Manco Big Cat

ohman11 · 09-04-2008, 04:09 PM

Well I dropped off my big cat today to have some work done to it. I work out of town so it is easier sometimes to pay to have it done.
I replaced the 5hp briggs with a Honda Clone 6.5..

They are removing the governor and putting a Mikuni 22 on it.

I am having a new jack shaft made for it and all of the wheel bearings replaced.

I am also having a new clutch put on, they think the torque converter is in good shape so at this point it wont be replaced.

I will post pics as it come along. The shop doing the work builds jr dragsters and go karts and it looks like they do beautiful work.

.

**GTO** · 09-04-2008, 10:32 PM

Is that engine going to fit?

ohman11 · 09-05-2008, 06:46 AM

Quote:

Originally Posted by GTO

Is that engine going to fit?

Yes. I had to take the gas tank off to get it in but it will go back on after it is in. I am not sure if you have seen a big cat before but the are huge. Thats the rason I got it because I am 6'2 and 225 and I fit on it fine.

Knuckledragger · 09-05-2008, 07:49 AM

Is the shop going to straighten the forks?

ohman11 · 09-05-2008, 10:51 AM

Quote:

Originally Posted by Knuckledragger

Is the shop going to straighten the forks?

Yes they are going to work on them

COOP1418 · 09-09-2008, 12:31 AM

I have the same bike,forks got bent by my stunt rideing daughter.Tube bends inside gooseneck had no luck repairing.You can still order these parts from American Sportworks(MANCO).If I remember right this is model
596E.You can go on website with model # and get the part #'s.There is phone # to order parts.I got forks and new head set(bearings etc.)with shipping to Texas $90.00.

COOP

Jim Criste · 09-11-2008, 02:49 PM

I have one of those bikes, and it had a bent fork as well. I made the fork work like a small mini with some plate and tubing. It works good, and it didn't cost much. I also changed the motor to a HM100. It is a tight fit, but it has good power. KBS8Ball made me a great seat for it. I plan to finish it this winter. I know it will be good in the snow.

Vette · 09-11-2008, 03:47 PM

I would have to say the forks are the biggest weak spot on the Big Cats, at least half of the Big Cats I have seen have bent forks and then people will, instead of getting the forks fixed or replacing them, turn the front fender around backwards to solve the fender clearance problem.

As strong as the double tube braced frame is, Manco should have used a heavier wall tube for the forks.
The second big gripe I have with them is the engine being so cold blooded that it is a real pain to ride in cold weather, caused mainly by the cheap, no choke, no adjust, so called automatic carb.

Replacing the engine sure takes care of the carb problem.
The knobbys don't do too bad in the snow if it isn't too deep. it is fun sliding around on these things.

Jim Criste · 09-12-2008, 04:13 PM

Here are the pictures of the fork repair and the 10hp in the Manco frame. It is still very rough, but at least the seat looks good.

COOP1418 · 09-12-2008, 04:24 PM

Cool repair glad I kept my old forks you never know what future
holds.