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© 2017 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 598000 REV072717

68

680ES SERVICE MANUAL

21. BAR STUDS & BAR PAD

21.1

Remove bar studs.

A.  Remove side cover. 
B.  Install side cover nuts, flange to flange 
and tighten together. 
C.  Attempt to remove the inside nut which 
should pull out the bar stud. 
D.  Repeat on the second bar stud.

21.2

Remove bar pad.

A.  Remove sealing o-ring.

21.3

Assemble in reverse order.

21.  This section covers the removal and installation of the bar studs 
and bar pad.

Summary of Contents for 680ES

Page 1: ... 2017 ICS Blount Inc Specifications and pricing are subject to change without notice P N 598000 REV072717 1 680ES SERVICE MANUAL ...

Page 2: ...KE 21 6 SPARK PLUG 22 7 CLUTCH RIM SPROCKET 24 8 STARTER SYSTEM 28 9 WALLWALKER 29 10 CYLINDER COVER 35 11 MUFFLER 38 12 CARBURETOR 40 13 CYLINDER PISTON 42 14 WATER HOSE CAP 51 15 IGNITION COIL 53 16 FLYWHEEL 55 17 BOTTOM GUARD 57 18 FRONT HANDLE 58 19 FUEL TANK 59 20 CRANKCASE 61 21 BAR STUDS BAR PAD 68 22 CHAIN TENSIONER 69 23 CARBURETOR TUNING 70 24 IDLE SPEED ADJUSTMENT 73 25 DIAGRAMS 74 26 F...

Page 3: ...aged Use a plastic dead blow 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 reassembling clean all parts carefully lubricate moving parts and replace all oil seals o rings gaskets washers and self locking nuts For best results use only original ICS ...

Page 4: ... 2017 ICS Blount Inc Specifications and pricing are subject to change without notice P N 598000 REV072717 4 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 5: ... 71544 Manifold Assembly Tool 6 71546 Shock Absorber Tool 7 71547 Spark Tester 8 71548 Flywheel Disassembly Tool 9 71565 Electronic Tachometer 10 71569 Induction Seal Flange with Screws 11 71570 Exhaust Seal Flange with Screws 12 71573 Tuning Screwdriver 13 73461 Flywheel Puller 14 73462 Main Bearing Driver Tool 15 571227 2 Stroke Oil 50 1 Mix 2 6 oz 77 ml 6 Pack 15 571228 2 Stroke Oil 50 1 Mix 2 ...

Page 6: ... and water resistant Ignition Special water resistant electronic ignition Clutch Centrifugal three shoe single spring Fuel ratio 2 50 1 gasoline to oil Fuel Capacity 0 88 liter 0 23 gallon Water Supply Requirement Minimum 1 5 bar 20 psi Water Flow Requirement Minimum 4 lpm 1 gpm Guaranteed Sound Power Level Lwa 1 117 dB A Kwa 3 0 dB A Equivalent Sound Pressure at the Operator s Ear LpA 1 101 0 dB ...

Page 7: ...2017 ICS Blount Inc Specifications and pricing are subject to change without notice P N 598000 REV072717 680ES SERVICE MANUAL 3 SERIAL LOCATION 3 This section shows the two locations of the serial number ...

Page 8: ...8 Starter Rope Handle A3 73904 Starter Rope A4 531103 Starter Coil Spring Housing A5 71451 Starter Case Plate A6 505380 Recoil Housing Screw A7 528661 Starter Rope Pulley A8 73905 Starter Pulley Washer A9 73907 Starter Pulley Screw A10 528637 Starter Cover Assembly A11 530367 Starter Assembly Washer A12 532026 Spring Housing Washer A13 508853 Starter Assembly Cap A1 A2 A3 A4 A12 A13 A8 A7 A11 A6 A...

Page 9: ...2717 680ES SERVICE MANUAL 4 SPARE PARTS DIAGRAM Key Part No Description B31 531109 Flange starter pulley 680 B45 528651 Flywheel 680 B48 73891 Nut M8x1 B51 73911 Washer B57 73912 Washer B71 509163 Starter Pawl Assembly Not Shown 71734 Gasket Set B48 B31 B57 B51 45 B71 Flywheel and Starter Pawl Assembly ...

