ICS 603GC Service Manual
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ICS 603GC Service Manual

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603GC
SERVICE MANUAL
F/N 518537 Oct 07
© 2007 ICS, Blount Inc.

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Summary of Contents for ICS 603GC

  • Page 1 603GC SERVICE MANUAL F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 3: Table Of Contents

    IGNITION COIL FLYWHEEL FRONT HANDLE FUEL TANK CRANKCASE BAR STUDS TENSIONER CARBURETOR TUNING IDLE SPEED ADJUSTMENT TROUBLESHOOTING DIAGRAMS TROUBLESHOOTING: FUEL SYSTEM LEAKS TROUBLESHOOTING: CRANKCASE LEAKS APPENDIX 1. SPARK PLUG REFERENCE GUIDE F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 4: Shop Manual Use

    This manual contains all the technical information necessary for carrying out repairs on the 603GC cut-off 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 cut-off saw.

  • Page 5: Tools

    SHOCK ABSORBER TOOL 71547 SPARK TESTER 71548 FLYWHEEL PULLER TOOL 71550 LIMITER CAP REMOVAL TOOL 71565 ELECTRONIC TACHOMETER 71569 INDUCTION SEAL FLANGE W/ SCREWS 71570 EXHAUST SEAL FLANGE W/ SCREWS 71573 TUNING SCREWDRIVER F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 6: Saw Specifications

    100 db @ 1 meter Vibration Level 11.0 m/s Spark Plug TYPE Champion RCJ-7Y (for spark plug reference guide see page 81) Spark Plug Gap 0.02 inches (0.5 mm) Sprocket Type 8-tooth rim sprocket © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 7: Serial Number Location

    603GC SERVICE MANUAL 3. SERIAL # LOCATION TITLE 3 603GC Cut-Off serial number series. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 8: Spare Parts Diagram (Torque And Loctite®)

    4. SPARE PARTS DIAGRAM TITLE 603GC SERVICE MANUAL 4 This section covers torque, Loctite , and lubrication requirements of the individual ® components. The key numbers used are not related to the key numbers in the 603GC Replacement Parts Price List. CYLINDER & PISTON ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs.
  • Page 9 BAR MOUNT PAD COVER PLATE 505467 CRANKCASE GASKET 505440 CHOKE LEVER BUSHING 73955 CRANKCASE BOLT 73930 SCREW, 5 X 50mm 509709 CRANKCASE 505427 TENSIONER 505393 CRANKSHAFT BEARING 505375 FUEL LINE GROMMET 505627 F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 10 CLUTCH CUP WITH SPLINED ADAPTOR 505422 TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. CRANKSHAFT SEAL FLYWHEEL SIDE 73877 CRANKSHAFT BEARING 505375 CRANKSHAFT SEAL 505381 CRANKSHAFT BUSHING 509487 WRIST PIN NEEDLE BEARING 505403 CRANKSHAFT ASSEMBLY 505397 © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 11 PART NUMBER in‑lbs. MUFFLER SUPPORT BRACKET SCREW 73885 SERRATED WASHER 73327 MUFFLER SUPPORT BRACKET 505392 MUFFLER MOUNTING SCREW 73883 SCREW 71482 WASHER 73897 MUFFLER DEFLECTOR 505396 MUFFLER ASSEMBLY 505418 CYLINDER-TO-MUFFLER GASKET 505385 F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 12 CARBURETOR ATTACHMENT SCREW 73902 OUTER INTAKE MANIFOLD FLANGE SCREW 73901 CARBURETOR MOUNTING BRACKET 505411 CARBURETOR 505654 OUTER INTAKE MANIFOLD FLANGE 505384 OUTER INTAKE MANIFOLD 507427 ADJUSTMENT GUIDE 505391 BREATHER TUBE BODY 71751 © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 13 71748 REAR HANDLE SHOCK ABSORBER 505425 TUBE CLAMP, WITH TABS 71588 BREATHER TUBE ELBOW 71759 TUBE CLAMP, NO TABS 71760 FUEL BREATHER, REMOTE 71761 RUBBER WATER DEFLECTOR 505445 SHOCK ABSORBER 505387 F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 14 4. SPARE PARTS DIAGRAM TITLE 603GC SERVICE MANUAL FLYWHEEL ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. FLYWHEEL SHROUD 505438 FLYWHEEL 505399 73891 WAVE WASHER 73911 PLAIN WASHER 73912 STARTER PAWL ASSEMBLY 508852 © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 15 IGNITION TOGGLE CABLE 73919 IGNITION COIL 505426 SWITCH, IGNITION TOGGLE 73237 SCREW 73914 PLAIN WASHER 73890 IGNITION TOGGLE SWITCH NUT 73239 IGNITION TOGGLE PLATE ON/OFF 73238 SWITCH GROUND CONNECTION PLATE 71449 F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 16: Starter Assembly

