🏷️ Basic Information

Make:

KTM

Model:

200

Year:

1999

Product Type:

Factory Service Repair Manual

👋 Introduction

Positioning:

The KTM 200 from 1999 was positioned as a versatile off-road/enduro or supermoto-style motorcycle, known for its lightweight design and spirited performance, appealing to riders seeking agility and a focused riding experience.

Competitors:

Competed against similar displacement models from Japanese manufacturers like Yamaha (DT200/WR200), Honda (CRF200 variants), and Suzuki (DR200/DRZ200), as well as other European brands offering lightweight dual-sport or off-road machines.

Features:

Likely featured a robust two-stroke engine, a capable suspension system suitable for varied terrain, and a minimalist, performance-oriented design characteristic of KTM's off-road heritage.

📋 Manual Details

Primary Coverage:

All aspects of repair, maintenance, diagnostics, and troubleshooting for the KTM 200 motorcycle.

Estimated Pages:

N/A (PDF Download)

Type:

Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Complete engine disassembly, assembly, inspection, and repair procedures. Includes top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rod, bearings), valve train, cooling system, lubrication system.

Fuel System:

Carburetor (Mikuni VM series or similar) tuning, cleaning, rebuilding, jetting, float bowl adjustment, fuel lines, fuel pump (if applicable).

Ignition System:

CDI unit, spark plug, ignition coil, timing checks, troubleshooting electrical faults related to ignition.

Transmission:

Gearbox disassembly, assembly, inspection of gears, shift drum, shift forks, bearings, clutch operation, clutch plate replacement, clutch cable adjustment.

Chassis Frame:

Frame inspection, welding repairs (if necessary), headstock bearing replacement, swingarm disassembly and maintenance.

Suspension Front:

Front fork disassembly, seal replacement, oil level and type specification, spring inspection, damping adjustments.

Suspension Rear:

Rear shock absorber removal, inspection, linkage maintenance, bearing checks, spring pre-load adjustment.

Braking System:

Front and rear brake caliper maintenance, piston service, pad replacement, brake fluid flush and bleed, master cylinder service, brake line inspection.

Electrical System:

Wiring diagrams, battery maintenance, lighting system, horn, starter motor (if applicable), charging system (stator, rectifier/regulator), fuse box.

Cooling System:

Radiator maintenance, coolant specifications, fan operation (if applicable), hose inspection and replacement.

Exhaust System:

Exhaust pipe and muffler removal, inspection, gasket replacement.

Bodywork Plastics:

Fairing removal and installation, seat, fuel tank, fenders, graphics.

Routine Maintenance:

Oil change intervals and specifications, filter replacement, chain adjustment and lubrication, air filter cleaning/replacement, spark plug replacement, coolant checks.

Troubleshooting:

Diagnostic flowcharts, common problems and their solutions, electrical system troubleshooting, engine performance issues.

Repair Procedures:

Step-by-step guides for all major component repairs and replacements.

Special Tools:

Identification and usage of specialized tools required for specific maintenance or repair tasks.

Torque Specifications:

Detailed torque values for all critical fasteners and components.

Cleaning And Lubrication:

Specific guidance on cleaning and lubrication points throughout the motorcycle.

Depth:

Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Covers complete engine rebuilds, suspension overhauls, and detailed electrical diagnostics.

📊 Manual Specifications

Format Details:

Searchable PDF document. May include high-resolution diagrams and schematics.

Quality:

Digital, high-resolution for clarity. Printable.

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, single-cylinder, two-stroke.

Displacement:

Approximately 194 cc (exact figure may vary by specific model variant).

Bore X Stroke:

Refer to manual for exact dimensions, typically around 66 mm x 57 mm for similar displacements.

Compression Ratio:

Refer to manual for exact specifications, likely in the range of 8.5:1 to 10.5:1.

Horsepower:

Estimated 25-35 HP (actual figures vary by specific tuning and market).

Torque:

Refer to manual for exact specifications. Torque delivery is typically strong in the mid-range for this type of engine.

Carburetor Type:

Likely a Mikuni VM series (e.g., VM34 or VM36) or a Keihin equivalent.