Page 10: ... 680ES SERVICE MANUAL Key Part No Description C20 576463 Ground Cable 680ES C21 73914 Screw m4x20 C22 73285 Wave Washer 4 5mm C23 73890 Washer C24 73241 Spark Plug cap and spring kit C25 73917 Spark Plug Spring C26 576437 Ignition Coil 680ES C21 C26 C25 C24 C23 C22 C20 Ignition Assembly 4 SPARE PARTS DIAGRAM ...

Page 11: ... D8 577754 Carburetor Walbro WJ 136 680ES D9 517547 Screw Guide D10 576462 Multifunction Actuator for 680ES D11 73866 Screw D12 576435 Carburetor Support Bracket for 680ES D13 73868 Intake Manifold D14 545870 Intake Manifold Clamp D15 514770 Spark Plug D16 73874 Cylinder Bolt washer D17 545874 Gasket Base D18 548084 Complete Piston Cylinder Assembly D19 73869 Wrist Pin Needle Bearing D20 577630 Sc...

Page 12: ...P N 598000 REV072717 12 680ES SERVICE MANUAL Key Part No Description E1 545875 Cylinder to Muffler Gasket E2 545872 Muffler Assembly E3 73327 Washer serrated E4 73883 Muffler Mounting Screw E5 73866 Screw starter cover lower muffler E1 E2 E3 E4 E5 Muffler Assembly 4 SPARE PARTS DIAGRAM ...

Page 13: ...598000 REV072717 680ES SERVICE MANUAL Crankshaft Assembly Key Part No Description F1 73877 Crankshaft Seal Flywheel Side F2 73878 Crankshaft Flywheel Woodruff Key F3 71410 Crankshaft Assembly F4 73209 Crankshaft Seal Clutch Side F5 71452 Crankshaft Bushing F1 F2 F3 F4 F5 4 SPARE PARTS DIAGRAM ...

Page 14: ...ter Crankcase Seal Body G3 73940 Pump Body Bolt G4 73285 Wave Washer 4 5 mm G5 73945 Clutch Spacer Washer G6 70949 680 695 Drive Sprocket G6 525496 680PG Drive Sprocket G7 73939 Clutch Needle Bearing G8 71520 Clutch Cup includes p n 73939 G9 73941 Clutch Spacer Washer Inside G10 71419 Clutch Assembly G11 73943 Clutch Spring G1 G9 G8 G6 G7 G5 G4 G3 G2 G11 G10 Clutch Assembly 4 SPARE PARTS DIAGRAM ...

Page 15: ...ft Bearing H5 545968 Crankcase Gasket H6 531107 Crankcase Grommet Right Side H7 73897 Washer H8 73930 Crankcase Bolt m5x22 H9 528657 Chain Guard 680 H10 73397 Cover Guard Mounting Bolt H11 73379 Screw H12 73933 Bar Mounting Stud H13 71740 Bar Mount Pad Spacer H14 71738 Bar Mount Pad Cover Plate H15 73935 Premium Tensioner Kit H16 73936 Tensioner Screw Retainer H1 H11 H7 H16 H15 H13 H14 H12 H10 H7 ...

Page 16: ...12 73980 Shock Absorber I13 71588 Clip Fuel Filter I14 73375 Fuel Line I15 73270 Bumper Shock Absorber Fuel Tank Top I16 73983 Front Handle Bolt I17 545971 Front Handle I18 71748 Fuel Breather Complete I19 71766 Water Deflector Bottom I20 71751 Breather Tube Body I21 71759 Breather Tube Elbow I22 71761 Fuel Breather Remote I23 71777 Breather Tube Extension I24 71760 Tube Clamp I25 581117 Plug Fuel...

Page 17: ...1756 Filter Cover Gasket J7 71771 Screw Cylinder Cover Long Socket Head J8 73336 Internal Screen J9 71758 Air Filter Mount Screw J10 73337 Filter Support Screw J11 73335 Filter Canister Gasket J12 71472 O Ring J13 71760 Tube Clamp J14 505382 Compensator Tube J15 576459 Screw Torx T27 J16 577628 Throttle rod assembly for 680ES J17 576461 Support Bushing Multifunction lever J18 73897 Washer J19 5764...

