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38

Copyright © 2005 ICS, Blount Inc.

633GC SHOP MANUAL

EXHAUST

INTAKE

3.3  Make sure wrist pin retaining clip is in 

the proper orientation. 

3.4  Lubricate wrist pin and partially install 

in piston.

3.5  Align piston in correct orientation.

13. CYLINDER & PISTON

Summary of Contents for 633GC

Page 1: ...633GC Cut Off Saw Shop Manual...

Page 2: ......

Page 3: ...KER 27 10 CYLINDER COVER 29 11 MUFFLER 31 12 CARBURETOR 32 13 CYLINDER PISTON 34 14 WATER HOSE CAP 41 15 IGNITION COIL 43 16 FLYWHEEL 45 17 BOTTOM GUARD 47 18 FRONT HANDLE 48 19 FUEL TANK 49 20 CRANKC...

Page 4: ...te 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 reassembling clean...

Page 5: ...SASSEMBLY TOOL 8 71550 LIMITER 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 7...

Page 6: ...throttle shaft seals Air Filtration Washable cotton K N or washable dry nylon Starter Dust and water shielded Ignition Electronic water sealed Spark plug type Champion RCJ 7Y for conversion chart see...

Page 7: ...633GC SHOP MANUAL Copyright 2005 ICS Blount Inc 3 SERIAL LOCATION 3 This section shows the two locations of the serial number...

Page 8: ...15 STARTER PULLEY COVER SCREW 2 17 X 73236 16 STARTER COVER DUST SHIELD 73194 17 STARTER COVER ASSEMBLY COMPLETE 73195 18 IGNITION TOGGLE SWITCH 73237 19 IGNITION TOGGLE PLATE ON OFF 4 35 73238 20 IGN...

Page 9: ...201 11 MUFFLER BODY 73203 12 MUFFLER SUPPORT BRACKET SCREW 4 43 X 73255 13 MUFFLER SUPPORT BRACKET NUT 2 25 26 X 73256 14 MUFFLER SUPPORT BRACKET 73204 15 MUFFLER SCREW LOCKING PLATE 73257 16 MUFFLER...

Page 10: ...633GC SHOP MANUAL Copyright 2005 ICS Blount Inc 4 SPARE PARTS DIAGRAM...

Page 11: ...14 CRANKCASE GASKET 73447 15 CRANKCASE DOWEL PIN 73281 18 PREMIUM TENSIONER KIT REPLACES 73283 ASSEMBLY 73935 19 BAR MOUNT PAD COVER PLATE 73225 20 SCREW X 73284 21 WASHER 73285 22 CRANKCASE OUTSIDE...

Page 12: ...73309 20 RUBBER BUMPER COVER 73310 21 COVER RUBBER FLAP 73311 22 SIDE COVER W O BRAKE COMPONENTS 73449 23 COVER CLAMPING NUT 73313 25 CLUTCH SPACER WASHER 73314 26 CLUTCH NEEDLE BEARING 73423 27 CLUT...

Page 13: ...28 10 INTAKE MANIFOLD BRACKET 73329 11 FILTER CANNISTER COVER 73330 12 O RING AIR FILTER 73331 13 AIR FILTER GASKET 71719 14 AIR FILTER CANNISTER POLY 71752 15 FILTER CANNISTER GASKET 73335 16 PREFILT...

Page 14: ...57 9 THROTTLE LEVER 73358 10 TRIGGER LOCKOUT LEVER 73359 11 TRIGGER LOCKOUT LEVER SPRING 73360 12 FUEL TANK ASSEMBLY 73458 13 SCREW 7 61 X 73275 14 THROTTLE OPERATING WIRE 73366 15 MOUNTING NUT 73367...

Page 15: ...WASHER 71456 43 633GC WATER CAP 504388 44 FUEL CAP O RING 73448 45 WATER HOSE 71455 46 HOSE HANGER 71461 47 HOSE CLAMP 71465 49 WATER HOSE SCREW 71463 50 GUARD FLAP CLAMP 71531 51 GUARD FLAP 71534 54...

