Hi Guys,
Here's a, Margay Handbook Panther X ,courtesy of Frank Weir,

           

hi recently  guys have been asking about making a kart motor from a mcculloch saw.
as i've posted this stuff in the past i figured tell them to go back and read the forum stuff.
hasn't worked so here one more time is the basics for breaking a saw down to it's power head.
i lost count a long time ago but there'sat least 20 saws that i've broken down so far.

short version, remove all chainsaw parts
replace intake and stuffer with kart ones.
add either mc5 crank or crank extension.
you could go the extra bit and add a kart piston too.
done
grumpy dave

btw there is a max torque clutch that will screw right onto the saw crank.
a little pricey but a perfect fit and excellent clutch.
d


this is a slightly longer  version but it should be of help to those who want to tinker and won't want to wait on me getting something online.
this is an article that i'llpublish sooner or later on the net.
warning if enough people pester me i'll change that to SELL so Be patient please.

the first thing is to get your tools handy.
you'll need a flat screwdriver or two, a bunch of sockets, and a few wrenches and pullers.
you start by removing the bar.
then remove the front aluminum handle.
take all the screws out of the top of the gas tank. theres some that hide pretty good especially near the gas cap and back near the rear handle.
after all the screws are out gently pry the gas tank cover off.
if it doesn't pop off check for a missed screw, some hide under all the oil imprenated saw dust so look carefully.
 but sometimes you have to pry pretty hard.
with the top off remove the screw holding the felt filter thingy and take out.
theres two (sometimes four) screws/bolts under there that need to be removed.
at this time you can also pull the carby as the bolts are easy to access.
save the carb, they're usually pretty good tilly's or flat backs.
remove the two lower bolts holding the carb manifold also take out the third one near the gas tank. take out manifold.
flip the saw on it's back.
remove the bolts holding the rear handle to the power head.
now the handle and lower gas tank should seperate from the powerhead. you have to kinda jigger the handle to get the gas bar clear. also be sure to cut the kill wire from the switch. be sure to leave as much as possible on the power head.
remove the four bolts holding in the oiler next. one of those bolts is a pain. i've got a ground down socket that fits to make bolt removal easier. most of the oilers will have a steel stuffer that also holds the oil in the oil tank. you need this part to keep stuff out of the motor so pop it off.Important put the saw over something that'll catch the old oil or you'll refresh the oil finish on your bench!!!
now it depends on which saw you have.
on all clutch removals you need to find the small hole in the fan cover thats used for pinning the flywheel. it's down near the powerhead on the back of the fan cover. put a small point , allen wrench, pick or whatever thru the hole and rotate the motor till you can push the pin a little father in . the motor shouldn't be able to rotate now. turn to the other side and remove the clutch nut.be careful some are left threads - some are right.
at this point the bigger saws require alot more parts removed to pull the gearbox.
smaller saws require the clutch to be pulled.
use a clutch puller regardless. i ruined a crank being impatient by hammering the nut to loosen the clutch. take five minutes and build a puller if you don't have one. i used a scrap of angle iron , two screws that fit the threads in the clutch and an i bolt with a nut threaded on.i just drilled three holes one in the middle and two to fit the puller span on the clutch.
i put the big bolt thru the middle hole and thread the nut on .install the two puller screws and then tighten the middle nut so it lifts the angle iron away from the clutch. you may have to tap the middle rod a little to get the clutch to let go.
remove inner clutch and pop off the key.
take out the gear drum.
now you'll need to clean the motor of the years of goo.
depending on which motor you have you can then add a manifold and stuffer, mount it and run.
or with the step cranks you'll need to change the crank or fit up an adapter.

dave

Post Prices on the forum if you are selling stuff here.

• FOR SALE SECTION IS FOR MEMBERS ONLY , POSTING NON MEMBER ITEMS IS NOT ALLOWED
  

• POST PIX OR THE FOR SALE ITEM WILL BE DELETED.
  

