Looking for advice on 2-strokes...

[nowhere.elysium]

Hi all. I've been offered a basket case '91 KTM 300 with a slightly bent crankshaft as a project bike.

I've never had a 2-stroke before, never even ridden one. Does anyone have any advice on how I should approach this? I've had a couple of mates tell me to be a bit leery of it, but I've been looking for a cheap project bike for a while now, and my neighbour's offered me this one for £150. I've got no problem with putting large amounts of work into it, and I've got full access to a very comprehensive metal workshop and CNC mill, if needs be.
I'm told that it's in workable condition, just that the current owner can't be arsed, more than anything, because he's just built up a more modern KTM, and he doesn't want/need two of them.

Firstly, I can't find any parts manuals or even exploded diagrams for this year of bike other than the ones offered on cyclepedia (here), which doesn't even list a price for it, so I'm a bit unsure of buying from there.

Secondly - are there any significant pitfalls that I should look out for when rebuilding a bike of this age/type/make? I'm of the impression (and correct me if I'm wrong here) that KTMs of this age tend to eat components - specifically, expensive components.

I'm interested in doing this, because I want to be able to say to myself afterwards that yes, I do know what's happening when I start the bike/twist the throttle/change gear et cetera.
Also, the sense of pride when I finally get to ride it, knowing that I've made it out of funny-shaped bits of metal that were presented in greasy cardboard boxes will (I imagine) be immeasurable.

Thoughts, warnings, advice and general gibberings are sought.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[G]

I'd be tempted to try and knock the price down a bit more. A while ago I got a fully working 87 KTM 350 with spares for £350.
Do expect that it's probably going to end up costing a chunk more in the long run than getting a working one.

There's lots of good advice on www.ktmtalk.com but beware, think you get banned if you ask for manual downloads (someone did send me one for my 87, but this was a while before the harsher rules were introduced.)

[Mr.Ormes]

big job, lots of hasstle. personally i wouldent bother, however the choice is yours, might be difficult to sorce correct parts unless you order them from ktm main dealer, then this will cost you a fortune
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DT 125 1995
Thumpstar 120
Suzuki ZR 50

[nowhere.elysium]

Cool. Thanks for the heads-up on the ktmtalk bods. I've posted on there now, and I'm awaiting their musings...
I'm expecting it to be hard work: that's kind of the point, really. It's being sold to me as functional, so I'm thinking that all the parts should be included; if they're damaged, I'm hoping to be able to fabricate my own: as I say, I've got access to a CNC mill, a metal workshop and a laser cutter, so between all of those, I can do most things short of springs. Hopefully.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[1016]

brave approach, but I prolly don't have to tell you - see if you can source a crankshaft and how much before going any further, as no amount of conventional tools will straighten the existing one..

[Kickstart]

Hi

I would make sure that parts are sti available. You might have issues getting gaskets, rod kit, etc. OK, not show stoppers but does make life more difficult.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Vincent]

As above, tread carefully, check out how much the parts will cost before buying the bike. For a cheaper project look towards a more commen bike, and Japanese rather than European. I've always found Eurpean bikes more expensive for parts, sometimes it can work out ok if they're more reliable but sadly, not all European bikes are.
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Space Is Deep

[nowhere.elysium]

Yeah, I've been searching for parts without any real success. I figure I might pass up on this one...
Thanks for all the responses on this. I'm going to continue looking for a project bike for the time being, methinks.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project