Page 16: ...eaning solution and water B Let dry and reinstall 5 2 Remove filter canister cover and air filter A Inspect air filter B Replace filter if necessary P N 71752 5 This section covers the disassembly ins...

Page 17: ...filter mount screws 3 A Make sure filter canister gasket and air filter water seal are secure B Replace air filter water seal if it is damaged permanently depressed hard due to slurry or missing P N 7...

Page 18: ...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 the spark plug 6 4 Ins...

Page 19: ...33GC SHOP MANUAL B Gap if necessary to 0 20 0 5 mm NOTE If the sparkplug must be replaced refer to the Spark Plug Reference Guide on page 70 6 5 Assemble in the reverse order A Make sure the plug boot...

Page 20: ...clutch removal rim sprocket removal inspection and assembly Refer to sections 5 and 6 if necessary 7 1 Insert piston stop tool into spark plug hole 7 2 Pull starter handle until piston stops against t...

Page 21: ...threads rotate clockwise to loosen NOTE If an impact wrench is available steps 7 1 and 7 2 do not have to be performed 7 5 Remove all drive components 7 6 Inspect the clutch shoes for wear A Replace...

Page 22: ...20 Copyright 2005 ICS Blount Inc 633GC SHOP MANUAL 7 7 Inspect spring for cracks 7 8 Assemble clutch shoes as shown 7 9 Finish installation of clutch shoe as shown 7 CLUTCH RIM SPROCKET...

Page 23: ...ints as shown on right 7 11 Clean and assemble A Clean all parts in solvent B Grease clutch cup bearing with a waterproof grease ICS P N 70885 C Assemble clutch use spacer washer bearing clutch cup wi...

Page 24: ...move 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 10 15 cm of rope out B Line rope up with notch on pulle...

Page 25: ...ey 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 spring from u...

Page 26: ...g 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 10 15 cm out B Make sure that the pulley spring catch is...

Page 27: ...tate the pulley with the rope clockwise 5 times C Untangle rope and release 8 15 Assemble starter cord shield 8 16 Remove starter pawl snap rings pawls spring and plain washer 8 17 Inspect and clean p...

Page 28: ...ring spring is in the correct position B Make sure the spring is in the correct position 8 19 Install starter cover A Pull out cord 4 6 10 15 cm Slowly release while placing cover to allow pawls to en...

Page 29: ...the WallWalker and guard flap 9 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 9 4 Remove guard flap screws...

Page 30: ...28 Copyright 2005 ICS Blount Inc 633GC SHOP MANUAL 9 6 Assemble in the reverse order A Install crankcase screws and wave washers B Use blue Loctite C Torque to 70 in lbs 7 9 Nm 9 WALLWALKER...

Page 31: ...ired Refer to sections 5 and 18 if necessary 10 1 Remove the cylinder cover screws 10 2 Remove spark plug lead from cylinder cover 10 3 Partially remove intake manifold from cylinder cover while lifti...

Page 32: ...plug lead into slot in cylinder cover B Push the cylinder cover down on the crankcase guide intake manifold into cylinder cover 10 7 Push down cylinder cover until it sits flat on crankcase A Install...

Page 33: ...uffler screw 11 2 Remove muffler screws muffler support bracket nut and muffler assembly 11 3 Clean and inspect parts of muffler assembly A Replace any damaged components 11 4 Install muffler A Assemb...

Page 34: ...tion of the carburetor Removal of several groups of components is needed Refer to sections 5 and 10 If necessary carburetor tuning is covered in section 23 12 1 Remove fuel line from carburetor and pl...

Page 35: ...33GC SHOP MANUAL 12 4 Remove intake manifold 12 5 Remove carburetor A Lift and twist carburetor away from throttle linkage to remove 12 6 Assemble in the reverse order A Torque carburetor body screws...

