ICS 613GC Service Manual Download Page 56

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F/N 71537 Oct 07

TITLE

613GC SERVICE MANUAL

18. FRONT HANDLE

This section covers the removal,
inspection, and installation of
the front handle.

18.1 Remove front handle screws on right

side.

18.2 Remove front handle screws on

bottom.

18.3 Install front handle.

A  Roll front handle into place.
B  Install front handle screws (4).
C  Use blue Loctite

D T

orque to 69 in-lbs. (8 Nm).

Summary of Contents for 613GC

Page 1: ...F N 71537 Oct 07 2007 ICS Blount Inc 613GC SERVICE MANUAL...

Page 2: ......

Page 3: ...9 WALLWALKER 29 10 CYLINDER COVER 31 11 MUFFLER 34 12 CARBURETOR 36 13 CYLINDER PISTON 38 14 WATER HOSE 47 15 IGNITION COIL 49 16 FLYWHEEL 51 17 BOTTOM GUARD 53 18 FRONT HANDLE 54 19 FUEL TANK 55 20...

Page 4: ...separate parts attached solidly to each other Mark mating parts as a reassembly reference Keep component parts together as a group Assemble screws and nuts into appropriate subgroups When reassemblin...

Page 5: ...MITER CAP REMOVAL TOOL 9 71565 ELECTRONIC TACHOMETER 10 71569 613GC INDUCTION SEAL FLANGE W SCREWS 11 71570 613GC EXHAUST SEAL FLANGE W SCREWS 12 71573 TUNING SCREWDRIVER 13 73410 633GC FLYWHEEL PULLE...

Page 6: ...ches 29 cm height 10 inches 25 cm width Carburetor Walbro diaphragm WJ 85B Air Filtration Dry nylon Starter Dust and water shielded Ignition Electronic speed governing water sealed Clutch Three weight...

Page 7: ...F N 71537 Oct 07 2007 ICS Blount Inc TITLE 613GC SERVICE MANUAL 5 3 SERIAL LOCATION 3 613GC Cut Off serial number series...

Page 8: ...5 STARTER CASE PLATE 71451 6 STARTER COIL SPRING HOUSING SCREW 73910 7 STARTER ROPE PULLEY 73913 8 STARTER PULLEY WASHER 73905 9 STARTER PULLEY SCREW 0 6 52 X 73907 10 STARTER COVER ASSEMBLY 71415 11...

Page 9: ...MBLY 71411 11 CYLINDER BLOCK BOLT 1 1 95 X 73874 12 MUFFLER MOUNTING SCREW 1 0 87 73883 13 CARBURETOR PULSE TUBE 73898 14 MUFFLER SUPPORT BRACKET 73884 15 MUFFLER SUPPORT BRACKET SCREW 0 9 78 73885 16...

Page 10: ...NEEDLE BEARING 73869 6 CLUTCH SIDE MAIN BEARING SEAL INSIDE 73289 7 CRANKSHAFT BUSHING 71452 KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 OUTER CRANKCASE SEAL CLUTCH SIDE 73931 2 OUTER C...

Page 11: ...43 X 71479 7 GUARD FLAP WASHER 71483 8 GUARD FLAP SPACER 71480 9 WATER HOSE GASKET 71469 10 FITTING 71467 11 RING NUT 71457 12 WATER HOSE O RING 71468 13 WATER SHUT OFF VALVE 71458 14 FITTING 71454 15...

Page 12: ...71747 7 CHOKE LEVER SPLIT PIN 73927 8 CRANKCASE GASKET 73934 9 CRANKCASE BOLT 0 8 69 X 73930 10 WASHER 73897 11 BOTTOM COVER 73950 12 BAR MOUNT PAD SPACER 71740 13 COVER GUARD MOUNTING BOLT 0 8 69 X 7...

Page 13: ...71743 2 SIDE COVER NUT 1 2 104 73958 3 CHAIN COVER CAP 71462 4 MOUNTING NUT 73367 5 WALLWALKER SIDE ARM 71533 6 WASHER 73951 7 WALLWALKER SIDE ARM SCREW 507355 8 SCREW 0 3 26 X 71487 9 SIDE COVER PLAT...

