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680GC SERVICE MANUAL

13. CYLINDER & PISTON

13.21

Install cylinder.

A. Remove ring compression tool.
B. Slide cylinder down piston and into
crankcase.
C. Align cylinder bolt holes with crankcase.

13.22

Install 4 cylinder screws and washers.

A. Use Loctite

242.

B. Torque bolts to 95 in-lbs. (10.7 Nm).

13.20

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.

Summary of Contents for 680GC

Page 1: ...i 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL...

Page 2: ...ET 29 8 STARTER SYSTEM 33 9 WALLWALKER 38 10 CYLINDER COVER 40 11 MUFFLER 43 12 CARBURETOR 47 13 CYLINDER PISTON 49 14 WATER HOSE CAP 58 15 IGNITION COIL 60 16 FLYWHEEL 62 17 BOTTOM GUARD 64 18 FRONT...

Page 3: ...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 appropri...

Page 4: ...ck Absorber Tool 7 71547 Spark Tester 8 71548 Flywheel Disassembly Tool 9 71550 Limiter Cap Puller 10 71565 Electronic Tachometer 11 71569 Induction Seal Flange with Screws 12 71570 Exhaust Seal Flang...

Page 5: ...ns 18 inches 46cm length 11 5 inches 29cm height 10 inches 25cm width Air Filter Water resistant polyester Carburetor Walbro WJ122B Starter Dust and water resistant Ignition Special water resistant el...

Page 6: ...11 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 3 SERIAL LOCATION 3 This section shows the two locations of the serial nu...

Page 7: ...er Coil Spring Housing 531103 5 Starter Case Plate 71451 6 Screw 505380 7 Starter Rope Pulley 528661 8 Starter Pulley Washer 73905 9 Starter Pulley Screw 5 9 52 X 73907 10 Starter Cover Assembly 52863...

Page 8: ...RE PARTS DIAGRAM KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 31 Flywheel Shroud 531109 45 Flywheel Assembly 6 9 61 528651 48 Nut 29 3 260 73891 51 Washer 73911 57 Washer 73912 71 Starter...

Page 9: ...GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM 1 2 3 For saws with serial numbers starting 977 see page 7 for serial number starting 967 KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 Flywheel Sh...

Page 10: ...Base Gasket Assembly 71412 6 Spark Plug 27 5 243 514770 11 Cylinder Bolt 10 7 95 X 73874 13 Carburetor Pulse Tube 73898 16 Carburetor Walbro WJ 122B 528628 17 Intake Manifold Flange Screw 4 0 35 X 739...

Page 11: ...Carburetor Spring 73888 7 Carburetor Pulse Tube 545877 8 Carburetor Walbro WJ 122B 528628 9 Screw 4 0 35 X 73866 10 Carburetor Support Bracket 73895 11 Screw Guide 517547 12 Intake Manifold 73868 13...

Page 12: ...lbs 242 7 Cylinder to Muffler Gasket 73881 9 Serrated Washer 73327 10 Muffler Assembly 71411 12 Muffler Mounting Screw 9 8 87 73883 14 Muffler Support Bracket 73884 15 Muffler Support Bracket Screw 8...

Page 13: ...C SERVICE MANUAL 4 SPARE PARTS DIAGRAM KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 Cylinder to Muffler Gasket 545875 2 Muffler Assembly 545872 3 Screw WASHER 9 8 87 505469 4 Screw 4 0 3...

Page 14: ...number starting 967 977 KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 Crankshaft Seal Flywheel Side 73877 2 Crankshaft Bearing 73209 3 Crankshaft Flywheel Woodruff Key 73878 4 Crankshaft...

Page 15: ...r Crankcase Seal Clutch Side 73931 2 Outer Crankcase Seal Body 73949 3 Bolt 2 9 26 73940 4 Washer 73285 5 Clutch Spacer Washer 73945 6 8T Rim Sprocket Kit 70949 7 Clutch Needle Bearing 73939 8 Clutch...