    STARTER PULLEY SCREW 73907 RECOIL HOUSING SCREW 505380 STARTER PULLEY WASHER 73905 STARTER ROPE PULLEY 508857 STARTER ASSEMBLY 505416 STARTER COIL SPRING & HOUSING 73909 STARTER CASE PLATE 71451 STARTER ASSEMBLY CAP 508853 © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 17 71758 FILTER SUPPORT SCREW 505437 FILTER CANISTER GASKET 73335 O-RING 71472 TUBE CLAMP, NO TABS 71760 COMPENSATOR TUBE 505382 BREATHER GROMMET 71763 THROTTLE ASSEMBLY 71750 O-RING, AIR FILTER 73331 WASHER 73897 F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 18 WATER HOSE 509488 WATER HOSE COVER 71464 HOSE HANGER 71461 WATER SHUT-OFF VALVE 71458 WATER HOSE O-RING 71468 RING NUT 71457 FITTING 71467 WATER HOSE GASKET 71469 FITTING 71454 FITTING 71466 © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 19 GUARD FLAP SCREW 71479 GUARD FLAP 505492 RUBBER BUMPER, COVER 73310 SCREW 71487 SIDE COVER PLATE 505419 SIDE COVER GASKET 505417 MOUNTING NUT 509852 RUBBER WALLWALKER 505493 FITTING 71454 BOLT 73983 F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 20 4. SPARE PARTS DIAGRAM TITLE 603GC SERVICE MANUAL CARBURETOR REPAIR KIT TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. ABOVE CARBURETOR WALBRO HDA-225 517742 CARBURETOR REPAIR KIT 505441 © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 21: Air Intake

    Remove air filter from cover. Inspect air filter. Replace if necessary (P/N 71752). Remove secondary filter from air filter mount. Clean secondary filter with cleaning solution and a nylon brush. Let dry and reinstall. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 22 Inspect air filter cover gasket. Replace if permanently depressed or hard due to slurry. Inspect filter cannister gasket. Clean. Replace if necessary. Secure air filter mount screws (3) using Loctite 242. ® © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 23: Spark Plug

    Clean area around the spark plug to prevent debris from entering the cylinder. Remove the spark plug. Inspect the spark plug for proper size, gap and condition. If dirty, clean with a wire brush as shown. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 24 NOTE: If the spark plug must be replaced refer to the Spark Plug Reference Guide on page 81 to select the correct replacement plug. Assemble in the reverse order. Make sure the plug boot is seated completely. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 25: Clutch & Rim Sprocket

    Pull starter handle until piston stops against tool. Remove clutch. Left hand threads – rotate clockwise to loosen. NOTE: If an impact wrench is available steps 7.1 and 7.2 do not have to be performed. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 26 603GC SERVICE MANUAL Remove all drive components. Inspect the clutch shoes for wear. Replace if the shoe has less than 0.04” (1 mm) of material, as shown. Inspect spring for cracks. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 27 Insert top edge of clutch shoe over spring as shown. Snap clutch shoe into place. Inspect the rim sprocket for wear. Replace if the rim sprocket teeth are worn to points, as shown on right. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 28 (ICS P/N 70885). ® Assemble clutch spacer washer, bearing, clutch cup with rim sprocket, and inside clutch spacer washer. 7.11 Install clutch. Tighten firmly. Left hand threads © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 29: Starter System