Fuel Type:

Unleaded gasoline with appropriate octane rating (refer to manual). Pre-mix or oil injection system likely.

Lubrication System:

Premix or automatic oil injection system (refer to manual for system type and oil specifications).

Cooling Method:

Liquid Cooling.

🔧 Transmission

Transmission Type:

6-speed constant mesh manual transmission.

Optional Gearbox:

N/A

Clutch Type:

Wet multi-plate clutch.

Gear Ratios:

Refer to manual for specific gear ratios.

Final Drive:

Chain drive.

Transmission Fluid:

Refer to manual for specific fluid type and capacity (typically a dedicated transmission oil or engine oil for wet clutch systems).

📐 Dimensions

Overall Length:

Refer to manual for exact dimensions.

Overall Width:

Refer to manual for exact dimensions.

Overall Height:

Refer to manual for exact dimensions.

Wheelbase:

Refer to manual for exact dimensions, typically around 1400-1450 mm.

Dry Weight:

Approximately 105-115 kg (may vary by specific configuration).

Curb Weight:

Refer to manual for exact specifications (includes fluids).

Fuel Capacity:

Approximately 8-10 liters (refer to manual).

🛡️ Safety Features

Safety Certification:

Motorcycles are typically certified to relevant roadworthiness standards in their respective markets, but specific crash test ratings are not generally applicable in the same way as cars.

Braking System:

Disc brakes front and rear for effective stopping power.

Lighting:

Headlight, taillight, brake lights, turn signals (market dependent).

Frame Construction:

Robust steel frame designed for torsional rigidity and impact resistance.

Ergonomics:

Designed for rider control and awareness in off-road or dynamic riding conditions.

💡 Technology Features

Infotainment System:

N/A (Motorcycle of this era typically did not feature infotainment systems).

Driver Assistance:

N/A (Motorcycles of this era typically did not feature electronic driver assistance systems beyond basic lighting and braking).

Connectivity:

N/A

🔧 Maintenance

Oil Change:

Refer to manual. Typically every 1,000-3,000 km or 6-12 months, depending on usage. For 2-stroke, refers to gearbox oil and premix/injection oil.

Air Filter:

Clean/inspect every few hundred kilometers, replace as needed, especially after dusty riding.

Spark Plug:

Inspect and gap at regular intervals (e.g., 1,000-2,000 km), replace if fouled or worn.

Chain Lubrication:

Lubricate and adjust chain tension regularly, typically every 500-1000 km or after washing/wet riding.

Engine Oil 2 Stroke:

High-quality 2-stroke motorcycle oil (premix or injection type as per manual).

Transmission Oil:

Refer to manual for specific viscosity and API rating (e.g., SAE 80 or SAE 10W-40 gear oil).

Coolant:

Ethylene glycol-based antifreeze mixed with distilled water (typically 50/50 ratio). Refer to manual for specific type and capacity.

Brake Fluid:

DOT 3 or DOT 4 brake fluid (refer to manual for exact specification).

Common Wear Items:

Piston rings, seals (fork, engine), wheel bearings, chain and sprockets, clutch plates, exhaust packing (if applicable).

Carburetor Tuning:

Can require periodic adjustment due to altitude, temperature changes, or wear. Improper jetting can lead to poor performance or engine damage.

Cooling System:

Potential for leaks at hoses or radiator fins, or overheating if coolant levels are low or flow is restricted.

Electrical Connections:

Corrosion or loose connections can cause intermittent electrical faults.

📚 Vehicle History

Heritage:

KTM AG is an Austrian motorcycle manufacturer renowned for its off-road racing success, particularly in motocross and enduro, and its 'Ready to Race' philosophy.

Evolution:

The KTM 200 likely evolved from KTM's established lineup of small-displacement two-stroke off-road motorcycles, adapting for various uses including enduro, cross-country, and potentially supermoto conversions.

Production Period:

The 1999 model year represents a specific iteration within the early to mid-production run of the KTM 200 series.

🏆 Awards & Recognition

Awards:

While specific awards for the 1999 KTM 200 might not be documented in general literature, KTM as a brand has a strong history of accolades in off-road racing and motorsport. The 200 model would have been recognized for its performance and handling within its class.