Market Segment:
Lightweight Off-Road Motorcycle (Enduro/Cross Country)
Key Competitors:
KTM 200 EXC (later iterations), Husqvarna WR250, Yamaha YZ250, Honda CR250R (though displacement differs).
Brand Philosophy:
KTM's 'Ready to Race' ethos, emphasizing performance, lightweight design, and off-road capability.
Applicable Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Engine Variants:
Primarily covers the 200cc 2-stroke engine used in the 200 EGS.
Estimated Page Count:
300-450
Manual Type:
Service Repair Workshop Manual
Engine Systems:
Top-end rebuild (cylinder, piston, head), bottom-end rebuild (crankshaft, connecting rod, bearings), cooling system, lubrication system, fuel injection system (if applicable to specific variants), carburetor (if applicable), exhaust system, ignition system, starting system.
Transmission Systems:
Clutch operation and replacement, gearbox disassembly and reassembly, shift mechanism, final drive (chain and sprockets).
Chassis Systems:
Frame inspection and repair, suspension (forks and rear shock absorber), steering system, wheel bearings, brake system (front and rear), electrical system (wiring diagrams, components, lighting, charging system, battery), bodywork (fairings, seat, tank, fenders).
Maintenance Procedures:
Routine servicing, oil changes, filter replacements (oil, air), spark plug inspection and replacement, chain adjustment and lubrication, brake fluid checks and bleeding, coolant checks and flushing, tire pressure and condition checks.
Repair Procedures:
Engine component replacement, transmission overhaul, suspension fork seal replacement, carburetor tuning and rebuilding, brake caliper servicing, electrical component diagnosis and replacement.
Troubleshooting Guides:
Diagnostic procedures for common starting issues, performance problems, electrical faults, and mechanical noises.
Suspension Tuning:
Adjustment procedures for front and rear suspension (preload, compression, rebound damping) as applicable to the specific model's adjustability.
Electrical Diagnostics:
Wiring diagrams, troubleshooting flowcharts for ignition, lighting, and charging systems.
Technical Depth:
Comprehensive, covering routine maintenance to full engine and component rebuilds. Includes detailed torque specifications, clearances, diagnostic flowcharts, and exploded views.
Internal Components:
Detailed diagrams and procedures for crankshaft, connecting rod, bearings, seals, and gaskets.
Power Valve System:
Disassembly, cleaning, adjustment, and troubleshooting of the engine's exhaust power valve mechanism.
Engine Type:
2-stroke, single-cylinder
Bore X Stroke:
67.5 mm x 55 mm (typical for this era's 200cc KTM 2-strokes)
Cooling System:
Liquid-cooled
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Horsepower Estimate:
Approximately 35-40 hp (subject to specific tuning and year)
Torque Estimate:
Approximately 20-23 lb-ft (subject to specific tuning and year)
Fuel Delivery:
Carburetor (e.g., Keihin PWK 38mm or similar, specific model dependent)
Fuel Type:
Unleaded gasoline, minimum 90 octane (RON+MON)/2
Oil Mixing:
Premix (ratio typically 32:1 or 40:1 with high-quality 2-stroke oil), or oil injection system (depending on specific variant).
Reed Valve System:
Yes, typically VForce or similar performance reed block.
Transmission Type:
6-speed manual
Clutch Type:
Hydraulically operated, multi-plate wet clutch
Gear Ratios:
Specific ratios detailed within the manual, optimized for off-road use.
Transmission Oil Type:
SAE 10W/50 or SAE 80 gear oil (check manual for specific viscosity and API rating)
Transmission Oil Capacity:
Approximately 0.8 - 1.0 liters (refer to manual for exact quantity and level check procedure)
Wheelbase:
Approximately 1450 mm (57.1 inches)
Seat Height:
Approximately 940 mm (37.0 inches)
Dry Weight:
Approximately 105-110 kg (231-243 lbs)
Fuel Tank Capacity:
Approximately 7.5 - 9.5 liters (1.98 - 2.5 US gal)
Front Wheel Size:
21 inches (typical for Enduro)
Rear Wheel Size:
18 inches (typical for Enduro)
Front Tire Size:
80/100-21 (common)
Rear Tire Size:
110/100-18 (common)
Wheel Bolt Pattern:
N/A (spoked wheels with hub mounting)
Safety Ratings:
Motorcycles are not rated by standard automotive safety bodies like NHTSA or Euro NCAP.
Braking System:
Hydraulic disc brakes front and rear. Brembo components often used.
Suspension:
Upside-down front forks (e.g., WP Suspension), Monoshock rear suspension with adjustable preload and damping.
Lighting:
Headlight, taillight/brake light, turn signals (depending on street legality and specific market configuration).
Oil Change Interval:
Every 15-20 hours of riding or annually (for transmission oil).
Air Filter Cleaning:
Every 10-15 hours of riding, or more frequently in dusty conditions.
Spark Plug Inspection:
Every 20-30 hours of riding.
Top End Rebuild:
Typically recommended every 50-100 hours of aggressive use, or as indicated by performance decline/compression loss.
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors. Typically 50/50 mix with distilled water. Consult manual for specific KTM coolant or equivalent.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Issues:
KTM 2-strokes of this era are generally robust but can experience wear on clutch plates, occasional carburetor jetting issues, and suspension seal leaks if not maintained. Power valve operation can also require periodic cleaning/adjustment. Overheating can occur if cooling system is not properly maintained.
Engine Head Torque:
Specific torque sequence and values for cylinder head bolts will be in the manual (critical for 2-stroke engines).
Brand Origin:
KTM is an Austrian manufacturer founded in 1934, renowned for its off-road motorcycles.
200 Egs Positioning:
The 200 EGS was part of KTM's aggressive expansion in the late 90s and 2000s, offering a potent lightweight off-road machine.
Common Upgrades:
Owners often upgraded exhaust systems, reeds, and jetting (or EFI mapping for later models) for increased performance.
Manufacturing Location:
Austria