    Pull 4-6” (10-15 cm) of rope out. Line rope up with notch on pulley. To release pulley, slowly rotate pulley counterclockwise until spring pressure is released. Use thumb as a brake. Remove rubber screw seal. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 30 Attempting to re-bend the spring hook may cause the hook to break off. Carefully remove coil spring and housing to prevent spring from unwinding. Lubricate with light weight oil. Replace parts carefully. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 31 Pull the end of the rope down and in front of the tail. Send the end through the loop a second time, creating a double knot; cinch tight. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 32 Torque to 26 in-lbs. (2.9 Nm). 8.15 Wind the recoil spring. Line rope up with notch on pulley. Rotate the pulley with the rope clockwise 5 times. Untangle rope and release. 8.16 Assemble starter cord shield. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 33 Make sure the spring is in the correct position. Use Loctite 242 on the pawl screws. ® Torque to 60 in-lbs. (6.8 Nm). 8.20 Install starter cover. Pull out cord 4-6”. Slowly release while placing cover to allow pawls to engage. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 34 8. STARTER TITLE 603GC SERVICE MANUAL 8.21 Install starter cover screws. Use Loctite 242. ® Torque to 60 in-lbs. (7 Nm). © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 35: Wallwalker

    This section covers the removal, inspection, and assembly of the rubber padded wallwalker and guard flap. Inspect bumpers. Replace if worn. Remove side cover assembly. Remove cover plate. Remove crankcase screws and wave washers. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 36 Replace the flap if it is torn or damaged in any way. Remove guard flap screws and washers. Reassemble in the reverse order. Install crankcase screws and wave washers. Use Loctite 242. ® Torque to 70 in-lbs. (7.9 Nm). © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 37: Cylinder Cover

    Remove cylinder cover. Pull up on front. Push intake manifold through hole. Make sure throttle linkage is disengaged from cylinder cover. Guide fuel breather tube and compensator tube through cylinder cover. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 38 10.7 Remove stop switch leads. 10.8 Inspect cylinder cover for damage. Replace if necessary. 10.9 Check filter cover gasket. Replace if necessary. 10.10 Check cylinder cover water seal. Replace if necessary. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 39 (Install compensating tube first). NOTE: Be careful to not pull tubes away from their point of connection. Approximately 3/4” of tube B (1) should protrude from B (2) cylinder cover. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 40 Install air filter mount screws (3) using Loctite 242. ® Torque to 43 in-lbs. (4.9 Nm). 10.15 Install air filters and cover. Install pre-filter. Install clean air filter. Install air filter flange and tighten. Install air filter cover and tighten. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 41: Muffler

    Remove muffler support screws. 11.2 Remove muffler screws (2) – note there are two screws – and serrated washers located inside the muffler. 11.3 Remove muffler and heat shield gasket. Replace any damaged components. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 42 Install top 3 muffler support screws and serrated washer finger tight. Install bottom 2 muffler support screws with Loctite 242. ® Torque top screws to 78 in-lbs. (9 Nm). Torque bottom screws to 52 in-lbs. (6 Nm). © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 43: Carburetor

    12.2 Remove fuel line from carburetor and support bracker. 12.3 Remove carburetor support bracket. Remove carburetor support screw (1) with #4 Torx or straight blade screwdriver. Remove carburetor body screws (2). F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 44 Remove carburetor. Remove pulse tube. B Remove carburetor jet cover. Remove carburetor from choke linkage. 12.5 Assemble in the reverse order. Torque carburetor body screws to 43 in-lbs. (5 Nm). Torque supporter screw with Loctite 242 to 43 in-lbs. (5 Nm). ® © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 45: Cylinder & Piston