Page 36: ...on and assembly of the cylinder piston and related components Removal of several component groups is required Refer to sections 5 6 10 and 12 if necessary 13 1 Remove insulator base screws A Remove ca...

Page 37: ...33GC SHOP MANUAL 13 3 Remove cylinder A Remove cylinder gasket and clean case 13 4 Remove wrist pin retaining clips 13 5 Press wrist pin out with an 8 mm deep socket 13 6 Remove piston and inspect Rep...

Page 38: ...MANUAL 13 7 Remove wrist pin bearing 13 8 Cylinder gasket A Oil gasket with ICS 2 stroke engine oil B Install gasket and align holes and notch 13 9 Install wrist pin bearing in rod A Oil bearing with...

Page 39: ...37 Copyright 2005 ICS Blount Inc 633GC SHOP MANUAL 13 10 Install rings 13 11 Ring orientation 13 12 Install one wrist pin retaining clip 13 CYLINDER PISTON...

Page 40: ...t Inc 633GC SHOP MANUAL EXHAUST INTAKE 13 13 Make sure wrist pin retaining clip is in the proper orientation 13 14 Lubricate wrist pin and partially install in piston 13 15 Align piston in correct ori...

Page 41: ...n D Install second wrist pin retaining clip 13 17 Install cylinder A Lubricate cylinder bore with ICS 2 stroke oil B Compress rings with ring compression tool C Slide cylinder onto piston pushing ring...

Page 42: ...SHOP MANUAL 13 19 Install 4 cylinder screws and washers A Use blue Loctite B Torque bolts to 104 in lbs 11 75 Nm 13 20 Install insulator base A Install insulator base screws use blue Loctite and torqu...

Page 43: ...MANUAL 14 This section covers water hose and water tank cap 14 1 Remove water connection from hose end 14 2 Remove starter cover screw with hose hanger from saw 14 3 Remove water hose connector 14 4 U...

Page 44: ...42 Copyright 2005 ICS Blount Inc 633GC SHOP MANUAL 14 5 Release water tank cap from water tank tube A Depress orange fitting as shown 14 6 Assemble in the reverse order 14 WATER HOSE...

Page 45: ...val of the starter is required Refer to section 8 if necessary 15 1 Remove starter 15 2 Remove starter flywheel shroud by unhooking wires 15 3 Remove ignition coil screws wave washers and plain washer...

Page 46: ...screws wave washers and plain washers with blue Loctite D Holding shim rotate flywheel magnet around to coil E Torque ignition coil screws to 52 in lbs 5 9 Nm F Remove shim rotate flywheel to check cl...

Page 47: ...ired Refer to sections 6 and 8 if necessary 16 1 Remove sparkplug and insert piston stop 16 2 Remove flywheel nut counter clockwise wave washer and plain washer 16 3 Install flywheel puller bolts 3 fi...

Page 48: ...ight 2005 ICS Blount Inc 633GC SHOP MANUAL 16 5 Inspect woodruff key A Replace if broken or damaged 16 6 Install flywheel plain washer wave washer and flywheel nut A Torque nut to 390 in lbs 44 Nm 16...

Page 49: ...33GC SHOP MANUAL 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 Replace if damaged D Assembl...

Page 50: ...nspection 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 Instal...

Page 51: ...of the vibration isolaters fuel tank and rear handle 19 1 Remove vibration isolator screws and wave washers on clutch side of saw 19 2 Remove vibration isolator screws and wave washers on flywheel sid...

Page 52: ...fuel tank NOTE During assembly be careful not to kink the fuel line between the crankcase and fuel tank 19 4 Remove vibration isolators from fuel tank 6 if necessary 19 5 Separate the fuel tank halve...

Page 53: ...Separate the fuel tank halves using a large screwdriver A Clean the joining surface of the tank halves B Assemble in the reverse order NOTE Use a fuel proof liquid gasket material to reseal the tank...

Page 54: ...33GC SHOP MANUAL 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 wave washers 20 2 Re...

