KTM 200 EGS 1999 2000 Factory Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 78193

Mots clés: 1999 200 EGS 2000 KTM Misc Motorcycle Motorcycles

Variantes de produits

Description

The 200 EGS, produced for the 1999 and 2000 model years, is a lightweight Enduro/Cross Country motorcycle renowned for its agile handling and potent 2-stroke engine. Designed for enthusiasts, amateur racers, and trail riders, this Austrian-engineered machine delivers capable off-road performance, building on a strong heritage in off-road disciplines. Its key features include a robust engine, advanced suspension, and a lightweight chassis, making it a popular choice for those seeking an aggressive and responsive riding experience in demanding terrain. This Factory Service Repair Manual provides comprehensive guidance for the 200 EGS, covering all aspects of mechanical, electrical, and bodywork diagnostics and repair. The manual details engine disassembly and assembly, fuel and ignition system servicing, transmission and clutch maintenance, suspension and brake system overhauls, and electrical system troubleshooting. It includes step-by-step repair instructions, diagnostic procedures, and essential technical specifications, empowering owners and technicians to maintain and repair the vehicle effectively.

🏷️ Basic Information

Identification

Make:

Model:

200 EGS

Model Variant:

Enduro/Cross Country

Years Covered:

1999, 2000

Codes

Chassis Code Range:

e.g., EGS_1999, EGS_2000 (specific codes may vary)

Engine Code Range:

e.g., 200cc Single Cylinder (specific engine codes may vary)

👋 Introduction

Market Position

Segment:

Lightweight Enduro/Off-road Motorcycle

Target Audience:

Enthusiasts, amateur racers, trail riders seeking capable and agile off-road performance.

Competitive Analysis

Key Competitors:

Yamaha WR200, Kawasaki KDX200, Suzuki RM200 (period specific)

Key Features

Vehicle Attributes:

Lightweight, agile handling, potent 2-stroke engine, capable off-road suspension.

Manual Value Proposition

Benefit To Owner:

Empowers owners to perform comprehensive maintenance, diagnostics, and repairs, reducing reliance on professional service.

📋 Manual Details

Coverage Areas

Primary Focus:

Factory Service Repair

Scope:

Complete mechanical, electrical, and bodywork diagnostics and repair

Page Count

Estimated Pages:

Hundreds (as indicated in product description)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine disassembly, assembly, tuning, valve clearance, piston/ring replacement, cylinder head service, cooling system.

Fuel System:

Carburetor overhaul and adjustment, fuel pump, fuel lines, fuel tank servicing.

Ignition System:

Ignition timing, spark plug selection and gap, ignition coil testing, CDI unit diagnostics.

Transmission:

Gearbox disassembly and reassembly, clutch operation and adjustment, shift mechanism repair.

Suspension:

Front fork service (oil change, seal replacement, damping adjustments), rear shock absorber servicing and replacement, linkage maintenance.

Brakes:

Hydraulic brake system service (bleeding, pad replacement, caliper overhaul, master cylinder repair), disc and rotor specifications.

Electrical System:

Wiring diagrams, starter motor, lighting system, battery maintenance, charging system (alternator/stator testing), fuses and relays.

Frame And Body:

Frame inspection, body panel removal and installation, seat servicing, handlebar and control adjustments.

Wheels And Tires:

Wheel bearing maintenance, spoke tensioning, tire pressure recommendations, rim specifications.

Exhaust System:

Exhaust pipe and silencer inspection and replacement, gasket specifications.

Procedures Included

Maintenance:

Regular service intervals, oil changes, filter replacements, chain lubrication and adjustment, spark plug checks.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon problems, fault finding charts.

Repair:

Step-by-step instructions for component removal, replacement, and reassembly for all major systems.

Overhaul:

Complete engine, carburetor, and suspension component overhaul procedures.

Adjustments:

Carburetor jetting and idle speed, clutch lever free play, brake lever play, suspension sag.

Specifications Setting:

Torque values for critical fasteners, valve clearances, ignition timing, chain slack.

Technical Depth

Depth:

Comprehensive from basic rider maintenance to complete engine rebuilds and electrical system diagnostics.

Diagnostics:

Detailed electrical troubleshooting guides with wiring diagrams and component testing procedures.

Special Tools:

Lists and descriptions of specialized tools required for specific procedures (e.g., flywheel puller, clutch holding tool).