• FOR PAYMENTS OVER 500.00 USE ONLY PAYPAL OR DIRECT EXCHANGE OF CASH ONLY.
  

• YOU MAY ASK FOR A 10% NON REFUNDABLE DEPOSIT ON ANYTHING OVER $500.00
  

•  YOU ARE RESPONSIBLE FOR THE SHIPPING ARRANGEMENTS ON LARGE OBJECTS on your end.
  

• IF YOU GET THREE COMPLAINTS ABOUT BAD SALES YOUR SELLING RIGHTS WILL BE SUSPENDED
  
• FOR SALE SECTION IS FOR MEMBERS ONLY , POSTING NON MEMBER ITEMS IS NOT ALLOWED 
  

• Members can only bump their ads to the top once every two weeks.
  

On this forum we have alot of guys selling awesome stuff.
  90% of the sales are legit and go smoothly.
However there are times when rip offs can happen.


New forum members are usually just that new.
If they are selling something the deals they offer can be really good.
But sometimes the newest members are not too nice and here only to sell crap.
 or have stupid high prices and are trying to save on ebay fees.

Here's some advise:

• Check and see if the seller has a bunch of posts or has been a member for a long time. either one indicates they are part of the karting community not a newbe.
  

• Look up the sellers name and see if he's sold on forum before.our best sellers are repeat sellers almost always
  

• post a question on the general forum asking about the seller. if there's an issue you'll hear about it.
  

• NEVER buy from a seller with less then ten posts and/or isn't using a real name. if it's something like "kart king"  you can be pretty sure its made up.Less then ten posts means that they probably aren't well known.
  

• insist on good pictures of all sides of item. if you have any doubts have the seller take pix with todays newspaper next to item.
  
  

• Do a seller name search on google  site.
  

• Get a current phone number AND address call the number and google address.
  

•  and careful person only sends paypal money to people you don't know.
  

• If you're not completely sure of seller you can always ask to have the part shipped C.O.D.
  
  

McCulloch 2-CYCLE ENGINES
Listed below are the various models of the McCulloch Engines and some data regarding them.
Model     Engine Use     Bore     Stroke     Displacement     Carburetor           Spark Plug Type     Spark Plug Gap
MC-2       Racing           2.165     1.635        6.05                                          *J-6J or AC M-44C     0.025
MC-5      Racing           2.125     1.375        4.9         Tillotson Series HL           J-6J or AC M-44C     0.025
MC-6      Racing           2.125     1.500        5.3      mcculloch flatback carb        J-6J or AC M-44C     0.025
MC-7      Racing           2.165     1.635        6.05    mcculloch flatback carb        J-6J or AC M-44C     0.025
MC-8      Racing            2.165     1.375       4.9      mcculloch flatback carb        J-6J or AC M-44C     0.025
MC-9      Racing           2.165     1.375        4.9      mcculloch flatback carb        J-6J or AC M-44C     0.025
MC-10     Racing          2.125     1.500        5.3        mcculloch mc10 carb          J-6J or AC M-44C     0.025
MC-20     Racing          2.125     1.635        5.8       mcculloch flatback carb        J-6J or AC M-44C     0.025
MC-30     Racing          2.165     1.635        6.05     mcculloch flatback carb        J-6J or AC M-44C     0.025
MC-40     Racing          2.165     1.635        6.05        Tillotson Series HL            J-6J or AC M-44C     0.025
MC-45     Racing          2.165     1.635        6.05        Tillotson Series HL            J-6J or AC M-44C     0.025
MC-70     Racing          2.217     1.835        7.08        Tillotson Series HL             J-6J or AC M-44C     0.025
MC-75     Racing          2.250     1.835        7.29        Tillotson Series HL             J-6J or AC M-44C     0.025
*Spark Plug Data
          Operating Condition: Average Driving
                              Champion Plug Number = J-6J
                               AC Plug Number = M-44C
          Operating Condition: Light Racing
                               Champion Plug Number = J-4J
                               AC Plug Number = M-42k