Page 18: ...O Ring K13 71458 Water Shut Off Valve K14 71454 Barb Fitting 1 4 male thread K15 71455 Tube K16 71465 Hose Clamp K17 71461 Hose Hanger K18 71464 Water Hose Cover K19 71463 Water Hose Screw K20 71453 Fitting K21 71456 Copper Washer K22 73923 Water Tank Cap K23 73448 Fuel Cap O Ring K24 71459 Tube K25 71470 Fitting K26 71471 Fitting K27 71472 O Ring K20 K13 K16 K17 K16 K18 K15 K14 K9 K12 K27 K25 K26...

Page 19: ... Side Cover Insert Top L2 73958 Side Cover Nut L3 71462 Chain Cover Cap L4 73367 Nut L5 71533 WallWalker Side Arm L6 73951 Lock Washer L7 507355 WallWalker Side Arm Screw L8 71487 Screw L9 71447 Side Cover Plate L10 73957 Lower Guard L11 73972 Deflector Lower L12 73948 Deflector Upper L13 73310 Rubber Bumper Cover L14 528659 Side Cover Assembly Complete WallWalker Water Delivery System 4 SPARE PAR...

Page 20: ...072717 20 680ES SERVICE MANUAL Key Part No Description M1 577754 Carburetor Walbro WJ 136 M2 73996 Carburetor Repair Kit M3 577633 Needle Screw High 680ES Carburetor M4 577635 Limiter Cap M5 577634 Needle Screw Low 680ES Carburetor M2 M2 M2 2 M2 M4 M5 M3 M1 CARBURETOR REPAIR KIT 4 SPARE PARTS DIAGRAM ...

Page 21: ...P N 598000 REV072717 680ES SERVICE MANUAL 5 4 Inspect air filter cover gasket A Replace if permanently depressed or hard due to slurry 5 5 Inspect filter canister gasket A Clean B Replace if necessary 5 6 Check air filter mount screws and lightly secure them if they are loose 5 AIR INTAKE ...

Page 22: ...2717 22 680ES SERVICE MANUAL 6 1 Remove spark plug cap and spring spring is located inside of the cap 6 2 Loosen and remove the spark plug 6 3 Inspect spark plug for damage or corrosion Clean with a wire brush 6 This section covers the removal inspection and installation of the spark plug 6 SPARK PLUG ...

Page 23: ...EV072717 680ES SERVICE MANUAL 6 4 Gap if necessary to 0 02 0 5mm NOTE If the spark plug must be replaced refer to the spark plug reference guide at the end of this manual to select the correct replacement plug 6 5 Assemble in the reverse order Make sure the plug boot is seated completely 6 SPARK PLUG ...

Page 24: ...park plug hole 7 2 Pull starter handle until piston stops against tool 7 This section covers clutch removal rim sprocket removal inspection and assembly Refer to sections 5 and 6 if needed 7 3 Remove clutch Left hand threads rotate clockwise to loosen NOTE If an impact wrench is available steps 7 1 and 7 2 do not need to be performed CAUTION 7 CLUTCH RIM SPROCKET ...

Page 25: ...ect to change without notice P N 598000 REV072717 680ES SERVICE MANUAL 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 6 Inspect spring for cracks 7 CLUTCH RIM SPROCKET ...

Page 26: ...thout notice P N 598000 REV072717 26 680ES SERVICE MANUAL 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 teeth are worn to points as shown on right ...

Page 27: ...ERVICE MANUAL 7 10 Clean and Assemble A Clean all parts in solvent B Grease clutch cup bearing with a waterproof grease C Assemble clutch spacer washer bearing clutch cup with rim sprocket and inside clutch spacer washer 7 11 Install clutch Torque to 295 in lbs 33 3 Nm CAUTION Left hand threads 7 CLUTCH RIM SPROCKET ...

Page 28: ...ter 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 pulley C Slowly rotate pulley counter clockwise until spring pressure is released Use thumb as brake 8 5 Remove starter pulley screw and washer NOTE Hold starter cover firmly 8 This section covers the removal of the starter cover replacement of the starter rope and repl...

Page 29: ...ICE MANUAL e and 8 STARTER 8 6 Remove starter pulley 8 7 Inspect coil spring A Replace if spring hook is damaged Attemping to re bend the spring hook may cause the hook to break off B Carefully remove coil spring and housing to prevent spring from unwinding 8 8 Lubricate with lightweight oil 8 9 Replace parts carefully ...

