KTM 200 EGS 1999 2000 Workshop Repair Service Manual

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This manual covers the 200 EGS, a versatile off-road motorcycle produced for the 1999 and 2000 model years. Known for its potent two-stroke engine and agile handling, the 200 EGS...

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Taper: Motorcycle

Distributeur:

UGS: 78449

Mots clés: 1999 200 EGS 2000 KTM Misc Motorcycle Motorcycles

Variantes de produits

Description

This manual covers the 200 EGS, a versatile off-road motorcycle produced for the 1999 and 2000 model years. Known for its potent two-stroke engine and agile handling, the 200 EGS is a capable machine for enduro riding, often compared favorably against competitors like the Yamaha WR200 and Kawasaki KDX200. The heritage in off-road racing is evident in the 200 EGS's design, offering a blend of performance and reliability for enthusiasts and riders seeking a classic off-road experience. This workshop repair service manual is an essential resource for maintaining the peak performance and longevity of this iconic model. This comprehensive English-language workshop repair service manual provides detailed guidance for the maintenance, troubleshooting, and repair of the 200 EGS. It covers all major systems, including the 193cc liquid-cooled two-stroke engine, fuel system, ignition, transmission, suspension, brakes, and electrical components. The manual offers step-by-step instructions for routine maintenance, component overhauls, and diagnostics, complete with technical specifications, torque values, and clearances. Its thorough coverage and clear explanations make it an indispensable tool for owners, mechanics, and technicians dedicated to preserving the optimal condition and functionality of their 1999-2000 200 EGS.

🏷️ Basic Information

Identification

Make:

Model:

200 EGS

Model Years Covered:

1999, 2000

👋 Introduction

Market Position

Segment:

Off-road, Enduro

Target Audience:

Enthusiasts and mechanics servicing the KTM 200 EGS.

Competitive Analysis

Competitors At Time:

Yamaha WR200, Kawasaki KDX200, Suzuki TS200R.

Key Features

Vehicle Reputation:

Known for its potent two-stroke power and agile handling in off-road conditions.

Manual Value:

Essential resource for maintaining peak performance and longevity of a classic off-road KTM.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

Completeness:

Comprehensive All Models/Engines/Trim/Transmissions

Page Count:

Estimated 300-400 pages (typical for a comprehensive workshop manual).

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, tuning, diagnostics, and repair for the 200cc two-stroke engine.

Fuel System:

Carburetor adjustment, cleaning, rebuilding, fuel pump and line service.

Ignition System:

Ignition timing, coil testing, spark plug specifications, CDI unit diagnostics.

Cooling System:

Radiator, hoses, thermostat, coolant specifications and maintenance.

Transmission:

Clutch operation, gearbox disassembly, assembly, gear inspection, and lubrication.

Suspension:

Front fork disassembly, seal replacement, oil levels, rear shock absorber service and adjustments.

Brakes:

Hydraulic brake system bleeding, pad replacement, caliper service, master cylinder inspection.

Electrical System:

Wiring diagrams, component testing, battery maintenance, lighting, stator and rectifier service.

Chassis And Frame:

Frame inspection, headstock bearing service, swingarm maintenance.

Exhaust System:

Muffler and pipe maintenance, gasket replacement.

Wheel And Tire:

Wheel bearing service, spoke tensioning, tire pressure recommendations, and wheel balancing.

Bodywork And Fairings:

Removal and installation procedures for plastic panels, seat, and fuel tank.

Procedures Included

Maintenance:

Routine checks, oil changes, filter replacements, chain adjustment, brake adjustments.

Troubleshooting:

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

Repair:

Step-by-step instructions for component overhaul and replacement.

Diagnostics:

Methods for identifying and resolving issues across all major vehicle systems.

Electrical Troubleshooting:

Detailed troubleshooting flowcharts for electrical faults.

Suspension Tuning:

Guidance on adjusting suspension settings for various terrain and riding styles.