And heres a new more detailed chart maybe a little easier to use


Mcculloch standard series go kart motors
   
Mcculloch super series motors below

  Mcculloch specs chart super pdf.pdf (Size: 33.84 KB / Downloads: 276)


[size=undefined][size=undefined][size=undefined]
[url=https://web.archive.org/web/20100215000000/http://macbobaust.com/bores.html][/url][/size][/size][/size]

mcbobs old chart
Bores , strokes and capacities of McCulloch Chainsaws  
Crankshaft PTO style

1. Tapered with keyway

2. Tapered without keyway

3. Stepped  


[b][b]Model .............Crankshaft No ..........Bore/stroke...........Conrod No............Capacity......................Crank pto end[/b]
1-40...........................50659...............2.125"/ 1.375"...............55009............80cc or 4.9 cu/in.........................3
1-41...........................50659...................................................55009...............................................................3
1-42...........................50659...................................................55009...............................................................3
1-43...........................50659...................................................55009...............................................................3
1-45...........................50659...................................................55009...............................................................3.
1-46...........................50659...................................................55009...............................................................3.
[b]Model .............Crankshaft No ..........Bore/stroke...........Conrod No............Capacity......................Crank pto end[/b]

1-50...........................50659..............2.125"/ 1.375............ 55009............80cc or 4.9 cu/in...............................3
1-51...........................50959...............................................55009....................................................................3
1-52...........................50959...............................................55009....................................................................3
1-53...........................57830..............2.125"/ 1.375..............55009....................................................................3
====================================================================

1-60...........................50756..............2.125"/ 1.375.............55009............80cc or 4.9 cu/in.............................. 3
1-61...........................50756...................................................55009.............80cc or 4.9 cu/in .........................3
1-62...........................50756...................................................55009.............80cc or 4.9 cu/in .........................1
1-63...........................50756...................................................55009.............80cc or 4.9 cu/in .........................1[/b]

[b][b][b]Model .............Crankshaft No ..........Bore/stroke...........Conrod No............Capacity......................Crank pto end[/b][/b][/b]

1-70...................................................2.125"/ 1.50.......................................90.14cc or 5.5cu/in......................1
1-71...............................................................................................................................................................1
1-72............................................................................................................................................................
1-75...................................................2.125"/ 1.625........................,,...........95cc or 5.8 cu/in.......................
1-76...........................58128...............2.165"/ 1.635................48905............99cc or 6.04cu/in..........................1

[b][b]Model ............Crankshaft No ..........Bore/stroke...........Conrod No............Capacity......................Crank pto end[/b]

1-80............................55257..............2.125"/ 1.500...............55009..............87cc or 5.3 cu/in......................1
1-81............................55756.................................................55009.............................................................1
1-82............................57756.................................................55009.............................................................1
1-85............................58128..............2.125"/ 1.625................48905...............95cc or 5.8 cu/in....................1
1-86............................58128..............2.165"/ 1.635................48905...............99cc or 6.04 cu/in..................1
===================================================================
Mac 15.......................50659a............2.125"/1.375................47903................80cc or 4.9 cu/in.......................3
D-30...........................50025..............2.125"/1.375................50015................80cc or 4.9 cu/in ......................3
D-36...........................50210..............2.125"/1.375................55009................80cc or 4.9 cu/in ......................3
===================================================================
D-44...........................51225..............2.00"/ 1.375..................51220..............72cc or 4.4 cu/in........................1
Super 44..........................................2.125"/ 1.375........................................80cc or 4.9 cu/in.......................1
Super 44a..................55257.............2.125"/ 1.50...................55010..............90.14cc or 5.5 cu/in...................1
D-45.................................................2.125"/ 1.375........................................80cc or 4.9 cu/in
Super 55....................55005.............2.125"/ 1.375.................55010..............80cc or 4.9 cu/in........................1
Super 55a.....................................................................................................................................................1
Model ............Crankshaft No ..........Bore/stroke...........Conrod No............Capacity......................Crank pto end
Pro Mac 105...............89222.............2.250"/ 1.635.................88623..........106.5cc or 6.5 cu/in.......................2
SuperPro 105.............89222..................................................88623...............................................................2
===================================================================
CP125.........................69346.............2.280"/ 1.835.................69250.............123cc or 7.5 cu/in........................2
CP125s.......................69346.............2.280"/ 1.835.................69250.................................................................2
Super Pro 125............85476.............2.280"/ 1.835.................85606.................................................................2
Super Pro 125c..........85476.............2.280"/ 1.835 ................88623.................................................................2[/b]
Model .................Crankshaft No ..........Bore/stroke...........Conrod No............Capacity......................Crank pto end
200.............................50659..............2.125"/ 1.375...............55009a.............80cc or 4.9 cu/in.......................3
250.............................50659a............2.125"/ 1.375...............47782a.............80cc or 4.9 cu/in.......................1
250 late......................50659a.............2.125"/ 1.500..............47903...............90.14cc or 5.5 cu/in..................1
Super 250...................60313..............2.125"/ 1.500..............47903...............90.14cc or 5.5 cu/in...................1
Super 250 ..................50659a............2.125"/ 1.375..............47782a.............80cc or 4.9 cu/in........................1