Page 14: ...2007 ICS Blount Inc F N 71537 Oct 07 TITLE 613GC SERVICE MANUAL 12 4 SPARE PARTS DIAGRAM...

Page 15: ...VER ASSEMBLY 3 SCREW 71753 4 FILTER COVER SCREW 73992 5 FILTER SUPPORT 73338 6 FILTER COVER GASKET 71756 7 SCREW CYLINDER COVER LONG SOCKET HEAD X X X 71771 8 PREFILTER PLASTIC SECONDARY FILTER 73336...

Page 16: ...R 73459 8 TRIGGER LOCKOUT LEVER 73987 9 TRIGGER LOCKOUT LEVER SPRING 73988 0 WASHER 73897 11 SCREW 0 9 78 X 73982 12 SHOCK ABSORBER 0 4 35 73980 13 TUBE CLAMP WITH TABS 71588 14 FUEL LINE 73375 15 SHO...

Page 17: ...inspection and assembly air induction system 5 1 Loosen the air filter cover screws and remove air filter cover 5 2 Remove air filter from cover A Inspect air filter B Replace if necessary 5 3 Clean f...

Page 18: ...TITLE 613GC SERVICE MANUAL 16 5 AIR INTAKE 5 4 Inspect air filter cover gasket A Replace if permanently depressed or hard due to slurry 5 5 Inspect filter cannister gasket A Clean B Replace if necessa...

Page 19: ...s section covers the removal inspection and installation of the spark plug 6 1 Remove the spark plug lead 6 2 Clean area around the spark plug to prevent debris from entering the cylinder 6 3 Remove t...

Page 20: ...L 18 6 SPARK PLUG B Gap if necessary to 0 02 0 5 mm NOTE If the spark plug must be replaced refer to the Spark Plug Reference Guide on page 78 to select the correct replacement plug 6 5 Assemble in th...

Page 21: ...sprocket removal inspection and assembly Refer to sections 5 and 6 if needed 7 1 Insert piston stop tool into spark plug hole 7 2 Pull starter handle until piston stops against tool 7 3 Remove clutch...

Page 22: ...37 Oct 07 TITLE 613GC SERVICE MANUAL 20 7 CLUTCH RIM SPROCKET 7 4 Remove all drive components 7 5 Inspect the clutch shoes for wear A Replace if the shoe has less than 0 04 1 mm of material as shown 7...

Page 23: ...E 613GC SERVICE MANUAL 21 7 CLUTCH RIM SPROCKET 7 7 Assemble clutch shoes as shown 7 8 Finish installation of clutch shoe as shown 7 9 Inspect the rim sprocket for wear A Replace if the rim sprocket t...

Page 24: ...ROCKET 7 10 Clean and assemble A Clean all parts in solvent B Grease clutch cup bearing with a water proof grease ICS P N 70885 C Assemble clutch spacer washer bearing clutch cup with rim sprocket and...

Page 25: ...he recoil spring 8 1 Remove starter cover screws 8 2 Remove starter cover assembly from saw 8 3 Remove starter cord shield screws 8 4 Relieve spring tension A Pull 4 6 of rope out B Line rope up with...

Page 26: ...e starter pulley 8 7 Inspect coil spring A Replace if spring hook is damaged Attempting to re bend the spring hook may cause the hook to break off B Carefully remove coil spring and housing to prevent...

Page 27: ...ch A Clean with cleaning solution B Replace if worn or broken 8 11 Install starter rope and tie knot 8 12 Install pulley A Wind rope onto pulley clockwise leaving 4 6 out B Make sure that the pulley s...

Page 28: ...notch on pulley B Rotate the pulley with the rope clockwise 5 times C Untangle rope and release 8 15 Assemble starter cord shield 8 16 Remove starter pawl screws pawls spring and plain washer 8 17 In...

Page 29: ...e the spring is in the correct position B Use blue Loctite on the pawl screws C Torque to 60 in lbs 6 8 Nm 8 19 Wind the pawl spring A Use needle nose pliers to move the tail of the spring into positi...

