ICS 613GC Service Manual

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613GC

SERVICE MANUAL

F/N 71537 Jan O8

Table of Contents

Troubleshooting

Summary of Contents for ICS 613GC

Page 3: Table Of Contents
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 2. ENGINE REBUILD TIPS F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 4: Shop Manual Use
This manual contains all the technical information necessary for carrying out repairs on the 613GC 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
613GC EXHAUST SEAL FLANGE W/SCREWS 71573 TUNING SCREWDRIVER 73410 633GC FLYWHEEL PULLER 73425 633GC FUEL PRESSURE CAP 73428 613GC & 633GC MAIN BEARING DRIVER TOOL 73429 633 MAIN BEARING SPACING TOOL 73430 633GC SHOCK ABSORBER TOOL 73431 633GC INTAKE PORT COVER TOOL 73432...
Page 6: Saw Specifications
Starter Dust and water shielded Ignition Electronic speed governing, water sealed Clutch Three-weight, single spring, centrifugal Fuel Mix Ratio 25:1 gasoline to oil with brand name gasoline and ICS 2-stroke ® engine oil, or other high quality 2-stroke engine oil for air cooled engines. Fuel Capacity 0.23 gal (0.88 liter) 15-18 minute run time Water Supply Minimum 20 psi (1.5 bar)
Page 7: Serial Number Location
613GC SHOP MANUAL 3. SERIAL # LOCATION 3 613GC Cut-Off serial number series. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 8: Spare Parts Diagram
4. SPARE PARTS DIAGRAM 613GC SHOP 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 613GC Replacement Parts Price List. TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. SCREW 3.95 73866 STARTER ROPE HANDLE...
Page 9 INTAKE MANIFOLD FLANGE 73947 INTAKE MANIFOLD 71735 CARBURETOR PULSE TUBE PROTECTOR 73888 WASHER 73897 CARBURETOR ATTACHMENT SCREW 4.85 73902 SCREW 3.95 73866 SCREW GUIDE 5.87 73899 MUFFLER DEFLECTOR 71481 SCREW 3.95 71482 F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 10 2.93 73940 WASHER 73285 CLUTCH SPACER WASHER 73945 8T RIM SPROCKET KIT 70949 CLUTCH NEEDLE BEARING 73939 613GC CLUTCH DRUM ASSEMBLY 71520 CLUTCH SPACER WASHER, INSIDE 73941 CLUTCH 33.33 71419 CLUTCH SPRING 73943 © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 11 71464 WATER HOSE SCREW 19.65 71463 FITTING 71453 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 F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 12 7.79 73284 BAR MOUNT PAD COVER PLATE 71738 PREMIUM TENSIONER KIT (REPLACES 73283), ASSEMBLY 73935 TENSIONER SCREW RETAINER 73936 CHOKE LEVER 73928 CRANKCASE GROMMET, RIGHT SIDE 71741 CHOKE LEVER BUSHING 73955 © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 13 SCREW 2.93 71487 SIDE COVER PLATE 71447 LOWER GUARD 73957 SIDE COVER INSERT, BOTTOM REAR 73972 SIDE COVER INSERT, TOP REAR 73948 SIDE COVER GROMMET 73310 SIDE COVER ASSEMBLY, COMPLETE 71420 F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 15 AIR FILTER FLANGE 71758 FILTER SUPPORT SCREW 2.93 73337 FILTER CANNISTER GASKET 73335 O-RING 71472 TUBE CLAMP, NO TABS 71760 COMPENSATOR TUBE 71775 BREATHER GROMMET 71763 THROTTLE ASSEMBLY 71750 O-RING, AIR FILTER 73331 F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 16 FRONT HANDLE 71422 FUEL BREATHER COMPLETE 71748 WATER DEFLECTOR, BOTTOM 71766 BREATHER TUBE BODY 71751 BREATHER TUBE ELBOW 71759 FUEL BREATHER, REMOTE 71761 BREATHER TUBE EXTENSION 71777 TUBE CLAMP, NO TABS 71760 © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 17: Air Intake
Remove air filter from cover. Inspect air filter. Replace if necessary Clean filter with cleaning solution and a nylon brush. Clean filter with cleaning solution and water. Let dry and reinstall. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 18 TITLE 613GC SHOP MANUAL 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. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 19: Spark Plug
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. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 20 NOTE: If the spark plug must be replaced refer to the Spark Plug Reference Guide on page 78 to select the correct replacement plug. Assemble in the reverse order. Make sure the plug boot is seated completely. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 21: 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 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 22 613GC SHOP 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. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 23 Assemble clutch shoes as shown. Finish installation of clutch shoe as shown. Inspect the rim sprocket for wear. Replace if the rim sprocket teeth are worn to points, as shown on right. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 24 Grease clutch cup bearing with a water proof grease (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 © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 25: Starter System
