ICS 695GC/F4 Service Manual Download

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695GC/F4 SERVICE MANUAL

20.4

Turn the T-handle until it presses against

the shaft and pulls the seal from the

crankcase.

20.6

Lubricate the shaft with High Pressure

Grease.

20.5

Lift off the seal and inspect the shaft for

damage.

20. CRANKCASE

Summary of Contents for 695GC/F4

Page 1: ...2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL...

Page 2: ...ENSIONER 22 8 CLUTCH RIM SPROCKET 24 9 STARTER SYSTEM 30 10 CARBURETOR REMOVAL 35 11 MUFFLER W BAR STUD 39 12 MUFFLER W BAR STUD 40 13 IGNITION MODULE 41 14 STOP SWITCH 42 15 WATER HOSE 44 16 CYLINDER...

Page 3: ...d 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 app...

Page 4: ...iston Stop 10 546196 Wrist Pin Punch 11 546197 Cylinder Seal Exhaust 12 546198 Cylinder Seal Inlet Port 13 546289 Puller Sealing Ring 14 546291 Assembly Punch 15 546292 Universal Puller 16 546293 Grip...

Page 5: ...ght 21 lbs 9 5 kg powerhead only Dimensions 18 in 46 cm length 14 in 36 cm height 12 in 30 cm width Carburetor Walbro RWJ 5A Air Filtration Water resistant polyester Starter Dust and water resistant I...

Page 6: ...012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 6 695GC F4 SERVICE MANUAL 3 SERIAL NUMBER LOCATION 3 This section shows the single location of the serial numb...

Page 7: ...AGRAM KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 STARTER COVER ASSEMBLY 544013 2 STARTER PULLEY KIT 544127 3 SCREW x 543974 4 RECOIL SPRING 544021 5 STARTER CORD 544023 6 STARTER HANDL...

Page 8: ...030 2 STOP SWITCH 544031 3 STOP SWITCH CABLE 544032 4 SPARK PLUG CAP 544033 5 SPARK PLUG 544034 6 PROTECTIVE SLEEVE 544035 7 IGNITION MODULE 544036 8 IGNITION MODULE SCREW 10 12 89 105 x 544038 9 FLYW...

Page 9: ...R 543906 3 SPACER 543907 4 695F4 FORCE4 SPROCKET 525496 4 695GC RIM SPROCKET 70949 5 CLUTCH CUP 543909 6 NEEDLE BEARING 543910 7 BAR BRACKET SCREW x 543911 8 CRANK CASE BOLT x 543912 9 WALLWALKER 5441...

Page 10: ...UAL KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 SIDE COVER ASSEMBLY 543899 2 SIDE COVER NUT 27 34 240 300 543900 3 SIDE COVER NUT CIRCLIP 543901 4 TENSIONER COVER PLATE SCREW 543902 5 S...

Page 11: ...KIT 545873 3 HEAT DEFLECTOR 543844 4 MUFFLER GASKET 543938 5 MUFFLER 543845 6 LOWER MUFFLER MOUNTING SCREW x 543846 7 MUFFLER MOUNTING WASHER 543847 8 DECOMPRESSION VALVE 543848 9 CYLINDER BASE GASKET...

Page 12: ...KCASE ASSEMBLY 543929 2 CRANKCASE SCREW 12 14 106 124 x 543930 3 SEALING RING 543931 4 GUIDE PIN 543932 5 CRANKCASE GASKET 543933 6 MAIN BEARING 543934 7 RUBBER BUSHING 543935 8 GASKET KIT 543936 9 CY...

Page 13: ...ce REV11272012 P N 546529 13 695GC F4 SERVICE MANUAL KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 CRANKSHAFT ASSEMBLY 543952 2 MAIN BEARING 543934 3 CRANKSHAFT SHIELD 543953 4 NEEDLE BEA...

Page 14: ...ns subject to change without notice REV11272012 P N 546529 14 695GC F4 SERVICE MANUAL 4 SPARE PARTS DIAGRAM KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 CRANKCASE W PISTON CYL COMPLETE 5...

Page 15: ...LUTCH SIDE SCREW x 544072 5 FLANGE BRACKET 544073 6 SCREW x 544065 7 SEPARATOR PLATE 544074 8 CARBURETOR WALBRO RWJ 5A 544075 9 THROTTLE CABLE LEVER 544111 10 ADJUSTMENT GUIDE 544116 11 MANIFOLD BRACK...

