KTM 200 MXC EGS 1999-2010 Workshop Service Manual for Repair

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Taper: Motorcycle

Distributeur:

UGS: 72521

Mots clés: 1999 200 MXC 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 EGS KTM Misc Motorcycle Motorcycles

Variantes de produits

Description

The 200 MXC EGS represents a potent and performance-oriented off-road motorcycle, designed for the rigors of motocross and demanding terrain. Produced between 1999 and 2010, this model exemplifies renowned engineering for off-road competition, featuring a robust chromoly steel trellis frame and typically equipped with high-quality WP Suspension components. Its liquid-cooled, single-cylinder 2-stroke engine, displacing approximately 193cc, delivers a significant power-to-weight ratio, characteristic of a focus on aggressive performance. Known for its agility and capability, the 200 MXC EGS is built for riders who demand precision and power in challenging off-road environments, building upon an extensive legacy in motorsports. This comprehensive Workshop Service Manual, written in English, provides detailed guidance for the maintenance and repair of the 200 MXC EGS models from 1999 through 2010. Spanning 280 pages, it covers all essential aspects of the motorcycle, including in-depth engine and transmission overhauls, fuel and ignition system servicing, suspension and brake system repairs, and electrical diagnostics. The manual includes routine maintenance schedules, troubleshooting guides for common issues, and detailed technical specifications such as torque values and fluid capacities. It is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their 200 MXC EGS.

🏷️ Basic Information

Identification

Make:

Model:

200 MXC EGS

Codes

Chassis Codes:

Specific chassis codes may vary by exact sub-model and year, but typically relate to the 200cc off-road series.

Engine Codes:

KTM utilizes engine codes that denote displacement and series. The 200cc off-road models will have a specific designation within the LC4 or similar off-road engine family.

👋 Introduction

Market Position

Segment:

Performance off-road/motocross motorcycle.

Competitive Analysis

Key Competitors:

Competitors would have included models from Yamaha (YZ250, WR250), Honda (CR250, XR250), Suzuki (RM250, DR-Z250), and Husqvarna during this era.

Key Features

Off Road Capability:

Designed for closed-course motocross and off-road competition, emphasizing performance and durability.

Engine Type:

Known for potent 2-stroke performance, offering a high power-to-weight ratio.

Suspension Brand:

Typically features high-quality WP Suspension components, a hallmark of KTM's performance focus.

Frame Design:

Chromoly steel trellis frame for strength and rigidity.

📋 Manual Details

Coverage Areas

Supported Years:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, diagnostics, tuning, and repair for the 200cc 2-stroke engine.

Transmission:

Gearbox operation, maintenance, repair, clutch service, and shift mechanism.

Fuel System:

Carburetor identification, adjustment, cleaning, rebuilding, fuel tank, fuel lines, and fuel pump (if applicable).

Ignition System:

CDI unit, ignition coil, spark plug, timing, and troubleshooting.

Cooling System:

Radiator, coolant, hoses, thermostat (if applicable), and fan operation.

Exhaust System:

Exhaust pipe, silencer, baffle, and gasket replacement.

Suspension:

Front fork (WP Suspension typically), rear shock absorber, seals, bushings, oil levels, and adjustment procedures.

Brakes:

Hydraulic brake systems (front and rear), caliper service, master cylinder, brake pads, rotors, brake fluid specifications, and bleeding procedures.

Wheels And Tires:

Wheel bearing replacement, rim maintenance, spoke tension, tire fitting, and pressure recommendations.

Electrical System:

Wiring diagrams, battery maintenance, lighting, horn, starter motor (if electric start), kill switch, and general electrical troubleshooting.

Frame And Bodywork:

Frame inspection, plastic component removal/installation, seat, handlebars, and controls.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, air filter cleaning, spark plug checks, and general inspection routines.

Troubleshooting Guides:

Diagnostic flowcharts for common starting, running, and electrical issues.

Engine Rebuild:

Piston, rings, cylinder, crankshaft, bearings, seals, and gasket replacement.

Suspension Rebuild:

Fork seal replacement, damper rod service, shock absorber seal head replacement, and spring replacement.

Electrical Diagnostics:

Testing of CDI, stator, ignition coil, and troubleshooting of lighting and charging circuits.

Brake System Service:

Pad replacement, rotor inspection, caliper piston service, and brake fluid flush/bleed.