Page 30: ...2007 ICS Blount Inc F N 71537 Oct 07 TITLE 613GC SERVICE MANUAL 28 8 STARTER 8 21 Install starter cover screws A Use blue Loctite B Torque to 60 in lbs 7 Nm...

Page 31: ...1 Inspect WallWalker tip A If the tip is worn as shown replace 9 2 Remove crankcase screws and wave washers 9 3 Remove WallWalker from saw NOTE On late model saws it is necessary to remove the bar pl...

Page 32: ...7 ICS Blount Inc F N 71537 Oct 07 TITLE 613GC SERVICE MANUAL 30 9 WALLWALKER 9 6 Reassemble in the reverse order A Install crankcase screws and wave washers B Use blue Loctite C Torque to 70 in lbs 7...

Page 33: ...needed 10 1 Remove the air filter mount screws 10 2 Remove the cylinder cover screws 3 10 3 Remove spark plug lead from cylinder cover 10 4 Remove fuel tank breather cap and clamp 10 5 Partially remo...

Page 34: ...ver gasket are in place and in good condition A Replace if necessary 10 10 Reassemble stop switch leads 10 11 Make sure carburetor screw boot is in place 10 12 Lubricate compensating tube and fuel tan...

Page 35: ...D Install the cylinder cover screws Use blue Loctite Torque to 35 in lbs 4 0 Nm E Install fuel tank breather and clamp 10 14 Install air filter mount A Guide carburetor compensating tube through air f...

Page 36: ...spection and assembly of the muffler Removal of the WallWalker and cylinder cover is necessary Refer to sections 7 and 10 if necessary 11 1 Remove muffler support screws 11 2 Remove muffler screws and...

Page 37: ...B Hold muffler screws in place with heat shield gasket C Thread muffler screws into cylinder torque to 78 in lbs 9 Nm 11 5 Install muffler support A Install top 3 muffler support screws and serrated w...

Page 38: ...equired Please refer to sections 5 and 10 or 11 if necessary Carburetor tuning is covered in section 23 12 1 Remove throttle linkage A Push trigger end out of rear handle B Pivot linkage around C Remo...

Page 39: ...Torx or straight blade screwdriver 12 6 Remove carburetor body screws 2 12 7 Remove fuel line 12 8 Remove pulse tube 12 9 Remove carburetor compensator tube on top of carburetor 12 10 Assemble in the...

Page 40: ...several component groups is required Refer to sections 5 6 10 and 12 if necessary 13 1 Remove carburetor base screws A Remove carburetor base from rear manifold B Remove carburetor base from pulse tub...

Page 41: ...SERVICE MANUAL 39 13 CYLINDER PISTON 13 3 Remove rear manifold clamp 13 4 Remove rear manifold from cylinder A Inspect for holes and tears 13 5 Remove cylinder screws 4 and wave washers 13 6 Remove c...

Page 42: ...7 Oct 07 TITLE 613GC SERVICE MANUAL 40 13 CYLINDER PISTON 13 7 Remove wrist pin retaining clips 2 13 8 Press wrist pin out with an 8 mm deep socket 13 9 Remove piston and inspect Replace if damaged 13...

Page 43: ...13GC SERVICE MANUAL 41 13 CYLINDER PISTON 13 11 Cylinder gasket A Oil gasket with ICS 2 stroke engine oil B Install and align holes and notch 13 12 Install wrist pin bearing in rod A Oil bearing with...

Page 44: ...TLE 613GC SERVICE MANUAL 42 13 CYLINDER PISTON 13 14 Ring orientation 13 15 Install one wrist pin retaining clip 13 16 Make sure wrist pin retaining clip is in the proper orientation Improper installa...

Page 45: ...ist pin 13 18 Align piston in correct orientation 13 19 Install piston A Oil piston with ICS 2 stroke oil B Align wrist pin with wrist pin bearing C Complete wrist pin installation D Install second wr...