Page 16: ...RIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 1 FILTER COVER REAR SCREW 3 5 31 544060 2 FILTER COVER FRONT SCREW 2 20 544061 3 FILTER COVER 544062 4 AIR INTAKE INSERT 544063 5 AIR FILTER 544064 6 C...

Page 17: ...69 10 HOSE CLAMP 543970 11 FUEL FILTER 543971 12 TANK VENT ASSEMBLY 544990 13 TANK VENT FITTING 544122 14 REAR HANDLE GROUND SUPPORT 543972 15 PURGE BULB 543973 16 REAR HANDLE SCREW 543974 17 THROTTLE...

Page 18: ...HOSE HANGER 547969 3 WATER HOSE WITH PROTECTIVE COVERING 543999 4 CLAMP WATER HOSE TUBE SIDE 544000 5 CLAMP WATER HOSE VALVE SIDE 544001 6 FRONT HANDLE 544002 7 SHOCK ABSORBER FRONT HANDLE 544003 8 SC...

Page 19: ...546529 19 695GC F4 SERVICE MANUAL 5 This section covers the removal inspection and assembly of the air intake 5 2 Loosen air filter screw Inspect air filter for dirt or damage Replace with P N 544064...

Page 20: ...F4 SERVICE MANUAL 6 SPARK PLUG 6 This section covers the removal inspection and installation of the spark plug 6 1 Remove the spark plug cap 6 2 Remove the spark plug 6 3 Inspect spark plug If it s di...

Page 21: ...ubject to change without notice REV11272012 P N 546529 21 695GC F4 SERVICE MANUAL 6 SPARK PLUG 6 4 Gap if necessary to 0 20 0 5mm 6 5 Assemble in reverse order ensuring that the spark plug is properly...

Page 22: ...s side cover removal side cover nut removal inspection and assembly 7 1 Loosen side cover nut Remove side cover Remove tensioner plate screws and tensioner plate 7 2 Remove tensioner assembly Note the...

Page 23: ...to change without notice REV11272012 P N 546529 23 695GC F4 SERVICE MANUAL 7 SIDE COVER TENSIONER 7 4 Inspect side cover nut and circlip Replace if damaged Circlip can be removed with a large flathea...

Page 24: ...This section covers clutch removal rim sprocket removal inspection and assembly Refer to sections 5 and 6 if necessary Rim sprocket removal procedure 8 CLUTCH RIM SPROCKET 8 1 Using flat head screwdri...

Page 25: ...N 546529 25 695GC F4 SERVICE MANUAL 8 CLUTCH RIM SPROCKET 8 2 Remove the split retainer and spacer 8 3 Inspect rim sprocket and replace if necessary P N 70949 Replace if the rim sprocket teeth are wo...

Page 26: ...EV11272012 P N 546529 26 695GC F4 SERVICE MANUAL 8 CLUTCH RIM SPROCKET 8 5 Remove clutch cup and needle bearing Apply grease to needle bearing prior to reinstalling 8 6 Clutch removal Remove clutch cu...

Page 27: ...529 27 695GC F4 SERVICE MANUAL 8 CLUTCH RIM SPROCKET 8 8 Remove clutch with clutch tool P N 546659 Rotate clockwise to remove clutch clutch is left handed thread 8 10 Inspect clutch shoes P N 543927 f...

Page 28: ...Specifications subject to change without notice REV11272012 P N 546529 28 695GC F4 SERVICE MANUAL 8 12 Height of clutch shoes should not be less than 1 mm 8 12 Inspect and clean springs if necessary 8...

Page 29: ...rd OFF See illustration at right for an example 8 13 Remove the springs Set into a vice to hold in place Place a flat head screwdriver or flat tipped rod against the spring hook Tap lightly at the end...

Page 30: ...AL 9 STARTER 9 This section covers the removal of the starter cover replacement of the starter rope and replacement of the recoil spring 9 1 Loosen 4 starter cover screws 9 2 Remove starter cover from...

Page 31: ...1272012 P N 546529 31 695GC F4 SERVICE MANUAL 9 STARTER 9 5 Pulley removal from spring 9 4 Rotate pulley shaft counter clockwise allowing pulley to unwind using rope as a brake 9 6 Remove the center s...

Page 32: ...ion of the knot 9 7 Note the orientation of the parts for re installation 9 8 A Lift pulley from spring housing NOTE the spring catch and spring hook must be aligned during installation arrows B Remov...

Page 33: ...L 9 STARTER 9 12 Tension pulley Wind rope onto pulley clockwise leaving 6 8 in 15 20 cm of rope out Ensure the pulley spring catch is installed on the spring hook 9 10 Assemble in reverse order 9 11 I...