Technical Depth

Diagnostic Level:

Comprehensive diagnostic procedures, including symptom-based troubleshooting and component testing.

Repair Complexity:

Covers everything from basic adjustments to complete engine and component overhauls.

Specifications Detail:

Includes detailed torque specifications, clearances, fluid capacities, and electrical resistance values.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF, allowing for quick keyword finding.

Print Quality

Print Capability:

Printable for physical reference.

Binding Type

Binding:

Not applicable (Digital download).

Paper Type

Paper Quality:

Not applicable (Digital download).

⚙️ Engine Specifications

Primary Engine

Configuration:

Single-cylinder, 2-stroke

Displacement:

Approximately 193cc (exact may vary slightly by specific sub-model or year).

Bore X Stroke:

Specifics would be detailed in the manual, typically around 62.5 mm x 65 mm.

Cooling Method:

Liquid-cooled

Lubrication:

Pre-mix or Autolube (depending on specific variant within the production run).

Performance

Horsepower:

Estimated around 35-40 HP, with variations based on tuning and year.

Torque:

Torque figures would be detailed in the manual, crucial for off-road grunt.

Fuel System

Carburetor Type:

Typically a Keihin PWK series carburetor (e.g., PWK 38).

Fuel Type:

Unleaded gasoline with appropriate octane rating (91-98 RON/87-93 AKI).

Fuel Mixture:

If pre-mix, the recommended oil-to-fuel ratio (e.g., 30:1 or 40:1) will be specified.

🔧 Transmission

Standard

Type:

6-speed constant mesh

Features

Clutch Type:

Hydraulically actuated wet multi-disc clutch.

Gear Ratios:

Detailed gear ratios for each of the 6 speeds would be present in the manual for performance tuning and diagnostics.

📐 Dimensions

Exterior

Wheelbase:

Specific wheelbase would be provided in the manual, typically in the range of 1450-1480 mm.

Weights

Dry Weight:

Generally around 100-110 kg, emphasizing light weight for maneuverability.

🛡️ Safety Features

Active Features

Braking System:

High-performance hydraulic disc brakes (front and rear) with braided steel lines for consistent feel.

Passive Features

Frame Construction:

Robust chromoly steel frame designed to withstand off-road stresses.

Suspension Design:

Long-travel, high-quality suspension to absorb impacts and maintain control.

💡 Technology Features

Infotainment

Features:

Not applicable; this is a dedicated off-road competition machine with minimal electronics.

Driver Assistance

Features:

Not applicable; rider input and skill are primary.

🔧 Maintenance

Service Intervals

Oil Change Engine:

Frequent oil changes recommended for 2-stroke engines, typically every 15-20 hours of riding or as specified in the manual.

Air Filter Cleaning:

Recommended after every few rides or in dusty conditions.

Spark Plug Check:

Regular inspection and cleaning/replacement as needed, typically every 20-40 hours.

Chain Maintenance:

Lubrication and tension adjustment recommended every 5-10 hours of riding.

Fluid Specifications

Transmission Oil:

Specific gear oil (e.g., SAE 75W/80W or similar) and capacity will be detailed in the manual.

Brake Fluid:

DOT 3 or DOT 4 brake fluid (refer to manual for specific type).

Coolant:

Ethylene glycol-based coolant mixture, typically 50/50 with distilled water.

Known Issues

Carburetor Tuning:

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

Power Valve Cleaning:

Carbon buildup can affect power valve operation; requires periodic cleaning.

Suspension Seals:

Like all off-road bikes, fork and shock seals can wear and require replacement to prevent fluid leaks.

2 Stroke Top End Wear:

Piston and ring wear are expected components of 2-stroke engine maintenance and will need periodic replacement based on usage.

📚 Vehicle History

Brand Heritage

Ktm Offroad Legacy:

KTM has a long and successful history in off-road motorsports, including motocross and enduro, dating back decades.

Model Evolution

2 Stroke Era:

The 200 MXC EGS falls within a period where KTM refined its 2-stroke off-road platform, known for its performance and competitive edge.

Production

Manufacturing Origin:

Primarily manufactured in Austria.

🏆 Awards & Recognition

Recognitions

Motorsport Success:

KTM's 2-stroke motocross and enduro models have a strong history of success in professional racing, indicating the platform's inherent capability and performance.