Manco Interceptor Refurb.

[dustin.s]

Manco Interceptor, model 104D-07

My son’s first kart. The goal is strip it down, eliminate reduction chain drive, replace with CVT converter mated to predator 212cc, replace bearings, brakes, and tires. The seat bottom is rotted out but the seat back and all the vinyl is in decent shape for its age. Sand and paint rusted areas on kart and wheels. Then, SEND IT!

 

[G.W]

It is just begging for big @$$ tires

 

[dustin.s]

It is just begging for big @$$ tires

It is! The axle/frame setup doesn’t allow for much without having some serious front bias lean. Also, the stock axle is only ~28”, not allowing for much in the width department. We’ll see how much my son enjoys the hobby. If it’s in his blood I’ll swap to a 3/4” x 35 1/2” axle to allow wheel and tire upgrades.

 

[G.W]

I'd beef it up to a 1 inch axle. Boy is that 212 crammed into that frame, that thing is going to be fast

 

[dustin.s]

I'd beef it up to a 1 inch axle. Boy is that 212 crammed into that frame, that thing is going to be fast

If I ever decide a 1” axle is necessary, I’ll put it on a 1 1/2” tube frame. No real gain upgrading to 1” except in the amount of wheel/tire combinations. The frame, I haven’t measured, but would guess is probably 3/4” tube. For now the 5/8” axle, albeit an odd size, will suffice. I know I can upgrade to a 3/4” axle with little effort with the availability of bearings that are the same nominal OD (1 3/8”).

As for the engine, it fits well, but has a larger displacement(212cc) than the kart originally(126cc) intended. The only hiccup I can see is the alignment of the driven gear on the CVT and the axle gear. Looking forward to using a few choice words in the future.

 

[BaconBitRacing]

If I ever decide a 1” axle is necessary, I’ll put it on a 1 1/2” tube frame. No real gain upgrading to 1” except in the amount of wheel/tire combinations. The frame, I haven’t measured, but would guess is probably 3/4” tube. For now the 5/8” axle, albeit an odd size, will suffice. I know I can upgrade to a 3/4” axle with little effort with the availability of bearings that are the same nominal OD (1 3/8”).

As for the engine, it fits well, but has a larger displacement(212cc) than the kart originally(126cc) intended. The only hiccup I can see is the alignment of the driven gear on the CVT and the axle gear. Looking forward to using a few choice words in the future.

I feel for you on gear alignment. I'm locked out of a TC with the whole setup on my kart, without some cutting welding and an adjustable engine plate.

 

[G.W]

The only way I can cut the jackshaft from my build is welding in a whole new engine plate. No big deal since I'm upgrading to a 459cc max predator engine.

 

[dustin.s]

The only way I can cut the jackshaft from my build is welding in a whole new engine plate. No big deal since I'm upgrading to a 459cc max predator engine.

Just curious, do you have a picture of the output side?

 

[G.W]

Just curious, do you have a picture of the output side?

Not right now, I can get a few when I get home from work. It is currently just mocked up, so there is no cvt and it is not welded or bolted in.

 

[dustin.s]

I little work on the kart tonight. I mounted the CVT and scrapped some the loose paint. Cleaned up the vinyl on the seat and side pads. The good news is that the mock up with the CVT appears as though the driven gear and axle gear align perfectly with no modifications. I measured the frame tubing and to my surprise is 1”. More stout than originally thought.

 

[G.W]

Rustoleum rust reformer paint works great, and you can paint over the top of it.

 

[dustin.s]

Rustoleum rust reformer paint works great, and you can paint over the top of it.

Thanks for the confident tip.

 

[G.W]

Thanks for the confident tip.

I cleaned only the surface rust, and here is what it did to the deeper rust on my ct90 frame. I meaning when I say it works great. That was bare metal with rust on it, it turns black

 

[G.W]

All the black speckles is where there was rust starting to get deeper into the metal

 

[dustin.s]

Getting things sanded and primed. I did have a question for those familiar with the predator 212 line of engines. The model I have is 69730, which is not supposed to be a “hemi”, hemispherical piston. However, the valve cover is cast material and rectangular, which is typical of a “hemi” engine.

 

[G.W]

That is the hemi version.

 

[dustin.s]

That is the hemi version.

The model number specified it’s not, but I’m thinking like you, that’s a hemi valve cover. I’m going to have to pull the head at some point to verify.

 

[G.W]

The model number specified it’s not, but I’m thinking like you, that’s a hemi valve cover. I’m going to have to pull the head at some point to verify.

No need, the he.i and non hemi valves are a different shape, and don't interchange. Another thing is the hemi cover is cast and the non hemi is pressed sheet metal. It is without a doubt a hemi

 

[panchothedog]

Somewhere within the last month or so l read that Harbor Freight had changed the numbers, so that all of the 212cc engines had the same product or model number, regardless of if it were a hemi or not. No need to pull or remove anything. G.W is telling you correctly, your engine is a hemi. You need to know that only if you go to install aftermarket hop up parts. Aside from carburetor and header pipe, practically nothing is interchangeable between the two engines. Yours has the better piston, as it is a flattop. Non hemi's come with a dished piston. Combustion chamber is a little smaller.

 

[BrownStainRacing]

This guy's explains some info about the boxing. Looks like they using what ever boxes and stickers with model #'s on whatever they like.

The model number specified it’s not, but I’m thinking like you, that’s a hemi valve cover. I’m going to have to pull the head at some point to verify.

Theres a lil more difference in them then jus the head. The blocks are different, so they take a different cam. The cranks are different, so they take a different flywheel.

But yes, that is a hemi HEAD