300.............................60313..............2.125"/ 1.50.................47903..............90.14cc or 5.5 cu/in....................1
380.............................60313..............2.125"/ 1.50.................47782a............90.14cc or 5.5 cu/in....................1
380a...........................60313..............2.125"/ 1.50.................47782a............90.14cc or 5.5 cu/in ...................1
440.............................60724..............2.125"/ 1.50.................47782a............90.14cc or 5.5 cu/in ...................1
450.............................60313..............2.125"/ 1.50.................47903............. 90.14 cc or 5.5 cu/in ..................1

[b][b]Model ............Crankshaft No ..........Bore/stroke...........Conrod No............Capacity......................Crank pto end[/b]
550............................64440...............2.165"/ 1.635................47903............99cc or 6.03 cu/in.......................1
Super 550..................63440..............2.217"/ 1.635................47903...........103cc or 6.3 cu/in.........................1
===================================================================
640............................50756a..............2.125"/ 1.375................47903.........80cc or 4.9 cu/in...........................1
650............................61860................2.125"/ 1.50.................47903..........90.14cc or 5.5 cu/in......................3
660............................61860................2.125"/ 1.50.................47903..........90.14cc or 5.5 cu/in......................3
===================================================================
740............................58128................2.165"/ 1.635...............47782a...........99cc or 6.04 cu/in......................1
790.....................................................2.217"/ 1.635...................................103cc or 6.3 cu/in........................1
795............................58128...................................................47903...........103cc or 6.3 cu/in........................1
797............................66010.................2.280"/ 1.835...............66049...........123cc or 7.5 cu/in.......................1
Super 797...........................................2.280"/ 1.835...................................123cc or 7.5 cu/in ......................1
===================================================================
840............................58132..................2.165"/ 1.635.............47782a...........99cc or 6.04 cu/in......................1
890............................58128..................2.217"/ 1.635.............47782a...........103cc or 6.3 cu/in......................1
895............................58128..................2.217"/ 1.635.............47903.............103cc or 6.3 cu/in......................1
895c..........................89222..................2.217"/ 1.635.............88623.............103cc or 6.3 cu/in......................2
=================================================================== 
  [/b]

1. Tapered with keyway
2. Tapered without keyway
3. Stepped 

McCulloch Kart Engines ...Bore and stroke.