    603GC SERVICE MANUAL 13. CYLINDER & PISTON TITLE This section covers the NOTE When replacing the 603GC cylinder disassembly, inspection and and piston it is necessary to tune the assembly of the cylinder, piston carburetor prior to returning the saw to and related components.
  • Page 46 Remove rear manifold clamp. 13.4 Remove rear manifold from cylinder. Inspect for holes and tears. 13.5 Remove cylinder screws (4) and wave washers. 13.6 Remove cylinder. Remove cylinder gasket and clean case. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 47 13.7 Remove wrist pin retaining clips (2). 13.8 Press wrist pin out with an 8 mm deep socket. 13.9 Remove piston and inspect. Replace if damaged. 13.10 Remove wrist pin bearing. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 48 Install and align holes and notch. 13.12 Install wrist pin bearing in rod. Oil bearing with ICS 2-stroke ® engine oil. 13.13 Install rings. Install lower ring first for ease of installation. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 49 (toward the crankcase) or twelve o'clock (toward the cylinder head) position. Each retaining clip should produce an audible "click" as it seats in its groove in the piston. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 50 ® Align wrist pin with wrist pin bearing. Complete wrist pin installation. Install second wrist pin retaining clip. Make sure wrist pin retaining clip is in the proper orientation (see 13.16). © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 51 13.21 Install cylinder. Remove ring compression tool. Slide cylinder down piston and into crankcase. Align cylinder bolt holes with crankcase. 13.22 Install 4 cylinder screws and washers. Use Loctite 242. ® Torque bolts to 95.5 in-lbs. (11 Nm). F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 52 If over tightened, intake boot can tear, resulting in an air leak which will cause engine damage. 13.25 Install protective spring onto pulse tube. 13.26 Install the pulse tube onto cylinder barb. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 53 Make sure rear manifold lip is flat. 13.28 Install carburetor base screws. Use Loctite 242 on screws (3). ® Make sure to include stop switch wire on front screw. Torque to 35 in-lbs. (4 Nm). F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 54: Water Hose

    Assemble in reverse order. 14.3 Remove water hose connector from side cover. Remove clamp and hose from fitting. Unthread fitting from side cover. 14.4 Inspect side cover for damage. Replace if necessary. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 55: Ignition Coil

    15.2 Remove ignition coil screws, wave washers and plain washers. 15.3 Remove ignition coil. 15.4 Inspect ignition coil. Look for: • Cracks • Missing insulation • Wear marks in wire Clean flywheel magnets and coil if rusty. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 56 26 in-lbs. (3 Nm). Remove shim, rotate flywheel to check clearance. 15.6 Install flywheel shroud. 15.7 Route yellow ignition stop switch wire through crankcase into carburetor chamber. 15.8 Complete ignition wire routing. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 57: Flywheel

    Remove flywheel nut, wave washer, and plain washer. 16.3 Screw on flywheel removal tool finger tight. Unscrew tool 1 ½ turns leaving approximately 1/8 inch (5 mm) space between tool and flywheel. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 58 16.7 Inspect cast woodruff key inside the flywheel. NOTE: Key is cast into flywheel. 16.8 Install flywheel, plain washer, wave washer, and flywheel nut. Torque nut to 217 in-lbs. (25 Nm). © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 59: Front Handle

    Remove front handle screws on right side. 17.2 Remove front handle screws on bottom. 17.3 Install front handle. Roll front handle into place. Install front handle screws (4). Use Loctite ® 242. Torque to 69 in-lbs. (8 Nm). F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 60: Fuel Tank

    18.1 Remove vibration isolator screws (2) and wave washers on clutch side of saw. 18.2 Remove vibration isolator screws (2) and wave washers on flywheel side of saw. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 61 2 bottom vibration isolators on the clutch side (circled). 18.4 Remove vibration isolators (4) from fuel tank if necessary. 18.5 Assemble in reverse order. NOTE: During assembly be careful to avoid kinking the fuel line. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 62: Crankcase

    603GC SERVICE MANUAL This section covers the disassembly, inspection, and assembly of the crankcase seals and crankshaft bearings. 19.1 Remove outer crankshaft seal housing screws and wave washers. 19.2 Remove crankcase bolts (5). © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 63 Tap with mallet. NOTE: A nut should always be placed on a threaded shaft when pounding or pressing on it. 19.5 Remove the flywheel side crankcase seal with 1/2” (13 mm) socket. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 64 19.7 Remove crankshaft from the clutch-side crankcase tap crankshaft with a plastic mallet. Suspend above work surface. Tap with plastic mallet. 19.8 Remove the bearing from the flywheel side of crankshaft. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 65 19.10 Assembly of crankcase. Clean mating crankcase faces. 19.11 Heat crankcase halves to 150° F. 19.12 Install bearing into crankcase halves. 19.13 Tap with bearing driver and mallet. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 66 603GC SERVICE MANUAL 19.14 Repeat with other half. 19.15 Install crankshaft into clutch side of case. 19.16 Place clutch side crankcase seal on crankshaft. Tap lightly with bearing driver and mallet. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 67 603GC SERVICE MANUAL 19. CRANKCASE TITLE 19.17 Coat crankcase gasket with ® 2-stroke engine oil. 19.18 Align crankcase gasket on flywheel side crankcase pins. 19.19 Place crankcase halves together and align crankcase pins. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 68 19.20 Assemble crankcase halves – tap with bearing driver and mallet. 19.21 Install crankcase bolts. Use Loctite 242. ® Torque to 69 in-lbs. (8 Nm). 19.22 Install flywheel side crankcase seal – tap with bearing driver and mallet. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 69 603GC SERVICE MANUAL 19. CRANKCASE TITLE 19.23 Assemble in reverse order Install outer crankshaft seal housing with 3 bolts and use Loctite 242. ® 19.24 Trim crankcase gasket flush. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 70: Bar Studs