Page 55: ...Heat the flywheel side of crankcase with heat gun to 150 F 65 5 C 20 4 To remove the flywheel side of crankcase tap crankshaft with plastic mallet A Suspend above work surface B Tap with mallet 20 5...

Page 56: ...ide of crankcase with heat gun to 150 F 65 5 C 20 7 To remove crankshaft from the clutch side of crankcase Tap crankshaft with a plastic mallet A Suspend above work surface B Tap with plastic mallet 2...

Page 57: ...AL 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 crankcase halves 20 13...

Page 58: ...Blount Inc 633GC SHOP MANUAL 20 14 Repeat with other half 20 15 Install crankshaft into clutch side of case 20 16 Place clutch side of crank case seal on crankshaft A Tap lightly with bearing driver a...

Page 59: ...Blount Inc 633GC SHOP MANUAL 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 together and align crank...

Page 60: ...earing driver and mallet 20 21 Install main crankcase bolts A Use blue Loctite B Torque to 70 in lbs 7 9 Nm NOTE Tighten bolts hand tight then torque bolts in sequence listed at right 20 22 Install fl...

Page 61: ...59 Copyright 2005 ICS Blount Inc 633GC SHOP MANUAL 20 23 Trim crankcase gasket flush 20 CRANKCASE...

Page 62: ...the bar studs and bar pad 21 1 Remove bar studs A Install side cover nuts flange to flange B Tighten side cover nuts against each other C Attempt to remove the inside nut which should pull out the ba...

Page 63: ...his section covers the removal and installation of the chain tensioner 22 1 Remove bar plate to expose the chain tensioner 22 2 Unscrew tensioner to remove A Remove tensioner pin B Remove tensioner sc...

Page 64: ...eyond this limit may seriously damage the engine Always check the air filter fuel filter and spark plug before making carburetor adjustments and clean or replace if necessary When adjusting the carbur...

Page 65: ...r blades into the release slots A Firmly hold the tool shaft while screwing in the puller screw until the screw head is against the puller shaft B Unscrew the puller screw 23 4 Using a 5 64 straight b...

Page 66: ...screw slowly 23 8 With a tachometer check the saw full throttle rpm with no bar and chain A Target 11 500 300 rpm 23 9 If the full throttle rpm falls below this range turn the H screw in clockwise 1...

Page 67: ...5 Copyright 2005 ICS Blount Inc 633GC SHOP MANUAL 23 11 When the carburetor is adjusted correctly set the limiter caps with a straight blade screwdriver A H horizontal B L vertical 23 CARBURETOR TUNIN...

Page 68: ...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 out turn 24 2 If chain turns at...

Page 69: ...igh Broken clutch spring Excessive vibration YES Damaged shock absorber Damaged or broken flywheel fins Bent crankshaft Replace shock absorbers Replace flywheel Replace crankshaft Adjust idle speed Re...

Page 70: ...ished or contaminated Empty tank and re fill with fresh fuel of the correct mixture 50 1 Loose spark plug If below 125 psi excess wear on the piston cylinder rings Tighten plug and re test Replace pis...

Page 71: ...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 material in the felt or the internal screen...

Page 72: ...Walbro Diaphragm Carburetor Service Manual 26 3 The fuel tank breather stabilizes the pressure in the fuel tank preventing both excessive pressure which could flood the engine and negative pressure w...

Page 73: ...26 5 If the pressure does not reduce to 0 psi disassemble or replace the breather A Clean the parts with fuel for the cut off saw B Assemble in reverse order C Make sure that the spring taper is orie...

Page 74: ...1 Install the exhaust seal flange A Be sure the spark plug is installed and tightened firmly 27 2 Install the intake seal flange 27 3 Install the pressure gauge and bulb 27 4 Pressurize the crankcase...

Page 75: ...eference 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 RESISTOR CHAMPION R...

Page 76: ...ICS Blount Inc 4909 SE International Way Portland Oregon 97222 TEL 800 321 1240 FAX 503 653 4393 www icsbestway com p n 71537...

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