Carburetor Rebuilding:

Step-by-step instructions for full carburetor overhaul and jetting changes.

Technical Depth

Depth:

Detailed, from basic maintenance to complete engine and component rebuilds.

Torque Specifications:

Precise torque values for all critical fasteners and engine components.

Clearances:

Specifications for valve clearances (if applicable to 2-stroke port timing), piston ring gap, and other critical tolerances.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for quick information retrieval.

Printability:

Printable for hard copy reference.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, single-cylinder

Displacement:

193 cc

Bore X Stroke:

64 mm x 60 mm

Cooling Method:

Liquid-cooled

Power Output:

Approx. 30-35 HP (Varies by tune and specific model variant)

Torque Output:

Approx. 25-28 Nm (Varies by tune and specific model variant)

Spark Plug Type:

NGK BR8ES (or equivalent, check manual for precise fitment)

Performance

Compression Ratio:

Approx. 7.5:1

Fuel Delivery:

Keihin PWK 35 carburetor

Fuel System

Fuel Type:

Unleaded gasoline with 2-stroke oil mix (ratio specified in manual)

Fuel Tank Capacity:

Approx. 9-11 Liters (Varies slightly by model year/submodel)

🔧 Transmission

Standard

Transmission Type:

6-speed manual

Clutch Type:

Wet, multi-plate

Features

Gear Ratios:

Specific gear ratios detailed within the manual for optimal performance tuning.

Transmission Fluid:

Specific ATF or manual transmission fluid type and capacity listed in manual.

📐 Dimensions

Exterior

Wheelbase:

Approx. 1450 mm (57.1 inches)

Seat Height:

Approx. 920 mm (36.2 inches)

Weights

Dry Weight:

Approx. 115-120 kg (253-265 lbs)

Wet Weight:

Approx. 125-130 kg (275-287 lbs) (with fluids)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Off-road motorcycle, not subjected to typical automotive crash testing standards).

Active Features

Braking System:

Hydraulic disc brakes front and rear for effective stopping power.

Passive Features

Frame Construction:

Chromoly steel frame for strength and rigidity.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Minimalist off-road design).

Driver Assistance

Driver Assistance Features:

N/A (Focus on rider input and control).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10-15 hours of use or annually, whichever comes first (refer to manual for exact specification).

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (typically every 5-10 hours).

Spark Plug Replacement:

Every 20-30 hours of use or as per manual recommendations.

Chain And Sprocket Maintenance:

Regular cleaning, lubrication, and tension adjustment (check after every ride).

Fluid Specifications

Engine Oil Type:

Fully synthetic 2-stroke premix oil, specific API/JASO rating detailed in manual.

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors, specific mixture ratio detailed in manual.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Transmission Fluid Type:

Specified ATF or dedicated manual transmission fluid (refer to manual for exact type and quantity).

Known Issues

Common Wear Items:

Piston rings, clutch plates, crank seals, suspension seals, and carburetor jets are common wear items for this era of two-stroke.

Carburetor Tuning:

Can be sensitive to altitude and temperature changes, requiring periodic adjustments.

Cooling System Maintenance:

Regular flushing and refilling of the cooling system is crucial to prevent overheating.

📚 Vehicle History

Brand Heritage

Brand Focus:

KTM has a long-standing reputation for producing high-performance off-road motorcycles, particularly in motocross and enduro racing.

Model Evolution

Egs Lineage:

The EGS line represents KTM's commitment to versatile enduro machines, bridging the gap between pure motocross and adventure touring.

Production

Manufacturing Location:

Austria (Primary)

🏆 Awards & Recognition

Recognitions

Brand Awards:

KTM regularly receives accolades in off-road racing disciplines, reflecting the performance and reliability of their models.

Ratings

Motorcycle Reviews:

Period reviews of the 200 EGS often highlighted its potent engine and capable chassis for competitive enduro riding.

Certifications

Manual Quality:

Professionally compiled technical documentation adhering to industry standards for repair manuals.