KTM 200 EGS 1999 2000 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: KTM 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...

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类型: Motorcycle

斯库: 78193

标签: 1999 200 EGS 2000 KTM Misc Motorcycle Motorcycles

产品多属性

Description

🏷️ 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.