Page 46: ...il B Compress rings with ring compression tool C Slide cylinder onto piston pushing ring compression tool down 13 21 Install cylinder A Remove ring compression tool B Slide cylinder down piston and in...

Page 47: ...old A Lubricate rear manifold with ICS 2 stroke oil B Push rear manifold onto cylinder intake C Align rear manifold seam with cylinder and crankcase seam 13 24 Install rear manifold clamp A Torque to...

Page 48: ...stall carburetor base A Slip pulse tube into carburetor base B Slip rear manifold into carburetor base C Make sure rear manifold lip is flat 13 28 Install carburetor base screws A Use blue Loctite on...

Page 49: ...ICE MANUAL 47 14 WATER HOSE 14 This section covers water hose and water tank cap 14 1 Loosen hose clamp screw 14 2 Remove water connection from hose 14 3 Remove hose from hose hanger 14 4 Remove water...

Page 50: ...2007 ICS Blount Inc F N 71537 Oct 07 TITLE 613GC SERVICE MANUAL 48 14 WATER HOSE 14 6 Release water tank cap from water tank tube A Depress orange fitting as shown 14 7 Assemble in the reverse order...

Page 51: ...stallation of the ignition coil Removal of the starter is required Refer to section 8 if necessary 15 1 Remove starter flywheel shroud by unhooking wires 15 2 Remove ignition coil screws wave washers...

Page 52: ...ion coil in place C Install ignition coil screws wave washers and plain washers with blue Loctite Holding shim rotate flywheel magnet around to coil E Torque ignition coil screws to 26 in lbs 3 Nm F R...

Page 53: ...stallation of the flywheel Removal of the starter and spark plug is required Refer to sections 6 and 8 if necessary 16 1 Insert piston stop 16 2 Remove flywheel nut wave washer and plain washer 16 3 S...

Page 54: ...agnet counterweight 16 5 Strike flywheel removal tool with a ball peen hammer The flywheel should release from crankshaft 16 6 Inspect and clean flywheel Replace if any of the fins are broken 16 7 Ins...

Page 55: ...613GC SERVICE MANUAL 53 17 BOTTOM GUARD 17 This section covers the removal inspection and installation of the bottom guard A Remove bottom guard screws and split washers B Inspect bottom guard C Repl...

Page 56: ...tion covers the removal inspection and installation of the front handle 18 1 Remove front handle screws on right side 18 2 Remove front handle screws on bottom 18 3 Install front handle A Roll front h...

Page 57: ...ANK 19 This section covers the disassembly inspection and assembly of the vibration isolaters fuel tank and rear handle 19 1 Remove vibration isolator screws and wave washers on clutch side of saw 19...

Page 58: ...crankcase and fuel tank NOTE Saws have a rubber water deflector connected to the 2 bottom vibration isolators on the clutch side circled 19 4 Remove vibration isolators from fuel tank 6 if necessary...

Page 59: ...613GC SERVICE MANUAL 57 20 CRANKCASE 20 This section covers the disassembly inspection and assembly of the crankcase seals and crankshaft bearings 20 1 Remove outer crankshaft seal housing screws and...

Page 60: ...eat gun for 5 minutes approximately 150 F 65 5 C 20 4 Remove the flywheel side crankcase tap crankshaft with plastic mallet A Suspend above work surface B Tap with mallet NOTE A nut should always be p...

Page 61: ...ASE 20 6 Heat the clutch side crankcase with heat gun to 150 F 65 5 C 20 7 Remove crankshaft from the clutch side crankcase tap crankshaft with a plastic mallet A Suspend above work surface B Tap with...

Page 62: ...MANUAL 60 20 CRANKCASE 20 9 Remove the bearing seal and bushing from the clutch side of crankshaft 20 10 Clean mating crankcase faces 20 11 Heat crankcase halves to 150 F 20 12 Install bearing into c...

Page 63: ...unt Inc TITLE 613GC SERVICE MANUAL 61 20 CRANKCASE 20 14 Repeat with other half 20 15 Install crankshaft into clutch side of case 20 16 Place clutch side crank case seal on crankshaft A Tap lightly wi...