Page 30: ...t pulley spring catch 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 10 15 cm out B Make sure that the pulley spring catch is in the spring hook 8 13 Install center screw spacer and washer A Use Loctite 242 B Torque to 26 in lbs 2 9 Nm ...

Page 31: ...h 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 NOTE Piston stop tool may be required to remove the starter pawl screws 8 17 Inspect and clean pawl components A Inspect the components Replace if necessary B Clean the components with a brush and solvent ...

Page 32: ...R 8 18 Assemble components A Make sure the spring is in the correct position B Use Loctite 242 on the pawl screws C Torque to 60 in lbs 6 8 Nm 8 19 Install starter cover A Pull out cord 4 6 10 15cm B Slowly release while placing cover to allow pawls to engage 8 20 Install starter cover screws A Use Loctite 242 B Torque to 60 in lbs 6 8 Nm ...

Page 33: ...L 9 1 Inspect WallWalker tip A If the tip is worn as shown replace 9 2 Remove bar mount pad 9 This section covers the removal inspection and assembly of the WallWalker and guard flap 9 WALLWALKER 9 3 Remove crankcase screws and wave washers Remove WallWalker from the power cutter Install new WallWalker Assemble in reverse order ...

Page 34: ...072717 34 680ES SERVICE MANUAL 9 4 Remove guard flap screws and washers 9 5 Remove and inspect guard flap A Replace the flap if it is torn or damaged in any way 9 6 Reassemble in the reverse order A Install guard flap screws and washers B Use blue Loctite 242 C Torque to 43 in lbs 4 8 Nm 9 WALLWALKER ...

Page 35: ...e fuel tank breather cap and clamp 10 This section covers the disassembly and assembly of the cylinder cover Removal of the air intake components and front handle is necessary Refer to sections 1 and 14 if needed 10 5 Partially remove intake manifold from cylinder cover 10 6 Remove cylinder cover A Pull up on front B Push intake manifold through hole C Make sure throttle linkage is disengaged from...

Page 36: ...er cover 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 tank breather tube with soapy water guide through cylinder cover install compensating tube first NOTE Be careful as to not pull tubes away from their point of connection Approximately 3 4 2 cm of tu...

Page 37: ...fold into cylinder cover D Install the cylinder cover screws Use Loctite 242 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 filter mount Make sure manifold sits flat over lip on cylinder cover B Install air filter mount screws 3 using Loctite 242 C Torque to 43 in lbs 4 9 Nm 10 15 Install air filters...

Page 38: ... 11 1 Remove muffler support screws 11 2 Remove muffler screws located inside the muffler 11 3 Remove muffler and heat shield gasket A Replace any damaged components 11 This section covers the disassembly inspection and assembly of the muffler Removal of the WallWalker and cylinder cover is necessary Refer to sections 7 and 10 if necessary ...

Page 39: ...l muffler A Insert muffler screws 2 into muffler B Hold muffler screws in place with heat shield gasket C Thread muffler screws into cylinder with Loctite 242 Torque to 78 in lbs 8 8 Nm 11 5 Install bottom 2 muffler support screws with Loctite 242 A Torque top screws to 78 in lbs 8 8 Nm B Torque bottom screws to 52 in lbs 5 8 Nm 11 MUFFLER ...

Page 40: ... components and cylinder cover is required Please refer to section 5 10 or 11 if necessary Carburetor tuning is covered in section 23 12 1 Remove throttle rod assembly A Pull the trigger to push the rod assembly out of the handle NOTE All 680ES power cutters are equipped with carburetor model WJ 136 12 2 Remove carburetor support screw 1 with Torx or straight blade screwdriver 12 2a Remove carbure...

Page 41: ... from carburetor 12 6 Remove carburetor compensator tube on top of carburetor 12 7 Assemble in the reverse order A Torque carburetor body screws to 43 in lbs 4 9 Nm B Torque supporter screw with blue Loctite to 43 in lbs 4 9 Nm 12 2b Remove air intake boot 12 2c Remove groundwire B C fuel line pulse tube Note If installing a new carburetor it must be tuned to factory specifications carburetors are...

Page 42: ...r base while holding carburetor base B Remove carburetor base from pulse tube 13 This section covers the removal inspection 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 NOTE When replacing the 680ES cylinder and piston it is necessary to tune the carburetor prior to returning the power cutter...