Page 34: ...s and seat cover Tighten side cover screws 9 14 Rope must fully retract into starter cover 9 13 Insert the rope into the pulley notch Wind rope clockwise around pulley shaft 3 4 times Then pull starte...

Page 35: ...f air intake components and front handle is required Refer to sections 5 15 if necessary 10 1 Remove air filter cover and air filter Refer to section 5 Remove 2 screws P N 544065 Lift cylinder cover o...

Page 36: ...36 695GC F4 SERVICE MANUAL 10 6 Remove fuel line check valve tube and carburetor 10 5 Remove bracket screw P N 544072 Remove air intake manifold P N 544113 Inspect for damage 10 4 Remove 2 carburetor...

Page 37: ...fications subject to change without notice REV11272012 P N 546529 37 695GC F4 SERVICE MANUAL 10 7 Remove throttle cable from carburetor 10 8 Remove clutchside flange screw P N 544072 and screw P N 544...

Page 38: ...ot Remove the flange bracket and flange from the inlet boot Note orientation of plate UP 10 10 Loosen clamp Inspect and replace inlet boot if damaged see section 16 2 Cylinder must be loosened in orde...

Page 39: ...nch Remove 1 lower muffler mounting screw P N 543846 and muffler mounting washer P N 543847 11 This section covers the removal inspection and assembly of the muffler Removal of WallWalker and cylinder...

Page 40: ...129 12 GUIDE BAR STUD 12 3 Inspect bar stud P N 544129 Replace if damaged Install in reverse order using Loctite 242 12 2 Using a 6 mm allen or hex head remove 2 bolts holding bar stud 12 This section...

Page 41: ...e Removal of the starter is required Refer to section 8 if necessary 13 2 Remove 2 ignition module screws P N 544038 Remove ignition module P N 544036 Inspect and replace if damaged 13 3 Reassemble in...

Page 42: ...Blount Inc Specifications subject to change without notice REV11272012 P N 546529 42 695GC F4 SERVICE MANUAL 14 STOP SWITCH 14 2 Remove screw P N 544030 14 1 Remove stop switch P N 544031 Disconnect c...

Page 43: ...ce REV11272012 P N 546529 43 695GC F4 SERVICE MANUAL 14 STOP SWITCH 14 4 Pull the right side out first Replace switch if damaged Install in reverse order Switch will snap back into place Use Loctite 2...

Page 44: ...95GC F4 SERVICE MANUAL 15 1 Inspect hose P N 543999 water pipe P N 543915 and water valve P N 543996 Replace if damaged 15 This section covers water hose and water tank cap 15 2 Release clip from wate...

Page 45: ...der piston and related components Refer to section 5 10 if necessary 16 1 Remove outer shock absorber screw set aside for reassembly P N 543981 Loosen 4 cylinder screws P N 543942 16 2 Remove cylinder...

Page 46: ...without notice REV11272012 P N 546529 46 695GC F4 SERVICE MANUAL 16 3 Remove wrist pin clip from each side of piston 16 4 Remove wrist pin using the wrist pin punch P N 543196 Remove piston and cylind...

Page 47: ...o change without notice REV11272012 P N 546529 47 695GC F4 SERVICE MANUAL 16 8 Note the ring locator pins 16 7 Install piston rings Install lower piston ring first 16 CYLINDER PISTON 16 6 Inspect cyli...

Page 48: ...bricate crankcase gasket mating surface with ICS 2 stroke oil Install cylinder base gasket 16 11 Lubricate needle roller with ICS 2 stroke oil Insert into the connecting rod 16 CYLINDER PISTON 16 9 No...

Page 49: ...cate wrist pin with ICS 2 stroke oil and partially install in the piston 16 CYLINDER PISTON 16 13 Install wrist pin clip into opposite side of the piston Make sure wrist pin clip is in the proper orie...

Page 50: ...lide cylinder onto piston pushing ring tool down D Remove ring compressor E Slide cylinder onto piston and into the crankcase F Align cylinder bolt holes with crankcase Align cylinder screw with holes...

Page 51: ...HANDLE 17 2 Remove 2 screws from lower front handle P N 544009 17 1 Remove 2 screws P N 544012 and guard flap backing plate P N 544011 Inspect guard flap for damage P N 544010 replace if damaged Reass...

Page 52: ...P N 546529 52 695GC F4 SERVICE MANUAL 17 4 Lift up crankcase and remove handle inspect and replace if damaged Install in reverse order Use Loctite 242 on all screws except shock absorber screw 17 3 R...

