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ICS 660GC, Service Manual

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ICS 660GC Service Manual Download Page 65

 

© 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011

660GC SERVICE MANUAL

64

19.14  Repeat with other half.

19.15  Install crankshaft into clutch side 

of case. 

19.16  Place clutch side crankcase seal 

on crankshaft. 

A  Tap lightly with bearing driver 

and mallet.

19. CRANKCASE

Summary of Contents for 660GC

Page 1: ...2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL...

Page 2: ...NTAKE 19 6 SPARK PLUG 21 7 CLUTCH RIM SPROCKET 23 8 STARTER SYSTEM 27 9 WALLWALKER 33 10 CYLINDER COVER 35 11 MUFFLER 39 12 CARBURETOR 41 13 CYLINDER PISTON 43 14 WATER HOSE 52 15 IGNITION COIL 53 16...

Page 3: ...w mallet to 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...

Page 4: ...Cylinder Assembly Clamps Piston Stop 10 55 5 73462 Main Bearing Driver Tool 38 65 6 71546 Shock Absorber Tool 22 15 7 71547 Spark Tester 46 35 8 71548 Flywheel Disassembly Tool 31 45 9 71550 Limiter C...

Page 5: ...4 cm length 10 inches 25 5 cm height 11 6 inches 29 5 cm width Air Filter Water Resistant Polyester Carburetor Walbro HDA225 Starter Dust and Water resistant Ignition Special water resistant electroni...

Page 6: ...2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 5 3 660GC serial number series 3 SERIAL LOCATION...

Page 7: ...ents The key numbers used are not related to the key numbers in the 660GC Replacement Parts Price List KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 SPARK PLUG 27 5 243 73199 2 CYLINDER B...

Page 8: ...537665 4 CRANKCASE DOWEL PIN 73281 5 FUEL LINE GROMMET 505627 6 CRANKCASE GROMMET 505408 7 CRANKSHAFT BEARING 505375 8 BAR MOUNTING STUD 509555 9 TENSIONER 505393 10 BAR MOUNT PAD COVER PLATE 505467 1...

Page 9: ...397 4 WRIST PIN NEEDLE BEARING 505403 5 CRANKSHAFT BUSHING X 509487 KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 CRANKSHAFT RETAINER SEAL 540139 2 CRANKCASE SEAL RETAINER 505423 3 WASHER...

Page 10: ...notice P N 550416 REV06012011 660GC SERVICE MANUAL 9 4 SPARE PARTS DIAGRAM KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 CYLINDER TO MUFFLER GASKET 505385 2 MUFFLER 537692 3 MUFFLER SCREW...

Page 11: ...ASHER 73897 3 OUTER INTAKE MANIFOLD 507427 4 OUTER INTAKE MANIFOLD FLANGE SCREW 4 9 43 X 73901 5 OUTER INTAKE MANIFOLD FLANGE 505384 6 COMPENSATOR TUBE 505382 7 CARBURETOR SPRING 73888 8 CARBURETOR WA...

Page 12: ...CREW 4 0 35 505658 9 REAR HANDLE SHOCK ABSORBER 505425 10 BUMPER SHOCK ABSORBER FUEL TANK TOP 73270 11 FUEL TANK 548391 12 FRONT HANDLE BOLT 7 8 69 X 73983 13 FRONT HANDLE 548483 14 WASHER 73897 15 SC...

Page 13: ...N 550416 REV06012011 660GC SERVICE MANUAL 12 4 SPARE PARTS DIAGRAM KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 FLYWHEEL SHROUD 548514 2 FLYWHEEL 548515 3 NUT 24 5 217 73891 4 WASHER 73...

Page 14: ...R Nm in lbs 242 1 IGNITION TOGGLE SWITCH NUT 73239 2 IGNITION TOGGLE PLATE ON OFF 73238 3 IGNITION TOGGLE SWITCH 73237 4 TOGGLE SWITCH CONNECTING PLATE 71449 5 IGNITION TOGGLE CABLE 73919 6 SCREW 2 9...

Page 15: ...42 1 SCREW 6 8 60 73230 2 STARTER ROPE HANDLE 505514 3 STARTER ROPE 508854 4 STARTER ASSEMBLY 537666 5 STARTER CASE PLATE 71451 6 RECOIL HOUSING SCREW 505380 7 STARTER PULLEY WASHER 73905 8 STARTER AS...