Page 43: ... REV072717 680ES SERVICE MANUAL 13 6 Remove cylinder screws 4 and wave washers 13 4 Remove rear manifold clamp 13 5 Remove rear manifold from cylinder A Inspect for holes and tears in the manifold replace if damaged 13 3 Remove pulse tube and protective spring from cylinder base 13 CYLINDER PISTON ...

Page 44: ... P N 598000 REV072717 44 680ES SERVICE MANUAL 13 CYLINDER PISTON 13 9 Press wrist pin out with an 8mm deep socket 13 10 Remove piston and inspect Replace if damaged 13 8 Remove wrist pin retaining clips 2 13 7 Remove cylinder A Remove cylinder gasket and clean crankcase mating surface ...

Page 45: ... notice P N 598000 REV072717 680ES SERVICE MANUAL 13 CYLINDER PISTON 13 13 Install wrist pin bearing in rod A Oil bearing with ICS 2 stroke engine oil 13 12 Cylinder gasket A Oil gasket with ICS 2 stroke engine oil B Install and align holes and notch 13 11 Remove wrist pin bearing ...

Page 46: ...ange without notice P N 598000 REV072717 46 680ES SERVICE MANUAL 13 CYLINDER PISTON 13 16 Install 1 wrist pin retaining clip 13 15 Ring orientation 13 14 Install rings Install bottom ring first Installing the bottom ring over the top ring may cause the ring to break ...

Page 47: ...tice P N 598000 REV072717 680ES SERVICE MANUAL 13 CYLINDER PISTON 13 19 Align piston in correct orientation 13 18 Partially install wrist pin EXHAUST INTAKE 13 17 Make sure wrist pin retaining clip is in the proper orientation Improper installation may result in serious engine damage ...

Page 48: ...C Align cylinder bolt holes with crankcase 13 21 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 compression tool down 13 20 A Oil piston with ICS 2 stroke oil B Align wrist pin with wrist pin bearing C Complete wrist pin installation D Install second wrist pin retaining clip Make sure wrist pin ...

Page 49: ...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 25Install rear manifold clamp A Torque to 11 in lbs 1 2 Nm Do not over tighten damage to rear manifold may cause engine damage 13 23 Install 4 cylinder screws and washers A Use Loctite 242 B Torque bolts to 95 in lbs 10 7 Nm ...

Page 50: ...nto pulse tube 13 28 Install carburetor base screws A Use Loctite 242 on 3 screws without ground wire B Make sure to include stop switch wire installed on left rear screw C Torque to 35 in lbs 4 Nm 13 28 Install carburetor base A Slip pulse tube into and through carburetor base B Ensure bullet clip wire seats under the carburetor bracket C Slip rear manifold into and through carburetor base D Make...

Page 51: ... change without notice P N 598000 REV072717 680ES SERVICE MANUAL 14 WATER HOSE 14 4 Remove water hose connector 14 1 Loosen hose clamp screw 14 2 Remove water connection from hose 14 3 Remove hose from hose hanger 14 This section covers water hose and water tank cap ...

Page 52: ...thout notice P N 598000 REV072717 52 680ES SERVICE MANUAL 14 6 Release water tank cap from water tank tube A Depress orange fitting as shown to release water tank tube 14 7 Assemble in reverse order 14 5 Unscrew water tank cap from the power cutter 7 8 wrench 14 WATER HOSE ...

Page 53: ... coil screws wave washers and plain washers 15 3 Remove ignition coil 15 4 Inspect A Look for cracks missing insulation B Clean flywheel magnets and coil if rusty 15 1 Remove starter flywheel shroud by unhooking wires 15 This section covers the removal inspection and installation of the ignition coil Removal of the starter is required Refer to section 8 if necessary ...

Page 54: ...n coil in place C Install ignition coil screws wave washers and plain washers with Loctite 242 D Holding shim rotate flywheel magnet around to coil E Torque ignition coil screws to 26 in lbs 3 Nm F Remove shim rotate flywheel to check clearance 15 6 Install flywheel shroud 15 7 Route ignition stop switch wire through crankcase into carburetor chamber 15 8 Complete ignition wire routing 15 IGNITION...

