ICS 680GC Service Manual
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ICS 680GC Service Manual

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680GC
SERVICE MANUAL
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© 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012

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

  • Page 2: Table Of Contents

    BAR STUDS & BAR PAD CHAIN TENSIONER CARBURETOR TUNING IDLE SPEED ADJUSTMENT TROUBLESHOOTING DIAGRAMS TROUBLESHOOTING: FUEL SYSTEM LEAKS TROUBLESHOOTING: CRANKCASE LEAKS APPENDIX 1. SPARK PLUG REFERENCE GUIDE © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 3: Service Manual Use

    This manual contains all the technical information necessary for carrying out repairs on the 680GC saw. For safe, efficient work, it is of prime importance that the values indicated be adhered to. Routine periodic maintenance is covered in the operator’s manual included with each saw.

  • Page 4: Tools

    Not Shown 505882 2-Stroke Oil, 25:1 Mix, 5.2 oz (158 ml) (6-Pack) Not Shown 505883 2-Stroke Oil, 25:1 Mix, 5.2 oz (158 ml) (24-Pack) © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 5: Saw Specifications

    8.5 m/s (rear handle) One tank, without cutting, cycling Engine Break-in Period throttle NGK BPMR8Y Spark Plug Electrode gap .020 in (0.5 mm) © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 6: Serial Number Location

    680GC SERVICE MANUAL 3. SERIAL # LOCATION 3 This section shows the two locations of the serial number. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 7: Spare Parts Diagram

    STARTER PULLEY WASHER 73905 STARTER PULLEY SCREW 73907 STARTER COVER ASSEMBLY 528637 STARTER ASSEMBLY WASHER 530367 SPRING HOUSING WASHER 532026 STARTER ASSEMBLY CAP 508853 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 8 TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. FLYWHEEL SHROUD 531109 FLYWHEEL ASSEMBLY 528651 29.3 73891 WASHER 73911 WASHER 73912 STARTER PAWL ASSEMBLY 509163 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 9 (see page 7 for serial number starting 967) TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. FLYWHEEL SHROUD 531109 FLYWHEEL ASSEMBLY KIT 29.3 545963 STARTER PAWL ASSEMBLY 509163 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 10 12.8 71642 INTAKE MANIFOLD FLANGE 73947 INTAKE MANIFOLD 71735 CARBURETOR SPRING 73888 WASHER 73897 SCREW & WASHER 505469 SCREW 73866 SCREW GUIDE 517547 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 11 INTAKE MANIFOLD CLAMP 73867 SPARK PLUG 27.8 514770 CYLINDER BOLT 10.7 73874 COMPLETE PISTON/CYLINDER ASSEMBLY 548084 GASKET, BASE 545874 WRIST PIN NEEDLE BEARING 73869 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 12 71411 MUFFLER MOUNTING SCREW 73883 MUFFLER SUPPORT BRACKET 73884 MUFFLER SUPPORT BRACKET SCREW 73885 WASHER 73897 SCREW 73866 MUFFLER DEFLECTOR 71481 SCREW 71482 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 13 (see page 11 for serial number starting 967) TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. CYLINDER TO MUFFLER GASKET 545875 MUFFLER ASSEMBLY 545872 SCREW & WASHER 505469 SCREW 73866 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 14 CRANKSHAFT BEARING 73209 CRANKSHAFT FLYWHEEL WOODRUFF KEY 73878 CRANKSHAFT ASSEMBLY 71410 WRIST PIN NEEDLE BEARING 73869 CRANKSHAFT SEAL CLUTCH SIDE 73289 CRANKSHAFT BUSHING 71452 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 15 8T RIM SPROCKET KIT 70949 CLUTCH NEEDLE BEARING 73939 CLUTCH DRUM ASSEMBLY 71520 CLUTCH SPACER WASHER, INSIDE 73941 CLUTCH ASSEMBLY 33.3 71419 CLUTCH SPRING 73943 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 16 BAR MOUNT PAD COVER PLATE 71738 PREMIUM TENSIONER KIT 73935 TENSIONER SCREW RETAINER 73936 CHOKE LEVER 530469 CRANKCASE GROMMET, RIGHT SIDE 531107 CHOKE LEVER BUSHING 73955 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 17 BAR MOUNT PAD COVER PLATE 71738 PREMIUM TENSIONER KIT 73935 TENSIONER SCREW RETAINER 73936 CHOKE LEVER 530469 CRANKCASE GROMMET, RIGHT SIDE 531107 CHOKE LEVER BUSHING 73955 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 18 WATER DEFLECTOR, BOTTOM 71766 BREATHER TUBE BODY 71751 BREATHER TUBE ELBOW 71759 FUEL BREATHER, REMOTE 71761 BREATHER TUBE EXTENSION 71777 TUBE CLAMP 71760 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 19 WATER DEFLECTOR, BOTTOM 71766 BREATHER TUBE BODY 71751 BREATHER TUBE ELBOW 71759 FUEL BREATHER, REMOTE 71761 BREATHER TUBE EXTENSION 71777 TUBE CLAMP 71760 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 20 FILTER CANISTER GASKET 73335 O-RING 71472 TUBE CLAMP 71760 COMPENSATOR TUBE 505382 BREATHER GROMMET 19.7 71763 THROTTLE ASSEMBLY 71750 O-RING, AIR FILTER 73331 WASHER 73897 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 21 FILTER CANISTER GASKET 73335 O-RING 71472 TUBE CLAMP 71760 COMPENSATOR TUBE 505382 BREATHER GROMMET 19.7 71763 THROTTLE ASSEMBLY 71750 O-RING, AIR FILTER 73331 WASHER 73897 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 22 COPPER WASHER 71456 WATER TANK CAP 73923 FUEL CAP O-RING 73448 TUBE 71459 FITTING 71470 FITTING 71471 O-RING 71472 HOSE HANGER BUTTON 71744 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 23 LOWER GUARD 545975 SIDE COVER INSERT, BOTTOM REAR 71457 SIDE COVER INSERT, TOP REAR 71468 RUBBER BUMPER COVER 71458 SIDE COVER ASSEMBLY, COMPLETE 71454 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 24 For saws with serial number starting 967 & 977 TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. CARBURETOR, WALBRO WJ-122B 528628 CARBURETOR REPAIR KIT 73996 © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 25 680GC SERVICE MANUAL This page intentionally left blank. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 26: Air Intake