Super /101 series
[b][b]Model ..........Crankshaft No ..........Bore/stroke...........Conrod No............Capacity......................Crank pto end[/b]

Mc 10.................55257../..48696 .........2.125"/ 1.50.........................................90.14cc or 5.5 cu/in....................1
Mc 20.................58128 ......................2.125"/ 1.635.........................................................5.8 cu/in....................1
Mc 30.................58128.......................2.165"/ 1.635.........................................106.5 or 6.05 cu/in......................1
Mc 40.................47751.......................2.165"/ 1.635.........................................................6.05 cu/in...................1
Mc 45.................58128.......................2.165"/ 1.635.........................................................6.05 cu/in...................1
Mc 70.................47798.......................2.217"/ 1.835.........................................................7.08 cu/in...................1
Mc 75.................47798a.....................2.250"/ 1.835.........................................................7.29 cu/in...................1
Mc 100/ 1966......47798a.....................2.250"/ 1.835.........................................................7.29 cu/in....................1
Mc 101/ 1967......68898.......................2.280"/ 1.835..............66049..................123cc or...7.5   cu/in....................1
Mc 101a.............69250.......................2.280"/ 1.835..............66049..................................7.5   cu/in
Mc 101aa 1972....69346......................2.280"/ 1.835........................................................7.5    cu/in
Mc 101b   1974....69346......................2.280"/ 1.835..............66049.................................7.5    cu/in....note 90872 ?
Mc 101c...1969....69346......................2.280"/ 1.835..............66049.................................7.5    cu/in
Mc 101d...1971.....69346.....................2.280"/ 1.835..............69250.................................7.5    cu/in
Mc 101 mc 1973...69346.....................2.280"/ 1.835........................................................7.5    cu/in[/b]


Mc Culloch 90 series engines

[b][b]Model ..........Crankshaft No ..........Bore/stroke...........Conrod No............Capacity......................Crank pto end[/b]

MC5
1960.........................50756..............2.125/1.375.................55009..................4.9........................................1
MC6
1961.........................48744..............2.125/1.500..................55009..................5.3.......................................1
MC7
1962.........................48586..............2.165/1.635..................48905................6.05.......................................1
MC8
1963.........................48586b............2.165/1.635..................47782................6.05.......................................1
MC9
1964.........................48586c............2.165/1.635..................47903................6.05.......................................1
MC90
1966..........................48586c...........2.165/1.635..................47903................6.05.......................................1
MC91
1966..........................48586c............2.165/1.635..................47903...............6.05.......................................1

91A...........................48586c............2.165/1.635..................47903...............6.05.......................................1
1968
91B...........................48586c............2.165/1.635..................47903...............6.05.......................................1
1970
91B/1........................48586c............2.165/1.635...................47903...............6.05......................................1
1970 
91C............................48586c...........2.165/1.635...................47903..............6.05.......................................1
1972
91M/C........................89140............2.165/1.635...................47903...............6.05...............Straight grove and key
1973
MC92.........................91085............2.165/1.635...................47903...............6.05......................................2
1974 
MC93.........................91085a..........2.165/1.635...................47903...............6.05......................................2
1977  
  

Footnote this list has been compiled from my vaste array of Mc IPLS and Mike Acres excellent chainsaw site 
[/b]

Engine Capacities of McCulloch Two Man Chainsaws 

12-25a .......1948 - 49 .......... 130cc ... 2.250 in. (57mm) x 2.0 in. (51mm)

5-49 .......... 1949 - 52 .......... 130cc ... 2.250 in. (57mm x 2.0 in. (51mm)

7-55 ........... 1951 - 53 ......... 161cc ... 2.50 in. (63.5mm) x 2.00 in. (51mm)

99 .............. 1954 - 63 ......... 161cc ... 2.50 in. (63.5mm) x 2.00 in. (51mm)

1-92 ........... 1961 - 62 ......... 103cc ... 2.217 in. (56.3mm) x 1.635 in. (41.5mm)

1-93 ........... 1962 - 63 ......... 103cc ...  2.217 in. (56.3mm) x 1.635 in. (41.5mm)

940 ............ 1963 - 71 ......... 103cc ... 2.217 in. (56.3mm) x 1.635 in. (41.5mm)