Page 53: ...ge without notice REV11272012 P N 546529 53 695GC F4 SERVICE MANUAL 18 REAR HANDLE 18 1 Remove screw from rear handle P N 543974 18 2 Remove rear handle cover P N 543816 18 This section covers the rem...

Page 54: ...GC F4 SERVICE MANUAL 18 REAR HANDLE 18 3 Remove throttle lock out P N 543815 by squeezing pulling up and out 18 5 Pull the throttle trigger and spring P N 543977 down from the rear handle 18 4 Remove...

Page 55: ...o change without notice REV11272012 P N 546529 55 695GC F4 SERVICE MANUAL 18 7 Remove cable lever P N 543814 using needle nose pliers pulling up 18 6 Remove throttle cable P N 543975 See section 10 to...

Page 56: ...012 P N 546529 56 695GC F4 SERVICE MANUAL 18 8 Remove throttle cable from cable lever using an awl or small punch 18 10 Inspect all throttle component parts Replace if damaged Reassemble in reverse or...

Page 57: ...Remove fuel cap P N 543979 Inspect fuel cap and O ring Replace if damaged 19 3 Remove fuel filter Pull up on hose clamp P N 543970 Pull down on fuel filter 19 2 Remove fuel filter P N 543971 Use a sm...

Page 58: ...fuel filter and line Replace if damaged or dirty Reassemble in reverse order 19 6 Remove the 2 shock absorber screws from the flywheel side of the saw 19 5 Before separating the fuel tank from crankc...

Page 59: ...P N 546529 59 695GC F4 SERVICE MANUAL 19 7 Separate fuel tank from crankcase by pulling up on the crankcase while holding the fuel tank 19 9 Location of the tank vent on an assembled saw 19 8 Inspect...

Page 60: ...to change without notice REV11272012 P N 546529 60 695GC F4 SERVICE MANUAL 19 10 Inspect the tank vent and replace if damaged Refer to troubleshooting section 25 if necessary 19 11 Inspect fuel tank...

Page 61: ...s A Front shock absorber P N 543983 B Clutch side shock absorber P N 543982 C Flywheel side shock absorber P N 543984 Inspect and replace if damaged Install in reverse order using Loctite 242 except T...

Page 62: ...o disengage purge bulb 19 17 Reassemble in reverse order Check valve tube must be inserted back into channel and connected to fuel line with clip P N 543818 19 16 Inspect all components Replace if dam...

Page 63: ...kcase seal puller and punch 20 3 Seal removal A Insert T handle puller over the shaft B Apply downward pressure to the T handle and turn the barrel clockwise with a wrench to thread into the seal 20 2...

Page 64: ...e REV11272012 P N 546529 64 695GC F4 SERVICE MANUAL 20 4 Turn the T handle until it presses against the shaft and pulls the seal from the crankcase 20 6 Lubricate the shaft with High Pressure Grease 2...

Page 65: ...e without notice REV11272012 P N 546529 65 695GC F4 SERVICE MANUAL 20 7 Install the new seal Use caution as seal slides over the threads 20 9 Repeat procedure for the flywheel side 20 8 Use the punch...

Page 66: ...20 10 Using soapy water on both sides per form a crankcase leak down test using pressure gauge and vacuum gauge 20 12 Crankcase separation The universal puller and grip plate are required to separate...

Page 67: ...ce REV11272012 P N 546529 67 695GC F4 SERVICE MANUAL 20 13 Remove the shaft seals from both sides of the crankcase See seal removal 20 15 Attach universal puller and press out the crank shaft 20 14 In...

Page 68: ...P N 546529 68 695GC F4 SERVICE MANUAL 20 16 Using the same process press out the other half from the flywheel side 20 18 If the bearing s remain on the shaft upon separation the bearing removal tool m...

Page 69: ...1272012 P N 546529 69 695GC F4 SERVICE MANUAL 20 19 Install the bearing clamp and tighten nuts 20 21 Crankcase bearing tools These tools are required to remove the bearing from the crankcase 20 20 Ins...

Page 70: ...GC F4 SERVICE MANUAL 20 22 Heat crankcase halves to 150 F 65 5 C Use the shaft sleeve and soft mallet to tap out both bearings 20 24 Place the bearing on the bearing support plate Holding the bearing...

Page 71: ...Place the screw with nut and washers through the crankcase support plate and thread into the bearing support plate 20 27 Bearing Tools Shaft Sleeve Shaft Mandrels 20 26 Hold the screw in place and tu...