Page 55: ... removal tool finger tight Unscrew tool 1 1 2 turns leaving approximately 1 8 inch 5 mm space between tool and flywheel 16 1 Insert piston stop 16 2 Remove flywheel nut wave washer and plain washer 16 This section covers the removal inspection and installation of the flywheel Removal of the starter and spark plug is requried Refer to sections 6 and 8 if necessary ...

Page 56: ...ng pliers hold power cutter up by magnet 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 Inspect woodruff key 16 8 Install flywheel plain washer wave washer and flywheel nut A Torque nut to 260 in lbs 29 3 Nm ...

Page 57: ...without notice P N 598000 REV072717 680ES SERVICE MANUAL 17 BOTTOM GUARD A Remove bottom guard screws and split washers B Inspect bottom guard C Replace if damaged D Assemble in reverse order 17 This section covers the removal inspection and installation of the bottom guard ...

Page 58: ...AL 18 This section covers the removal inspection and installation of the front handle 18 FRONT HANDLE 18 1 Remove front handle screws on right side 18 3 Install front handle A Roll front handle into place B Install front handle screws 4 C Use Loctite 242 D Torque to 69 in lbs 7 8 Nm 18 2 Remove front handle screws on bottom A B ...

Page 59: ...CE MANUAL 19 FUEL TANK 19 This section covers the disassembly inspection and assembly of the vibration isolators fuel tank and rear handle 19 1 Remove vibration isolator screws and wave washers on clutch side of the power cutter 19 2 Remove vibration isolator screws and wave washers on flywheel side of the power cutter ...

Page 60: ...nk NOTE Power Cutters have a rubber water deflector connected to the 2 bottom vibration isolators on the clutch side circled 19 5 Assemble in reverse order NOTE During assembly be careful to avoid kinking the fuel line 19 4 Remove vibration isolators from fuel tank 6 if necessary Shock absorber tool p n 71546 should be used for removal and installation 19 FUEL TANK ...

Page 61: ...RVICE MANUAL 20 CRANKCASE 20 This section covers the removal inspection and assembly of the crankcase seals and crankshaft bearings 20 1 Remove outer crankshaft seal housing screws and wave washers 20 2 Remove crankcase bolts 20 3 Heat the flywheel side crankcase with heat gun for 5 minutes approximately 150 F 65 5 C ...

Page 62: ...E 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 placed on a threaded shaft when pounding or pressing on it 20 6 Heat the clutch side crankcase with heat gun to 150 F 65 5 C 20 5 Remove the flywheel side crankcase seal with 1 2 13 mm socket ...

Page 63: ...ES SERVICE MANUAL 20 7 Remove crankshaft from the clutch side crankcase tap crankshaft with a plastic mallet A Suspend above work surface B Tap with plastic mallet 20 8 Remove the bearing from the flywheel side of crankshaft 20 9 Remove the bearing seal and bushing from the clutch side of crankshaft 20 CRANKCASE ...

Page 64: ...ge without notice P N 598000 REV072717 64 680ES SERVICE MANUAL 20 CRANKCASE 20 10 Clean mating crankcase faces 20 11 Heat crankcase halves to 150 F 65 5 C 20 14 Repeat with other half 20 12 Install bearing into crankcase halves 20 13 Tap with bearing driver and mallet ...

Page 65: ...without notice P N 598000 REV072717 680ES SERVICE MANUAL 20 CRANKCASE 20 15 Install crankshaft into clutch side of case 20 16 Place clutch side crankcase seal on crankshaft A Tap lightly with bearing driver and mallet 20 17 Coat crankcase gasket with ICS 2 stroke engine oil ...

Page 66: ...nge without notice P N 598000 REV072717 66 680ES SERVICE MANUAL 20 CRANKCASE 20 18 Align crankcase gasket on flywheel side crankcase pins 20 20 Assemble crankcase halves tap with bearing driver and mallet 20 19 Place crankcase halves together and align crankcase pins ...

Page 67: ... SERVICE MANUAL 20 CRANKCASE 20 21 Install main crankcase bolts A Use Loctite 242 B Torque to 69 in lbs 7 8 Nm NOTE The 3 remaining crankcase bolts will be installed during the completion of the assembly 20 22 Install flywheel side crankcase seal tap with bearing driver and mallet 20 23 Trim crankcase gasket flush ...