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Jack Canaday,
Looking through stuff, I found this block. Since I cannot do pictures, will try to describe it.
Has 2.125 bore, fixed head, smallest combustion chamber I have ever seen, compression release on side above intake manifold, ball bearing on pto side, provision for late style boost ports, bottom accepts large stuffer, and distance from base to squish same as mc49.
Long winded I know but can this thing be used to build a 49?
Thanks jack

Paul Booth
Jack,
Your crankcase is a red and white Mc49M/C. It has 2.125 bore and 1.375 stroke making it 80cc.
It has fixed head.
Combustion chamber is same as 91 and 101 series motors 9:4 to 1.
 49 motors are 6:to1 compression.
The 49M/C has compression release valve, McCulloch called it a D.S.P. valve.[De Stroking Port]
 It comes with a 4 pedal v-reed and sloper manifold with BDC 22 carb. same setup as Mc91M/C and Mc101M/C.
 It came with dual ball bearing crankshaft with 3/4 pto shaft.
The boobs for the boost ports are on outside of block under coil assembly.
 The block has 3 intake ports and 3 transfer ports and 3 exhaust ports standard.
No boost ports machined from factory.
It also has recessed exhaust port.
It will make an awesome 49 Kart engine with boost ports done.
I have a N.O.S. Mc49M/C and 4 Mc91M/C and 1 Mc101M/C complete engines.
 These are very fast and good engines.
Any more questions just ask. Have a good one
Paul

SteveO
I believe the block has 6 transfer ports, three on each side.
No intake ports since there is no passage on the back side of the block to serve them. It is built to be a reed induction engine exclusively rather than a combo reed/ piston valve motor like the 49, 49c and 49E models.

Maybe just a semantics issue... some people use "intake" and "transfer" to describe the same ports.
But when talking about the early 49 models along with all of the pre Mc 45/75 models the engines typically came with 6 transfer ports and three intake ports opposite the exhaust that are located in the block in a position such that they cannot be seen when the piston is at BDC. Those small round ports do not transfer charge from the case to the cylinder, they transfer incoming air/fuel mix from outside to inside the case so they are often called "intake" but more commonly called "piston" ports.

Engines with the combo induction setup are easier to start with a rope starter and also idle better than the reed only versions.
The first generation Mc 49 came with only four transfer ports, two on each side.
SteveO

Jack Canaday
Thanks for the info, but this block has a combustion chamber smaller than a Mc 6 or Mc 10. Only about .9 Diameter. This makes for really wide squish band. Now for next question. How are builders addressing the extreme squish clearance? This thing must have .055
Thanks Jack

SteveO
I should clarify that I was describing the Mc 49 M/C type block. Yours sounds different.... I have never seen the combustion chamber shape of the 49M/C block to say if that is normal for that engine.
Does the block have a part number stamped on it?
SteveO


Jack Canaday 
Thanks Steve for the reply. No number on block. This thing has at least 60 percent squish band. But a large squish clearance.
Jack

SteveO
Jack,

All the 49 series engines have about the same squish clearance as your block. The unusual part is the small dome. If you can, measure the diameter and depth of the dome and I'll do the same for the 49E I'm working on right now. I'll post the dimensions later.
SteveO

Jack Canady
Steve,
Best I can measure, .9 diameter, and .486 deep. And yes it does look to have about .035 of straight before radius starts. Now with a little math, that is 80% squish band. I have never run more than 50%. Will this be tunable.
Jack


SteveO
Jack,

With the large squish dimension the engine will still be pretty forgiving on the mixture settings but it will have much higher compression than most 49 type motors so it should make more power. Does the motor have the spark plug located in the same position and angle as the other 49 blocks? Does it use a 1/2" reach plug?
Seems like the engine would have to have the plug in the center for it to work out right with that tiny dome.
SteveO

Jack Canady
Steve,
Plug is in normal position, offset over coil. A 1/2 reach shows one thread in chamber, 3/8 reach one thread short. Just as all MCs were. I think the heads had cast in something like .47 to .5 reach. Champion length perhaps. The NGK plugs I used needed an extra washer or no washer and the thick thermocouple.
Jack