Page 16: ...LY WITH 3 SCREWS 537661 4 AIR FILTER FLANGE 71758 5 AIR FILTER CANISTER POLYESTER 71752 6 PREFILTER PLASTIC SECONDARY FILTER 73336 7 WASHER 73897 8 CYLINDER COVER SCREW 4 0 35 X 505429 9 FILTER SUPPOR...

Page 17: ...N TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 WATER HOSE GASKET 71469 2 FITTING 71467 3 RING NUT 71457 4 WATER HOSE O RING 71468 5 WATER SHUT OFF VALVE 71458 6 FITTING 71466 7 FITTING 71454 8 HOSE CLAM...

Page 18: ...FRONT 505491 3 GUARD FLAP 505492 NUT 5 GUARD FLAP MOUNTING BRACKET BACK 505490 6 GUARD FLAP NUT 505468 7 BOLT 73983 8 RUBBER BUMPER COVER 73310 9 SIDE COVER GASKET 505417 10 MOUNTING NUT 509852 11 RU...

Page 19: ...subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 18 4 SPARE PARTS DIAGRAM KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 CARBURETOR REPAIR KIT 548394 2 CARBURET...

Page 20: ...rs the disassembly inspection and assembly of the 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 Replac...

Page 21: ...tice P N 550416 REV06012011 660GC SERVICE MANUAL 20 5 AIR INTAKE 5 6 Secure air filter mount screws 3 using Loctite 242 5 4 Inspect air filter cover gasket A Replace if permanently depressed or hard d...

Page 22: ...ection covers the removal inspection and installation of the spark plug 6 1 Remove the spark boot taking care not to pry or damage the wire 6 2 Clean area around the spark plug to prevent debris from...

Page 23: ...REV06012011 660GC SERVICE MANUAL 22 6 SPARK PLUG 6 6 Assemble in the reverse order A Make sure the plug boot is seated completely 6 5 Gap if necessary to 0 02 0 5 mm NOTE If the spark plug must be rep...

Page 24: ...ection covers clutch removal rim 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 stop...

Page 25: ...to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 24 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...

Page 26: ...P N 550416 REV06012011 660GC SERVICE MANUAL 25 7 CLUTCH RIM SPROCKET 7 7 Assemble clutch A Insert top edge of clutch shoe over spring as shown 7 8 Snap clutch shoe into place 7 9 Inspect the rim sproc...

Page 27: ...E MANUAL 26 7 CLUTCH RIM SPROCKET 7 10 Clean and assemble A Clean all parts in solvent B Grease needle bearing ICS P N 505378 with a waterproof grease C Assemble clutch spacer washer bearing clutch cu...

Page 28: ...of the starter rope and replacement of the recoil spring 8 1 Remove starter cover screws 4 8 2 Remove starter cover assembly from saw 8 3 Remove starter cord shield screws 8 4 Relieve spring tension A...

Page 29: ...28 8 STARTER 8 6 Remove starter pulley A Remove pulley screw 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 Careful...

Page 30: ...eplace if worn or broken 8 11 Install starter rope and tie knot 8 12 Knot tying instructions A Make a loop at the end of the pulley rope with the end of the rope crossing on top of the tail B Bring th...

Page 31: ...d rope onto pulley clockwise leaving 4 6 10 25 cm out B Make sure that the pulley spring catch is in the spring hook 8 14 Install center screw A Use Loctite 242 B Torque to 26 in lbs 2 9 Nm 8 15 Wind...

Page 32: ...equired to remove the starter pawl screws 8 18 Inspect and clean pawl components A Inspect the components Replace if necessary B Clean the components with a brush and solvent 8 19 Assemble components...

Page 33: ...ount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 32 8 STARTER 8 21 Install starter cover screws 4 A Use Loctite 242 B Torque to 60 i...

Page 34: ...6 REV06012011 660GC SERVICE MANUAL 33 9 WALLWALKER 9 This section covers the removal inspection and assembly of the rubber padded WallWalker and guard flap 9 1 Inspect bumpers A Replace if worn 9 2 Re...

Page 35: ...012011 660GC SERVICE MANUAL 34 9 WALLWALKER 9 5 Remove and inspect guard flap A Replace the flap if it is torn or damaged in any way 9 6 Remove guard flap screws and washers 9 7 Reassemble in the reve...