Page 68: ...Remove bar studs A Remove side cover B Install side cover nuts flange to flange and tighten together C Attempt to remove the inside nut which should pull out the bar stud D Repeat on the second bar stud 21 2 Remove bar pad A Remove sealing o ring 21 3 Assemble in reverse order 21 This section covers the removal and installation of the bar studs and bar pad ...

Page 69: ...0 REV072717 680ES SERVICE MANUAL 22 CHAIN TENSIONER 22 This section covers the removal and installation of the chain tensioner 22 1 Remove bar plate to expose the chain tensioner 22 3 Assemble in reverse order 22 2 Unscrew tensioner to remove A Remove tensioner pin B Remove tensioner screw keeper ...

Page 70: ...se II emissions standards However minor adjustments may be required in certain conditions such as high elevation NOTES These power cutters are equipped with an electronic speed limiter as part of the ignition system This will prevent the power cutter from going above 12 000 RPM Attempting to set the carburetor mixture to increase the speed or power beyond this limit may seriously damage the engine...

Page 71: ...aft while screwing in the puller screw until the screw head is against the puller shaft D Unscrew the puller screw 1 4 turn and pull straight out Repeat for second limiter cap Complete carburetor readjustment RPM settings for power cutters NOTE Power Cutters tuned without chain installed Idle Speed 3 000 200 rpm Full Throttle 11 500 500 rpm 23 3 Using a 5 64 straight blade screwdriver gently turn ...

Page 72: ... raise rpm counterclockwise to lower rpm 23 9 When the carburetor is adjusted correctly set the limiter caps securely onto the needle screws with a straight blade screwdriver 23 7 With a tachometer check the power cutter full throttle rpm with no bar and chain Target 11 500 500 rpm 23 8 If the full throttle falls below this range turn the H screw in clockwise 1 16th of a turn at a time A Pulse the...

Page 73: ...S SERVICE MANUAL 24 IDLE SPEED 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 out 1 2 turn 24 2 If chain turns at idle Back T screw out until chain stops moving ...

Page 74: ...gh Broken clutch spring Excessive vibration Damaged shock absorber Damaged or broken flywheel fins Bent crankshaft Replace shock absorbers Replace flywheel Replace crankshaft Adjust idle speed Replace clutch spring Inspect air intake boot Pressure test crankcase Replace carburetor Clean or replace the air filter Replace fuel filter See Carburetor Tuning section Repair or replace fuel tank breather...

Page 75: ...fuel of the correct mixture 50 1 Loose spark plug If below 125 psi excess wear on the piston cylinder rings and or improper fuel mixture Tighten plug and re test Replace piston and cylinder Ensure correct fuel oil mixture 50 1 Plug is soaked with fuel The plug is fouled or gapped improperly Plug is internally faulty or the wrong type Dry plug expel excess fuel from cylinder and crankcase Clean and...

Page 76: ...move and inspect the fuel filter A Replace the fuel filter if there is any foreign material in the felt or the internal screen 26 2 Test the main fuel pick up tube for leaks A Install the pressure gauge and bulb B Pressurize the tube to 7psi 0 5 bar C If the pressure does not maintain separate the fuel line from the carburetor D Plug one end of the main fuel pick up tube E Re pressureize the tube ...

Page 77: ...cated inside the air filter compartment 26 5 Testing the fuel tank breather A Attached the pressure gauge and bulb to the main 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 disassemble or replace the breather A Clean the parts with solvent or fuel B Ass...

Page 78: ...g 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 Pressurize the crankcase to 7psi 0 5 bar 27 6 If the pressure does not remain the same use soapy water to find the leak NOTE It is recommended that this test be performed after an engine rebuild 27 CRANKCASE LEAKS ...

Page 79: ... ICS Blount Inc Specifications and pricing are subject to change without notice P N 598000 REV072717 680ES SERVICE MANUAL Spark Plug Reference Guide ICS Part Number Champion NGK 514770 RCYJ4 BPMR8Y SPARK PLUG ...

Page 80: ...notice P N 598000 REV072717 80 ICS Blount Inc 4909 SE International Way Portland OR 97222 USA Tel 800 321 1240 Fax 503 653 4393 ICS Blount Europe S A Rue Emile Francqui 5 1435 Mont Saint Guibert Belgium Tel 32 10 301 251 Fax 32 10 301 259 icsdiamondtools com 680ES SERVICE MANUAL ...

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