KTM's maintenance schedule (detailed in manual).
Air Filter Cleaning:
Frequent checks and cleaning/replacement depending on riding conditions (e.g., every 5-10 hours).
Spark Plug Replacement:
Refer to manual for specific mileage or hours, typically 20-30 hours for aggressive use.
Chain And Sprockets:
Regular cleaning, lubrication, and adjustment (check tension every few rides), replacement based on wear.
Engine Oil Type:
Specific 2-stroke oil meeting JASO FD or higher standard, for premix. Manual will specify brand and type.
Coolant Type:
Ethylene glycol based coolant mixed with distilled water (typically 50/50). Manual will specify type and capacity.
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Manual will specify exact type and bleeding procedure.
Transmission Oil Type:
Specific gear oil for motorcycle transmissions (e.g., SAE 75W/90 or SAE 10W/40 depending on KTM's recommendation). Manual will specify.
Two Stroke Maintenance:
Two-stroke engines require diligent maintenance, including correct fuel/oil mixture, regular air filter cleaning, and decarbonization of the exhaust port and piston crown to maintain optimal performance.
Carburetor Tuning:
Carburetors can require periodic adjustment based on altitude, temperature, and fuel quality. Proper jetting is crucial for performance and engine longevity.
Suspension Seals:
Worn fork seals or rear shock seals are common maintenance items, especially with hard off-road use. Regular inspection is advised.
Power Valve Operation:
The power valve mechanism can accumulate carbon deposits, affecting engine performance. The manual will detail its cleaning and adjustment.
Brand Focus:
KTM has a long-standing heritage in off-road and racing motorcycles, consistently focusing on performance, durability, and rider engagement.
Egs Series:
The EGS line represented KTM's commitment to enduro and cross-country competition, often serving as a platform for performance enhancements and racing development.
Production Period:
The 200 EGS was produced for several years in the late 1990s and early 2000s, with 1999-2000 being specifically covered by this manual.
Brand Awards:
KTM motorcycles, in general, have a strong track record of wins and recognitions in various off-road racing disciplines (e.g., Dakar Rally, Enduro World Championship). Specific awards for the 200 EGS model may be limited to reviews and enthusiast accolades rather than formal industry awards.
Magazine Reviews:
Contemporary motorcycle press reviews from the late 90s and early 2000s would have rated its performance, handling, and off-road capability, which are best sought from archived sources.