Page 16: ...eft 528653 3 Crankcase Dowel Pin 73281 4 Crankshaft Bearing 73209 7 Choke Lever Split Pin 73927 8 Crankcase Gasket 73934 9 Crankcase Bolt 7 8 69 x 73930 10 Washer 73897 11 Chain Guard 528657 12 Bar Mo...

Page 17: ...Assembly right left 545967 3 Crankcase Dowel Pin 73281 4 Crankshaft Bearing 545969 5 Choke Lever Split Pin 73927 6 O ring 71748 7 Crankcase Gasket 545968 8 Crankcase Bolt 7 8 69 x 73930 9 Washer 7389...

Page 18: ...er Lockout Lever Spring 73988 10 Washer 73897 11 Screw 73982 12 Shock Absorber 73980 13 Clip Fuel Filter 71588 14 Fuel Line 73375 15 Shock Absorber Rear Handle 71745 16 Bumper Shock Absorber Fuel Tank...

Page 19: ...ttle Lever 530479 5 Fuel Cap Assembly with Outer Seal Ring 530471 6 Fuel Cap O Ring 73448 7 Fuel Filter 73459 8 Trigger Lockout Lever 532028 9 Trigger Lockout Lever Spring 73988 10 Washer 73897 11 Scr...

Page 20: ...2 Air Filter Canister Polyester 71752 3 Air Filter Cover 530473 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 Pre...

Page 21: ...3 2 Air Filter Canister Polyester 71752 3 Air Filter Cover 530473 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 Pr...

Page 22: ...4 Screw Washer x x 505469 5 Guard Flap Screw x x 4 8 43 x 71479 6 Washer x x 73951 7 Guard Flap Spacer x x 71480 8 Water Hose Gasket x 71469 9 Fitting x x 71467 10 Clip x x 545975 11 Ring Nut x x 714...

Page 23: ...PART NUMBER Nm in lbs 242 1 Side Cover Insert Top 71534 2 Side Cover Nut 71532 3 Chain Cover Cap 71531 4 Nut 505469 5 WallWalker Side Arm 4 8 43 x 71479 6 Washer 73951 7 WallWalker Side Arm Screw 714...

Page 24: ...without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL For saws with serial number starting 967 977 CARBURETOR REPAIR KIT KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 Carburetor Wa...

Page 25: ...24 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL This page intentionally left blank...

Page 26: ...osen 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 filter with cleaning solution and a nylon brush A Cl...

Page 27: ...525747 REV12Sep2012 680GC 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...

Page 28: ...Sep2012 680GC 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 w...

Page 29: ...2Sep2012 680GC SERVICE MANUAL 6 SPARK PLUG 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 co...

Page 30: ...park plug hole 7 2 Pull starter handle until piston stops against tool 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 nee...

Page 31: ...t to change without notice P N 525747 REV12Sep2012 680GC 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...

Page 32: ...thout notice P N 525747 REV12Sep2012 680GC 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...

Page 33: ...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...

Page 34: ...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 rele...

Page 35: ...ERVICE MANUAL 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 co...

Page 36: ...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...

Page 37: ...ch 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...

Page 38: ...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...

Page 39: ...E MANUAL 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 WALLWALK...

Page 40: ...12Sep2012 680GC 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 I...

Page 41: ...ve 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...

Page 42: ...water seal and filter 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 compen...

Page 43: ...ake manifold 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...

Page 44: ...ews and serrated washers 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 mu...

Page 45: ...ws in place with heat shield gasket C Thread muffler screws into cylinder torque to 78 in lbs 8 8 Nm 11 5 Install muffler support A Install top 3 muffler support screws and serrated washer finger tigh...

Page 46: ...uffler 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 Remov...

Page 47: ...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...

Page 48: ...omponents 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 linkage A Push trigger end out of rear handle B...

Page 49: ...rt screw 1 with 4 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 C...

Page 50: ...hile holding carburetor base B Remove carburetor base from pulse tube 13 2 Remove pulse tube and protective spring from cylinder base 13 This section covers the removal inspection and assembly of the...