Page 36: ...10 1 Remove the air filter mount screws NOTE May require heat to remove screws 10 2 Remove the cylinder cover screws 3 10 3 Remove spark plug boot from cylinder cover taking care not to pry or damage...

Page 37: ...notice P N 550416 REV06012011 660GC SERVICE MANUAL 36 10 CYLINDER COVER 10 7 Remove stop switch leads 10 8 Inspect cylinder cover for damage A Replace if necessary 10 9 Check filter cover gasket A Rep...

Page 38: ...10 12 Make sure carburetor screw boot is in place 10 13 Install cylinder cover A Pull spark plug lead into slot in cylinder cover B Lubricate compensating tube 1 and fuel tank breather tube 2 with so...

Page 39: ...linder cover screws Use Loctite 242 Torque to 35 in lbs 4 0 Nm 10 14 Install air filter mount A Guide carburetor compensating tube through air filter mount Make sure manifold sits flat over lip on cyl...

Page 40: ...section covers the disassembly inspection and assembly of the muffler Removal of the bumpers and cylinder cover is necessary Refer to sections 9 and 10 if necessary 11 1 Remove muffler support screws...

Page 41: ...Install muffler Insert muffler screws 2 into muffler Hold muffler screws in place with heat shield gasket Thread muffler screws into cylinder with Loctite 242 Torque to 78 in lbs 8 8 Nm 11 5 Install b...

Page 42: ...11 if necessary Carburetor tuning is covered in section 22 12 1 Remove throttle linkage A Push trigger end out of rear handle B Pivot linkage around C Remove carburetor end of linkage from throttle r...

Page 43: ...1 660GC SERVICE MANUAL 42 12 4 Remove carburetor A Remove pulse tube B Remove carburetor jet cover C Remove carburetor from choke linkage 12 5 Assemble in the reverse order A Torque carburetor body sc...

Page 44: ...of several component groups is required Refer to sections 5 6 10 and 12 if necessary 13 1 Remove carburetor base screws 3 A Remove carburetor base bracket from rear manifold B Remove carburetor base...

Page 45: ...16 REV06012011 660GC SERVICE MANUAL 44 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 2 on front a...

Page 46: ...o change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 45 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...

Page 47: ...46 13 11 Assemble 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 ICS 2 stroke engine oil 13 13...

Page 48: ...clip 13 16 Make sure wrist pin retaining clip is in the proper orientation Improper installation may result in serious engine damage NOTE Never attempt to reuse wrist pin retaining clips or substitut...

Page 49: ...t pin 13 18 Align piston in correct orientation A Make sure arrow points to exhaust port 13 19 Install piston A Oil piston with ICS 2 stroke oil B Align wrist pin with wrist pin bearing C Complete wri...

Page 50: ...ICS 2 stroke oil 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...

Page 51: ...o cylinder intake C Align mold seams of intake boot with casting seams of the cylinder 13 24 Install rear manifold clamp A Torque to 11 in lbs 1 Nm NOTE Insure that the intake boot is properly install...

Page 52: ...UAL 51 13 27 Install 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 L...

Page 53: ...14 This section covers water hose and side cover 14 1 Inspect water hose and side cover A Replace if damaged 14 2 Assemble in reverse order 14 3 Remove water hose connector from side cover A Remove cl...

Page 54: ...tallation 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 a...

Page 55: ...el B Set ignition coil in place C Install ignition coil screws wave washers and plain washers with Loctite 242 Holding shim rotate flywheel magnet around to coil E Torque ignition coil screws to 26 in...

Page 56: ...al inspection and installation of the flywheel Removal of spark plug and the starter is required Refer to sections 6 and 8 if necessary 16 1 Insert piston stop 16 2 Remove flywheel nut wave washer and...

Page 57: ...nterweight 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 Inspect cast...

Page 58: ...57 17 This section covers the removal inspection and installation of the front handle 17 1 Remove front handle screws 2 on right side 17 2 Remove front handle screws 2 on bottom 17 3 Install front han...

Page 59: ...0GC SERVICE MANUAL 58 18 This section covers the disassembly inspection and assembly of the vibration isolaters fuel tank and rear handle 18 1 Remove vibration isolator screws 2 and wave washers on cl...

Page 60: ...rubber water deflector connected to the front vibration isolator on the clutch side circled 18 4 Remove vibration isolators 4 from fuel tank if necessary NOTE Shock absorber tool p n 71546 must be us...