    B. Replace if necessary Clean filter with cleaning solution and a nylon brush. A. Clean filter with cleaning solution and water. B. Let dry and reinstall. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 27 5.5 Inspect filter canister gasket. A. Clean B. Replace if necessary Check air filter mount screws and lightly secure them if they are loose. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 28: Spark Plug

    Loosen and remove the spark plug. Inspect spark plug for damage or corrosion. Clean with a wire brush. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 29 Assemble in the reverse order. Make sure the plug boot is seated completely. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 30: Clutch & Rim Sprocket

    Left hand threads - rotate CAUTION clockwise to loosen. NOTE: If an impact wrench is available steps 7.1 and 7.2 do not need to be performed. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 31 Inspect the clutch shoes for wear. A. Replace if the shoe has less than 0.04" (1 mm) of material, as shown. Inspect spring for cracks. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 32 Finish installation of clutch shoe as shown. Inspect the rim sprocket for wear. A. Replace if the rim sprocket teeth are worn to points, as shown on right. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 33 7.11 Install clutch. Torque to 295 in-lbs (33.3 Nm). CAUTION Left hand threads. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 34: Starter System

    C. Slowly rotate pulley counter-clockwise until spring pressure is released. Use thumb as brake. Remove starter pulley screw and washer. NOTE: Hold starter cover firmly. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 35 B. Carefully remove coil spring and housing to prevent spring from unwinding. 8.8 Lubricate with lightweight oil. 8.9 Replace parts carefully. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 36 8.13 Install center screw, spacer and washer. A. Use Loctite 242. ® . B. Torque to 26 in-lbs (2.9 Nm). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 37 8.17 Inspect and clean pawl components. A. Inspect the components. Replace if necessary. B. Clean the components with a brush and solvent. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 38 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). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 39: Wallwalker

    Remove bar mount pad. Remove crankcase screws and wave washers. Remove WallWalker from saw. ® Install new WallWalker ® Assemble in reverse order. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 40 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). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 41: Cylinder Cover

    B. Push intake manifold through hole. C. Make sure throttle linkage is disengaged from cylinder cover. D. Guide fuel breather tube and compensator tube through cylinder cover. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 42 Be careful as to not pull tubes away from their point of connection. Approximately 3/4" 2 cm) of tube should protrude from cylinder cover. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 43 Install air filters and cover. A. Install pre-filter. B. Install clean air filter. C. Install air filter flange and tighten. D. Install air filter cover and tighten. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 44: Muffler

    11.2 Remove muffler screws and serrated washers located inside the muffler. 11.3 Remove muffler and heat shield gasket. A. Replace any damaged components. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 45 B. Install bottom (2) muffler support screws with Loctite 242. ® C. Torque top screws to 78 in-lbs. (8.8 Nm). D. Torque bottom screws to 52 in-lbs. (5.8 Nm). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 46 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. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 47 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). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 48: Carburetor

    C. Remove carburetor end of linkage from throttle rod tab on carburetor. 12.2 Remove choke lever split pin. 12.3 Remove choke lever. 12.4 Remove adjustment screw boot. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 49 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). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 50: Cylinder & Piston

