🏷️ Basic Information

Make:

KTM

Model:

200 EGS, 200 EXC, 200 XC, 200 XC-W

Years Covered:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

👋 Introduction

Segment:

Performance Off-Road Motorcycles (Enduro/Cross Country)

Target Audience:

Enthusiast riders, competitive racers, and dedicated mechanics seeking in-depth knowledge for maintenance and repair of KTM 200 series off-road bikes.

Competitors:

Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (though 2-stroke focus is key).

Ktm Legacy:

KTM's reputation for robust, race-bred off-road motorcycles known for their power-to-weight ratio and advanced suspension.

📋 Manual Details

Manual Type:

Workshop Service Manual

Manual Language:

English (Assumed, standard for KTM workshop manuals)

Format:

PDF Download

Page Count:

217

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, including top-end (piston, rings, cylinder, cylinder head), bottom-end (crankshaft, connecting rod, bearings), valve timing, and lubrication system.

Fuel System:

Carburetor (likely Keihin PWK) disassembly, cleaning, adjustment, jetting, fuel pump operation (if applicable), fuel tank, and fuel lines.

Ignition System:

CDI ignition, stator, rotor, spark plug, ignition timing, troubleshooting ignition faults.

Cooling System:

Radiator, cooling fan (electric), coolant hoses, coolant specifications, thermostat operation, bleeding the system.

Transmission Drivetrain:

Clutch operation, gear shifting mechanism, gearbox disassembly and assembly, transmission oil specifications and change intervals, chain and sprockets maintenance.

Suspension Front:

Upside-down fork service (WP Suspension), oil levels, seal replacement, spring preload adjustment, damping adjustments, fork leg disassembly.

Suspension Rear:

Monoshock absorber service (WP Suspension), linkage system maintenance, shock absorber disassembly, nitrogen recharging (if applicable), spring replacement.

Brakes Front:

Brake caliper service, piston seals, brake pad replacement, brake fluid specifications (DOT 4), bleeding procedure, master cylinder overhaul, brake disc inspection and replacement.

Brakes Rear:

Brake caliper service, piston seals, brake pad replacement, brake fluid specifications (DOT 4), bleeding procedure, master cylinder overhaul, brake disc inspection and replacement.

Electrical System:

Wiring diagrams, battery maintenance, headlight, taillight, turn signals, horn, starter motor, troubleshooting electrical faults.

Wheels Tires:

Wheel bearing maintenance, spoke tension adjustment, tire pressure recommendations, wheel removal and installation, rim specifications.

Frame Chassis:

Frame inspection, steering head bearing maintenance, swingarm bearing service, footpeg mounting, general chassis components.

Scheduled Maintenance:

Detailed service intervals for oil changes, filter replacements, spark plug checks, valve adjustments, chain lubrication, and general inspection.

Engine Repair:

Step-by-step instructions for engine disassembly, component inspection, repair, and reassembly, including torque specifications.

Carburetor Tuning:

Guidance on adjusting idle speed, fuel mixture, and throttle response, along with jetting recommendations for different altitudes and conditions.

Suspension Setup:

Instructions for adjusting suspension settings to suit rider weight and riding style, including sag measurements and damping adjustments.

Brake Bleeding:

Clear procedures for removing air from the brake hydraulic system.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for common issues across all major systems.

Depth:

Comprehensive coverage suitable for professional technicians and advanced DIY mechanics, including complete engine rebuilds and in-depth electrical diagnostics.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, clear text and diagrams suitable for printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

2-Stroke Single Cylinder

Displacement:

193 cc (approximately)

Bore X Stroke:

Typically around 62.5 mm x 65 mm (specific to model, requires confirmation in manual)

Cooling System:

Liquid-cooled

Carburetor Model:

Likely Keihin PWK 36 or similar (specific to year/model, confirmation needed)

Horsepower:

Estimated 35-40 HP (varies by specific model and tune)

Torque:

Estimated 25-30 Nm (varies by specific model and tune)

Fuel Type:

Unleaded Gasoline (with appropriate 2-stroke oil pre-mix or oil injection system)

Oil Type:

High-quality 2-stroke synthetic oil (specific recommendations in manual, e.g., Motorex)

🔧 Transmission

Type:

6-Speed Manual Transmission

Transmission Features:

Close-ratio gearbox for optimal performance in off-road conditions.

Clutch Type:

Hydraulically operated, multi-plate wet clutch

Transmission Oil Spec:

SAE 10W/40 or 10W/50 motorcycle gear oil (specific viscosity and API rating from manual)

📐 Dimensions

Wheelbase:

Approx. 1450-1480 mm (varies by model, check manual for exact spec)

Dry Weight:

Approx. 95-105 kg (varies by model, check manual for exact spec)

Fuel Capacity:

Approx. 7-9 liters (varies by model, check manual for exact spec)

🛡️ Safety Features

Safety Standard:

N/A (Off-road competition motorcycles generally not subject to road safety regulations).

Braking System:

Hydraulic disc brakes front and rear, designed for off-road performance and modulation.

Frame Design:

Strong, lightweight chromoly steel perimeter frame for rigidity and impact resistance.

💡 Technology Features

Infotainment Features:

N/A (Purely performance-oriented off-road motorcycles, no infotainment systems).

Assistance Features:

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

Connectivity Features:

N/A

🔧 Maintenance

Engine Oil Change:

Recommended every 10-15 engine hours or annually, whichever comes first (refer to manual for precise interval).

Air Filter Cleaning:

Clean after every few rides, especially in dusty conditions. Replace as needed.

Spark Plug Check:

Inspect every 20-30 engine hours. Replace as needed based on condition.

Valve Adjustment:

Not applicable for 2-stroke engines (no valves to adjust).

Chain Maintenance:

Clean and lubricate every 2-3 rides. Adjust tension as needed.

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors. Mixture of 50% coolant and 50% distilled water recommended. (Refer to manual for specific KTM-approved coolant).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Common Wear Items:

Clutch plates, piston rings, spark plugs, fork seals, wheel bearings, swingarm bearings, and steering head bearings are common wear items on high-performance off-road bikes.

Carburetor Maintenance:

Periodic cleaning and jetting adjustments are crucial for optimal performance, especially with changes in altitude or temperature.

📚 Vehicle History

Ktm Heritage:

KTM, an Austrian manufacturer, has a rich history in off-road racing and is renowned for its 'Ready to Race' philosophy, consistently producing high-performance dirt bikes.

200 Series Evolution:

The 200cc two-stroke models were popular for their blend of manageable power and lightweight agility, bridging the gap between 125cc and larger displacement off-road bikes. They saw continuous refinement through this period.

Manufacturing Location:

Austria (Primary)

🏆 Awards & Recognition

Off Road Performance:

KTM models from this era consistently received accolades in off-road magazines and racing circles for their performance, handling, and durability.