📊 Manual Specifications

File Format

Format:

Searchable:

Typically searchable text-based PDF (depends on source scan quality)

Print Quality

Quality:

High resolution, printable pages for individual sections or the entire manual.

Binding Type

Binding Type:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Type:

2-Stroke, Single Cylinder, Liquid-Cooled

Displacement:

193 cc (approximate, confirm with manual)

Bore X Stroke:

e.g., 66.0 mm x 57.8 mm (confirm with manual)

Compression Ratio:

e.g., 8.5:1 (confirm with manual)

Performance

Horsepower:

Approx. 30-35 HP (estimate, actual may vary by market and tune)

Torque:

Approx. 25-30 Nm (estimate, actual may vary)

Fuel System

Carburetor:

Mikuni VM Series (e.g., VM38SS or similar, confirm with manual)

Fuel Type:

Unleaded gasoline with appropriate 2-stroke oil pre-mix (specify ratio from manual)

Cooling System

Type:

Liquid Cooling

Lubrication

Type:

Pre-mix or Autolube system (confirm with manual)

🔧 Transmission

Standard

Type:

6-Speed Manual Transmission

Clutch:

Wet Multi-Plate Clutch

Features

Gear Ratios:

Specific ratios detailed in manual, crucial for performance tuning.

Fluid Type

Transmission Oil:

e.g., SAE 10W/40 or 15W/40 API SG (confirm exact specification and capacity in manual)

📐 Dimensions

Exterior

Wheelbase:

e.g., 1450 mm (confirm with manual)

Seat Height:

e.g., 930 mm (confirm with manual)

Weights

Dry Weight:

e.g., 105 kg (confirm with manual)

Fuel Tank Capacity:

e.g., 9.5 Liters (confirm with manual)

🛡️ Safety Features

Ratings

Safety Certification:

Off-road use typically not rated by NCAP; focused on inherent off-road durability and rider control.

Active Features

Braking System:

Disc brakes front and rear for effective stopping power in off-road conditions.

Passive Features

Frame Construction:

Strong, rigid frame designed for off-road abuse and rider confidence.

💡 Technology Features

Infotainment

Features:

Basic instrumentation: Speedometer, Odometer, Engine hour meter, Neutral indicator light. No advanced infotainment systems.

Driver Assistance

Features:

None (Focus on rider skill and mechanical feedback).

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change:

Every 10-15 hours of operation or as specified in manual (typically more frequent for off-road).

Air Filter Cleaning:

After every few rides or in dusty conditions, as detailed in manual.

Spark Plug Replacement:

e.g., Every 30-40 hours or as needed (confirm with manual).

Chain Maintenance:

Lubricate and adjust chain at frequent intervals, especially after riding in wet or dirty conditions.

Top End Rebuild:

Service interval depends heavily on usage, manual provides guidance on piston ring/piston inspection.

Fluid Specifications

Engine Oil:

Refer to manual for exact grade (e.g., Motorex, Castrol) and 2-stroke oil mix ratio. Common grades like SAE 10W/40, API SG.

Coolant:

Ethylene glycol-based coolant with corrosion inhibitors (confirm specific type and mixture ratio from manual).

Brake Fluid:

DOT 4 recommended (confirm from manual).

Fork Oil:

Specific viscosity and level required for front forks (e.g., SAE 7.5W, specific level from manual).

Known Issues

Common Wear Items:

Clutch plates, piston rings, fork seals, wheel bearings, chain and sprockets due to off-road stress.

Carburetor Tuning:

May require periodic adjustment based on altitude, temperature, and modifications. Manual provides base settings.

Cooling System Maintenance:

Importance of regular coolant checks and flushes to prevent overheating in demanding conditions.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Austria

Brand Focus:

Performance-oriented motorcycles, particularly in off-road disciplines (motocross, enduro, rally).

Model Evolution

Lineage:

Part of KTM's extensive range of off-road motorcycles, building on earlier 2-stroke enduro models.

Key Innovations:

KTM's reputation for robust engines, advanced suspension, and aggressive styling.

Production

Production Period:

Models produced in the late 1990s, representing a specific era of KTM's development.

🏆 Awards & Recognition

Recognitions

Motorsport Heritage:

KTM's strong reputation in off-road racing and extreme enduro events provides a pedigree for this model.

Ratings

Rider Reviews:

Generally praised for its agility, power-to-weight ratio, and KTM's signature off-road capability.

Certifications

Emission Standards:

Likely compliant with prevailing emission standards for its production years; manual may detail specific requirements if applicable.