Page 51: ...12 680GC SERVICE MANUAL 13 CYLINDER PISTON 13 5 Remove cylinder screws 4 and wave washers 13 6 Remove cylinder A Remove cylinder gasket and clean crankcase mating surface 13 3 Remove rear manifold cla...

Page 52: ...t to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 13 CYLINDER PISTON 13 8 Press wrist pin out with an 8mm deep socket 13 9 Remove piston and inspect Replace if damaged 13 10 Remo...

Page 53: ...ANUAL 13 CYLINDER PISTON 13 12 Install wrist pin bearing in rod A Oil bearing with ICS 2 stroke engine oil 13 13 Install rings Install bottom ring first Installing the bottom ring over the top ring ma...

Page 54: ...without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 13 CYLINDER PISTON 13 15 Install 1 wrist pin retaining clip 13 16 Make sure wrist pin retaining clip is in the proper orientation Improper...

Page 55: ...LINDER PISTON 13 18 Align piston in correct orientation 13 19 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 r...

Page 56: ...g compression tool B Slide cylinder down piston and into crankcase C Align cylinder bolt holes with crankcase 13 22 Install 4 cylinder screws and washers A Use Loctite 242 B Torque bolts to 95 in lbs...

Page 57: ...clamp A Torque to 11 in lbs 1 2 Nm Do not over tighten damage to rear manifold may cause engine damage 13 25 Install the pulse tube onto cylinder barb 13 26 Install protective spring onto pulse tube...

Page 58: ...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 27 Install carbu...

Page 59: ...525747 REV12Sep2012 680GC SERVICE MANUAL 14 WATER HOSE 14 4 Remove water hose connector 14 5 Unscrew water tank cap from saw 7 8 wrench 14 1 Loosen hose clamp screw 14 2 Remove water connection from h...

Page 60: ...ricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 14 WATER HOSE 14 6 Release water tank cap from water tank tube A Depress orange fitting as shown to release wat...

Page 61: ...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 b...

Page 62: ...012 B Set ignition 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...

Page 63: ...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...

Page 64: ...4 Using pliers hold saw 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...

Page 65: ...hout notice P N 525747 REV12Sep2012 680GC 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...

Page 66: ...NUAL 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...

Page 67: ...12 680GC SERVICE 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...

Page 68: ...kcase and fuel tank NOTE Saws 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 a...

Page 69: ...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...

Page 70: ...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 pres...

Page 71: ...GC SERVICE MANUAL 20 CRANKCASE 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...

Page 72: ...ge without notice P N 525747 REV12Sep2012 680GC 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 be...

Page 73: ...hout notice P N 525747 REV12Sep2012 680GC 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...

Page 74: ...nge without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 20 CRANKCASE 20 18 Align crankcase gasket on flywheel side crankcase pins 20 20 Assemble crankcase halves tap with bearing driver and ma...

Page 75: ...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 assem...

Page 76: ...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 st...

Page 77: ...REV12Sep2012 680GC 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 rev...

Page 78: ...o EPA Phase II emissions standards However minor adjustments may be required in certain conditions such as high elevation NOTES These saws are equipped with an electronic speed limiter as part of the...

Page 79: ...ld the tool shaft 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 c...

Page 80: ...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 ch...

Page 81: ...C 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 chai...

Page 82: ...gh 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 Rep...

Page 83: ...s 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 mixtu...

Page 84: ...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 gau...

Page 85: ...ocated 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 b...

Page 86: ...he 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...

Page 87: ...ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL Spark Plug Reference Guide ICS Part Number Champion NGK 514770 RCYJ4 BPMR8Y...

Page 88: ...ications and pricing are subject to change without notice P N 525747 REV12Sep2012 ICS Blount Europe S A Rue Emile Francqui 5 1435 Mont Saint Guibert Belgium Tel 32 10 301 251 Fax 32 10 301 259 icsbest...

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