Page 64: ...Oct 07 TITLE 613GC SERVICE MANUAL 62 20 CRANKCASE 20 17 Coat crankcase gasket with ICS 2 stroke engine oil 20 18 Align crankcase gasket on flywheel side crankcase pins 20 19 Place crankcase halves tog...

Page 65: ...ase halves tap with bearing driver and mallet 20 21 Install main crankcase bolts A Use blue Loctite B Torque to 69 in lbs 8 Nm NOTE The 3 remaining crankcase bolts will be installed during the complet...

Page 66: ...2007 ICS Blount Inc F N 71537 Oct 07 TITLE 613GC SERVICE MANUAL 64 20 CRANKCASE 20 23 Trim crankcase gasket flush...

Page 67: ...Serial s beginning 0482421700 and 071XXXXXXX it is necessary to remove the bar mount pad cover plate first 21 1 Remove bar studs A Remove side cover B Install side cover nuts flange to flange and tig...

Page 68: ...removal and installation of the chain tensioner 22 1 Remove bar plate to expose the chain tensioner NOTE Saws with serial s lower than 0482421700 are not equipped with a bar mount pad cover plate 22 2...

Page 69: ...missions standards However minor adjustments may be required in certain conditions such as high elevation NOTES These cut off saws are equipped with an electronic speed limiter as part of the ignition...

Page 70: ...to adjustment screw hole Observe orientation of the release slots on the adjustment screw limiter cap B Insert the limiter cap puller blades into the release slots C Firmly hold the tool shaft while s...

Page 71: ...y result in personal injury 23 5 Start the saw and warm up the engine 23 6 With a tachometer check the saw rpm with no bar and chain A Idle 3 000 300 rpm B If the idle rpm does not fall into this rang...

Page 72: ...Inc F N 71537 Oct 07 TITLE 613GC SERVICE MANUAL 70 23 CARBURETOR TUNING 23 9 When the carburetor is adjusted correctly set the limiter caps as shown with a 1 4 straight blade screwdriver A L vertical...

Page 73: ...ADJUSTMENT 24 This section covers idle speed adjustment 24 1 If engine stops while idling A Make sure the chain is properly tensioned B Turn T screw clockwise until chain begins to move C Back T screw...

Page 74: ...e Idle speed too high Broken clutch spring Excessive vibration YES Damaged shock absorber Damaged or broken flywheel fins Bent crankshaft Replace shock absorbers Replace flywheel Replace crankshaft Ad...

Page 75: ...nk breather Fuel is old varnished or contaminated Empty tank and re fill with fresh fuel of the correct mixture 25 1 Loose spark plug If below 125 psi excess wear on the piston cylinder rings Tighten...

Page 76: ...stem The five main components are the fuel tank fuel tank breather fuel filter delivery tubes and carburetor 26 1 Remove and inspect the fuel filter A Replace the fuel filter if there is any foreign m...

Page 77: ...G If the main fuel pick up tube does maintain pressure then the leak ha been isolated to the carburetor Refer to the Walbro Diaphragm Carburetor Service Manual 26 3 The fuel tank breather stabilizes...

Page 78: ...ain fuel pick up tube at the carburetor Pressurize the tube to 4 5 psi 0 3 bar B The pressure should reduce to nearly 0 psi 0 bar over about 3 seconds 26 6 If the pressure does not reduce to 0 psi dis...

Page 79: ...27 1 Install the intake seal flange A Plug cylinder pulse tube 27 2 Install the exhaust seal flange 27 3 Block one of the flange tubes with a rubber plug 27 4 Install the pressure gauge and bulb 27 5...

Page 80: ...The Spark Plug Reference Guide is to be used as a guide only When trying a plug from a different manufacturer perform a plug check to be sure that the plug will work SPARK PLUG REFERENCE GUIDE ICS RE...

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Page 84: ...2007 ICS Blount Inc F N 71537 Oct 07 ICS Blount Inc 4909 SE International Way Portland OR 97222 Tel 800 321 1240 Fax 503 653 4393 icsbestway com 613GC SERVICE MANUAL...

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