    (Refer to section 13 &19 for detailed instructions) Remove side cover. Remove bar pad cover. Split the crankcase. Press out bar studs. Assemble in reverse order. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 71: Tensioner

    Remove tensioner pin. Remove tensioner screw keeper. 21.3 Assemble in reverse order. NOTE: The tensioner is intended to perform as a fuse in high load or sudden impact situations. P/N 505393 F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 72: Carburetor Tuning

    This will prevent the saw from going above 12,500 rpm. Attempting to set the carburetor mixture to increase the speed or power beyond this limit may seriously damage the engine. • Always check the air filter, pre filter, fuel filter, and spark plug before making carburetor tunings and clean or replace if necessary © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 73 Insert the limiter cap puller blades into the release slots. Firmly hold the tool shaft while screwing in the puller screw until the screw head is against the puller shaft. Unscrew the puller screw. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 74 Pulse the throttle to help stabilize the system. Do not hold the saw at max rpm for more than 5 seconds or cylinder damage could occur. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 75 603GC SERVICE MANUAL 22. CARBURETOR TUNING TITLE 22.9 When the carburetor is adjusted correctly set the limiter caps as shown with a 1/4” straight blade screwdriver. L = vertical H = horizontal F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 76: Idle Speed Adjustment

    Turn T screw clockwise until chain begins to move. Back T screw out ½ turn. 23.2 If chain turns at idle: Back T screw out until chain stops moving. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 77: Troubleshooting Diagrams

    • Broken clutch spring. • Replace clutch spring. • Damaged shock absorber. • Replace shock absorbers. • Damaged or broken Excessive vibration. • Replace flywheel. flywheel fins. • Replace crankshaft. • Bent crankshaft. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 78 • Repair or replace fuel tank carburetor? • Plugged fuel tank breather. breather. Is the flywheel key • Loose flywheel. • Replace key and reinstall flywheel. sheared? © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 79: Troubleshooting: Fuel System Leaks

    Connect tube to the pressure gauge and to the fuel line. Pressurize the tube to 7 psi (0.5 bar). If the pressure does not maintain, separate the fuel line from the carburetor. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.
  • Page 80 Attach the pressure gauge and bulb to the fuel tank breather. Pressurize the tube to 7 psi (0.4 bar). The pressure should reduce to nearly 0 psi (0 bar) over about 3 seconds. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...
  • Page 81 Clean parts with solvent or fuel. 25.7 Assemble in reverse order. Make sure duck bill opens easily. Make sure that the spring taper is oriented in the correct direction. Assemble by snapping cap in place. F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 82: Troubleshooting: Crankcase Leaks

    7 psi (0.5 bar). 26.6 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. © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

  • Page 83: Spark Plug Reference Guide

    SPARK PLUG REFERENCE GUIDE ICS RESISTOR CHAMPION NGK RESISTOR BOSCH RESISTOR RESISTOR 73199 RCJ7Y BPMR7A WSR7F F/N 518537 Oct 07 © 2007 ICS, Blount Inc.

  • Page 86: 2007 Ics, Blount Inc

    603GC SERVICE MANUAL ICS, Blount Inc. 4909 SE International Way Portland, OR 97222 Tel 800‑321‑1240 Fax 503‑653‑4393 icsbestway.com © 2007 ICS, Blount Inc. F/N 518537 Oct 07...

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