Positioning:
The KTM 200 EGS was positioned as a capable off-road and dual-sport motorcycle, emphasizing performance and agility in its class. It catered to riders seeking a lightweight and energetic machine for trail riding and occasional street use.
Competitors:
Competed with other European and Japanese manufacturers in the lightweight dual-sport and enduro segment, such as select models from Yamaha (e.g., WR200/250), Suzuki (e.g., DR200SE), and Honda (e.g., XR200/250).
Features:
Robust off-road chassis, liquid-cooled 2-stroke engine (typical for the 200 EGS variants), strong low-end torque, capable suspension for varied terrain, and KTM's reputation for performance and durability.
Value:
This comprehensive service manual is invaluable for owners and technicians aiming to maintain, diagnose, and repair their KTM 200 EGS. Its detailed instructions and specifications ensure proper servicing, maximizing performance and longevity.
Engine:
Complete overhaul, top-end and bottom-end rebuilds, cooling system, lubrication, ignition, carburetor/fuel injection (depending on specific sub-model variations within the 200 EGS line), exhaust system.
Transmission:
Gearbox removal and installation, clutch operation and adjustment, gear shift mechanism, gearbox lubrication.
Chassis:
Frame inspection and repair, suspension (forks, rear shock absorber), steering head bearings, swingarm, bearings and bushings.
Brakes:
Hydraulic brake systems (front and rear), caliper service, master cylinder overhaul, brake fluid replacement, bleeding procedures, disc and pad inspection.
Electrical:
Wiring diagrams, lighting systems (headlight, taillight, indicators), charging system (stator, regulator/rectifier), ignition system components, battery service, starter motor (if applicable), diagnostic procedures for electrical faults.
Fuel System:
Carburetor identification, cleaning, adjustment, and rebuilding (e.g., Mikuni VM series), fuel lines, fuel tank maintenance.
Cooling System:
Radiator service, coolant replacement, water pump inspection and repair, hose routing and replacement.
Bodywork And Trim:
Panel removal and installation, seat maintenance, fender and fairing repairs.
Maintenance:
Routine checks, oil changes, filter replacements, chain adjustment, spark plug service, brake system bleeding, coolant flushes, battery maintenance, tire pressure checks.
Troubleshooting:
Diagnostic charts for common performance issues, starting problems, electrical faults, and operational anomalies.
Repair:
Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly across all major vehicle systems.
Rebuilds:
Engine top-end and bottom-end rebuilds, carburetor rebuilding, fork seal replacement, shock absorber servicing.
Adjustments:
Carburetor jetting and idle adjustments, clutch and throttle cable adjustments, suspension sag and damping adjustments.
Specifications:
Torque specifications for critical fasteners, clearances, fluid levels, electrical resistance values, and timing parameters.
Suspension Setup:
Instructions for adjusting suspension sag, compression, and rebound damping to suit rider weight and riding conditions.
Wheel And Tire Service:
Procedures for tire removal/installation, wheel balancing, spoke tensioning, and bearing replacement.
Frame And Subframe:
Guidance on inspection for cracks or damage, and potential repair considerations for the frame and subframe.
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to full engine and component overhauls.
Engine Type:
2-Stroke, Liquid-Cooled (typical for 200 EGS variants)
Displacement:
193cc (approximate, specific variations may exist)
Bore X Stroke:
Refer to manual for specific dimensions
Power Output:
Approximately 30-35 HP (subject to specific tuning and regulations, refer to manual for exact figures)
Torque Output:
Refer to manual for specific figures
Compression Ratio:
Refer to manual for specific figures
Carburetor Type:
Likely Mikuni VM series (e.g., VM34) or similar, with specific jetting details in the manual.
Fuel Type:
Unleaded Gasoline (Octane rating specified in manual)
Fuel Mixture:
Premix (Oil-to-fuel ratio specified in manual, typically 50:1 or 40:1 for 2-stroke)
Ignition System:
CDI (Capacitor Discharge Ignition)
Spark Plug Type:
Refer to manual for specific part numbers and heat ranges (e.g., NGK BR9EG)
Cooling Type:
Liquid Cooling
2 Stroke Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil meeting specific API or JASO standards as per manual.
Overall Length:
Refer to manual for precise dimensions.
Overall Width:
Refer to manual for precise dimensions.
Wheelbase:
Refer to manual for precise dimensions.
Dry Weight:
Approximately 100-110 kg (subject to specific model year and equipment, consult manual).
Wet Weight:
Refer to manual for precise figures with fluids.
Fuel Tank Capacity:
Approximately 8-10 liters (consult manual for exact specification).
Coolant Capacity:
Refer to manual for precise capacity.
Oil Change Interval:
Refer to manual for specific intervals based on operating conditions (e.g., every 10-20 operating hours for off-road use).
Air Filter Cleaning:
Frequent checks and cleaning/replacement recommended, especially in dusty conditions, as detailed in the manual.
Spark Plug Replacement:
Recommended at specified intervals or when performance degradation is noted (refer to manual).
Chain Lubrication Adjustment:
Regular inspection, lubrication, and tension adjustment required, per manual's schedule.
Engine Oil:
2-Stroke premix oil meeting specified standards (refer to manual for exact grades).
Gearbox Oil:
Specific gear oil or transmission fluid as recommended by KTM (refer to manual for capacity and type).
Brake Fluid:
DOT 4 hydraulic brake fluid (standard for most KTMs).
Coolant:
Ethylene Glycol based coolant with corrosion inhibitors (refer to manual for specific mixture ratio and type).
Common Wear Items:
Piston rings, cylinder wear, clutch plates, wheel bearings, steering head bearings, suspension seals (common to high-performance off-road bikes).
Carburetor Issues:
Carburetor jetting sensitivity to altitude and temperature; requires periodic cleaning and adjustment for optimal performance.
Electrical Gremlins:
While generally robust, connections and grounds can be susceptible to dirt and moisture ingress in off-road use, requiring periodic inspection.
Brand Focus:
KTM, headquartered in Austria, has a strong heritage in off-road motorcycle racing and production, known for its 'Ready to Race' philosophy.
200 Egs Lineage:
The 200 EGS falls within KTM's range of lightweight, performance-oriented off-road motorcycles. It represents a lineage of agile and potent machines developed for competitive enduro and cross-country riding.
Manufacturing Location:
Austria (primary manufacturing for KTM models)
Production Period Context:
Produced during a period when 2-stroke engines were still prevalent in performance off-road motorcycles, before stricter emissions regulations led to wider adoption of 4-strokes in some categories.