    B. Remove carburetor base from pulse tube. 13.2 Remove pulse tube and protective spring from cylinder base. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 51 13.5 Remove cylinder screws (4) and wave washers. 13.6 Remove cylinder. A. Remove cylinder gasket and clean crankcase mating surface. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 52 13.8 Press wrist pin out with an 8mm deep socket. 13.9 Remove piston and inspect. Replace if damaged. 13.10 Remove wrist pin bearing. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 53 2-stroke engine oil. ® 13.13 Install rings. Install bottom ring first. Installing the bottom ring over the top ring may cause the ring to break. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 54 Install (1) wrist pin retaining clip. 13.16 Make sure wrist pin retaining clip is in the proper orientation. Improper installation may result in serious engine damage. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 55 C. Complete wrist pin installation. D. Install second wrist pin retaining clip. Make sure wrist pin retaining clip is in the proper orientation (see 13.16). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 56 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). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 57 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. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 58 ® ground wire. B. Make sure to include stop switch wire (installed on left rear screw). C. Torque to 35 in-lbs. (4 Nm). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 59: Water Hose & Cap

    Remove water connection from hose. 14.3 Remove hose from hose hanger. 14.4 Remove water hose connector. 14.5 Unscrew water tank cap from saw (7/8 wrench). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 60 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. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 61: Ignition Coil

    Remove ignition 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. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 62 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. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 63: Flywheel

    Screw on flywheel removal tool finger tight. Unscrew tool 1 1/2 turns leaving approximately 1/8 inch (5 mm) space between tool and flywheel. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 64 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.) © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 65: Bottom Guard

    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. Assemble in reverse order. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 66: 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). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 67: Fuel Tank

    Remove vibration isolator screws and wave washers on clutch side of saw. 19.2 Remove vibration isolator screws and wave washers on flywheel side of saw. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 68 * Shock absorber tool p/n #71546 should be used for removal and installation. 19.5 Assemble in reverse order. NOTE: During assembly be careful to avoid kinking the fuel line. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 69: Crankcase

    20.2 Remove crankcase bolts. 20.3 Heat the flywheel side crankcase with heat gun for 5 minutes, approximately 150° F (65.5° C). © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 70 Remove the flywheel side crankcase seal with 1/2" (13 mm) socket. 20.6 Heat the clutch side crankcase with heat gun to 150°F (65.5°) C. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 71 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. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 72 Heat crankcase halves to 150° F (65.5°) C. 20.12 Install bearing into crankcase halves. 20.13 Tap with bearing driver and mallet. 20.14 Repeat with other half. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 73: Engine Oil

    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. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 74 Align crankcase gasket on flywheel side crankcase pins. 20.19 Place crankcase halves together and align crankcase pins. 20.20 Assemble crankcase halves — tap with bearing driver and mallet. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 75 20.22 Install flywheel side crankcase seal — tap with bearing driver and mallet. 20.23 Trim crankcase gasket flush. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 76: Bar Studs & Bar Pad

    D. Repeat on the second bar stud. 21.2 Remove bar pad. A. Remove sealing o-ring. 21.3 Assemble in reverse order. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 77: Chain Tensioner

    Remove bar plate to expose the chain tensioner. 22.2 Unscrew tensioner to remove. A. Remove tensioner pin. B. Remove tensioner screw keeper. 22.3 Assemble in reverse order. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 78: Carburetor Tuning

    • Always check the air filter, pre filter, fuel filter, and spark plug before making carburetor tunings and clean or replace if necessary. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 79 Failure to follow this procedure may result in personal injury and or damage to the saw. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 80 23.9 When the carburetor is adjusted correctly, set the limiter caps securely onto the needle screws with a straight blade screwdriver. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 81: Idle Speed Adjustment

    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. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 82: Troubleshooting Diagrams

    • Damaged shock absorber. • Replace shock absorbers • Damaged or broken Excessive vibration. • Replace flywheel. flywheel fins. • Replace crankshaft. • Bent crankshaft. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 83 • Repair or replace fuel tank carburetor? breather. breather. Is the flywheel key • Loose flywheel. • Replace key and reinstall flywheel. sheared? © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 84: Troubleshooting: Fuel System Leaks

    G. If the main fuel pick-up tube does maintain pressure, then the leak has been isolated to the carburetor. Refer to the Walbro Diaphragm Carburetor Service Manual. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 85 B. Assemble in reverse order. C. Make sure that the spring taper is oriented in the correct direction. Narrow end towards the end of the cap. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 86: Troubleshooting: Crankcase Leaks

    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. © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

  • Page 87: Appendix

    APPENDIX 680GC SERVICE MANUAL Spark Plug Reference Guide ICS Part Number Champion 514770 RCYJ4 BPMR8Y © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...
  • Page 88 680GC SERVICE MANUAL ICS, Blount Europe S.A. Rue Emile Francqui, 5 1435 Mont‑Saint‑Guibert, Belgium Tel +32 10 301 251 Fax +32 10 301 259 icsbestway.com © 2011 ICS- Blount Inc Specifications and pricing are subject to change without notice. P/N 525747 REV12Sep2012...

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