Page 72: ...ce REV11272012 P N 546529 72 695GC F4 SERVICE MANUAL 20 28 Bearing press kit 20 30 Slide the clutch side shaft through the bearing 20 29 Crankshaft install Secure clutch side crankcase face down so th...

Page 73: ...over the shaft against the crankcase Thread the M12 mandrel with the nut and washer until it bottoms Note REVERSE THREAD on the clutch side 20 33 Install the 2 crankcase guide pins 20 32 Hold mandrel...

Page 74: ...MANUAL 20 34 Lubricate the crankcase halves with ICS 2 stroke oil and install the crankcase gasket 20 35 Lubricate and assemble the flywheel side of the crankcase using the same method with the M8 sta...

Page 75: ...without notice REV11272012 P N 546529 75 695GC F4 SERVICE MANUAL 20 37 Tighten the screws to 106 124 in lbs 12 14 Nm using an x pattern 20 CRANKCASE 20 36 Loctite 242 and prefit the 8 screws and align...

Page 76: ...72012 P N 546529 76 695GC F4 SERVICE MANUAL 20 39 Install shaft seals refer to section 20 7 20 38 Cut the excess gasket over the cylinder port and carburetor area Tap both sides of the shaft with a so...

Page 77: ...ANUAL 21 1 Carburetor tuning A Throttle screw B Low speed jet C High speed jet D Model number 21 3 Carburetor adjustment Tachometer is required for proper tuning of the saw 21 2 Tools required Tuning...

Page 78: ...NUAL 21 4 Throttle screw Basic setting T 3 turns from closed Used to adjust chain speed at idle 21 5 Carburetor basic setting H 1 1 2 turns from closed L 1 5 8 turns from closed Insert the tuning scre...

Page 79: ...P N 546529 79 695GC F4 SERVICE MANUAL 21 7 Turn the screws counter clockwise to the carburetor basic settings Carburetor basic setting H 1 1 2 turns from closed L 1 5 8 turns from closed 21 6 Turn bo...

Page 80: ...RPM for more than 5 seconds If the full throttle RPM falls below this range turn the H needle clockwise 1 16 of a turn at a time checking the RPM s at each interval NOTE pulse the throttle to stabliz...

Page 81: ...amond chain moves at idle Idle speed too high Broken clutch spring Excessive vibration Damaged shock absorber Damaged or broken flywheel fins Bent crankshaft Replace shock absorbers Replace flywheel R...

Page 82: ...ank 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 mixutre Tighten plug and re test Replace pis...

Page 83: ...or malfunction of any of the main components of the fuel system 24 3 Remove and inspect the fuel filter Replace the fuel filter if the filter is excessively dirty or there is foreign material stuck to...

Page 84: ...not maintain separate the fuel line from the carburetor 24 6 The fuel tank breather stabilizes the pressure in the fuel tank preventing both excessive pressure which could flood the engine and negativ...

Page 85: ...G 24 8 Testing the fuel tank breather Attach the pressure gauge to the fuel tank plug Plug the fuel line at the carburetor end Pressurize the tube to 4 5 psi 0 3 bar The pressure should reduce to near...

Page 86: ...24 10 Inspect the fuel purge circuit Inspect the purge bulb for leaks or damage Replace if damaged See fuel tank section 24 9 If the pressure does not release disassemble or replace the breather 24 1...

Page 87: ...sections NOTE Remove intake plate from intake boot prior to installing intake seal flange 25 1 This section covers testing the the crankcase for leaks A leak in the crankcase can cause the engine to...

Page 88: ...re the seal flange Install the pressure gauge and pressurize the crankcase to 7 psi 0 5 bar If the pressure does not hold use soapy water to find the leak Note it is recommended to pressure test the e...

Page 89: ...UAL Remove the spark plug lead Clean area around the spark plug to prevent debris from entering the cylinder Remove the spark plug Inspect the spark plug If dirty clean with a wire brush as shown This...

Page 90: ...ut notice REV11272012 P N 546529 90 695GC F4 SERVICE MANUAL Gap if necessary to 0 02 0 5 mm 695GC Champion RCJ 6Y or NGK BPMR7A 695F4 Champion RCJ 6Y or NGK BPMR7A Assemble in the reverse order APPEND...

Page 91: ...Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695 SERVICE MANUAL ICS Blount Inc 4909 SE International Way Portland OR 97222 Tel 800 321 1240 Fax 603 653 4393 icsbe...

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