Page 61: ...t notice P N 550416 REV06012011 660GC SERVICE MANUAL 60 19 This section covers the disassembly inspection and assembly of the crankcase seals and crankshaft bearings 19 1 Remove outer crankshaft seal...

Page 62: ...de crankcase with heat gun for 5 minutes approximately 150 F 65 5 C 19 4 Remove the flywheel side crankcase tap crankshaft with plastic mallet A Suspend above work surface B Tap with mallet NOTE A nut...

Page 63: ...MANUAL 62 19 6 Disassembly of crankcase Heat the clutch side crankcase with heat gun to 150 F 65 5 C 19 7 Remove crankshaft from the clutch side crankcase tap crankshaft with a plastic mallet A Suspe...

Page 64: ...011 660GC SERVICE MANUAL 63 19 9 Remove the bearing seal and bushing from the clutch side of crankshaft 19 10 Assembly of crankcase A Clean mating crankcase faces 19 11 Heat crankcase halves to 150 F...

Page 65: ...o change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 64 19 14 Repeat with other half 19 15 Install crankshaft into clutch side of case 19 16 Place clutch side crankcase seal on cranksha...

Page 66: ...change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 65 19 17 Coat crankcase gasket with ICS 2 stroke engine oil 19 18 Align crankcase gasket on flywheel side crankcase pins 19 19 Place c...

Page 67: ...P N 550416 REV06012011 660GC SERVICE MANUAL 66 19 20 Assemble crankcase halves tap with bearing driver and mallet 19 21 Install crankcase bolts 5 A Use Loctite 242 B Torque to 70 in lbs 7 9 Nm 19 22...

Page 68: ...icing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 67 19 23 Assemble in reverse order A Install outer crankshaft seal housing with 3 bolts and use Loctite 242 19 24...

Page 69: ...ers the removal and installation of the bar studs and bar pad 20 1 On 660GC saws NOTE This requires the removal of the piston and cylinder and to split the crankcase Refer to section 13 19 for detaile...

Page 70: ...vers the removal and installation of the chain tensioner 21 1 Remove bar plate to expose the chain tensioner 21 2 Unscrew tensioner to remove A Remove tensioner pin B Remove tensioner screw keeper 21...

Page 71: ...Use the tuning instructions in this manual to adjust carburetor to factory recommended settings DO NOT adjust the carburetor for maximum rpm Adjusting the carburetor for maximum rpm will cause engine...

Page 72: ...ter the cylinder cover and screw boot have been removed Observe orientation of the release slots on the adjustment screw limiter cap See section 10 for cylinder cover removal B Insert the limiter cap...

Page 73: ...rpm B If the idle rpm does not fall into this range adjust the T screw clockwise to raise RPM counterclockwise to lower RPM 22 3 Using a 5 64 straight blade screwdriver gently turn the adjustment scre...

Page 74: ...G 22 7 With a tachometer check the saw full throttle rpm with a bar and no chain A Target 12 500 500 rpm 22 8 If the full throttle rpm falls below this range turn the H screw in clockwise 1 16th of a...

Page 75: ...SERVICE MANUAL 74 23 This section covers idle speed adjustment 23 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...

Page 76: ...d chain moves at idle 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 R...

Page 77: ...uel 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 and or improper fuel...

Page 78: ...system The five main components are the fuel tank fuel tank breather fuel filter delivery tubes and carburetor 25 1 Remove and inspect the fuel filter A Replace the fuel filter if there is any foreign...

Page 79: ...e carburetor Refer to the Walbro Diaphragm Carburetor Service Manual 25 3 The fuel tank breather stabilizes the pressure in the fuel tank preventing both excessive pressure which could flood the engin...

Page 80: ...f the pressure does not reduce to 0 psi disassemble or replace the breather A Disassemble by snapping off cap B Clean parts with solvent or fuel 25 7 Assemble in reverse order A Make sure duck bill op...

Page 81: ...ine not to run 26 1 Install the intake seal flange A Plug cylinder pulse tube 26 2 Install the exhaust seal flange 26 3 Block one of the flange tubes with a rubber plug 26 4 Install the pressure gauge...

Page 82: ...0GC SERVICE MANUAL 81 1 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...

Page 83: ...nc Specifications and pricing are subject to change without notice P N 550416 REV06012011 ICS Blount Inc 4909 SE International Way Portland OR 97222 Tel 800 321 1240 Fax 503 653 4393 icsbestway com 66...

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