Line rope up with notch on pulley. Slowly rotate pulley counterclockwise until spring pressure is released. Use thumb as a brake. Remove starter pulley screw and washer. NOTE: Hold starter cover firmly. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 26 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. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 27 Install pulley Wind rope onto pulley clockwise leaving 4-6” out. Make sure that the pulley spring catch is in the spring hook. 8.13 Install center screw. Use blue Loctite ® Torque to 26 in-lbs. (2.9 Nm). F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 28 Assemble starter cord shield. 8.16 Remove starter pawl screws, pawls, spring, and plain washer. 8.17 Inspect and clean pawl components. Inspect the components. Replace if necessary. Clean the components with a brush and solvent. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 29 Use needle nose pliers to move the tail of the spring into position. 8.20 Install starter cover. Pull out cord 4-6”. Slowly release while placing cover to allow pawls to engage. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 30 8. STARTER TITLE 613GC SHOP MANUAL 8.21 Install starter cover screws. Use blue Loctite ® Torque to 60 in-lbs. (6.8 Nm). © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 31: Wallwalker
Remove guard flap screws and washer. Remove and inspect guard flap. Replace the flap if it is torn or damaged in any way. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 32 9. WALLWALKER TITLE 613GC SHOP MANUAL Reassemble in the reverse order. Install crankcase screws and wave washers. Use blue Loctite ® Torque to 70 in-lbs. (7.9 Nm). © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 33: 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 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 34 (Install compensating tube first). NOTE: Be careful as to not pull tubes away from their point of connection. Approximately 3/4” of tube should protrude from cylinder cover. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 35 Install air filter mount screws (3) using blue Loctite ® 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 F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 36: Muffler
Refer to sections 7 and 10 if necessary. 11.1 Remove muffler support screws. 11.2 Remove muffler screws and serrated washers located inside the muffler. 11.3 Remove muffler and heat shield gasket. Replace any damaged components. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 37 11.5 Install muffler support. Install top 3 muffler support screws and serrated washer finger tight. Install bottom 2 muffler support screws with blue Loctite ® Torque top screws to 78 in-lbs. (8.8 Nm). Torque bottom screws to 52 in-lbs. (5.87 Nm). F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 38: Carburetor
Push trigger end out of rear handle. Pivot linkage around. 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. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 39 Remove pulse tube. 12.9 Remove carburetor compensator tube on top of carburetor. 12.10 Assemble in the reverse order. Torque carburetor body screws to 43 in-lbs. (4.85 Nm). Torque supporter screw with blue Loctite to 43 in-lbs. (4.85 Nm). ® F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 40: Cylinder & Piston
13. CYLINDER & PISTON TITLE 613GC SHOP MANUAL NOTE This section covers the When replacing the 613GC 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 41 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. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 42 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. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 43 Oil gasket with ICS 2-stroke ® engine oil. 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. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 44 613GC SHOP MANUAL 13.14 Ring orientation. 13.15 Install one 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. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 45 ® 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). F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 46 13. CYLINDER & PISTON TITLE 613GC SHOP MANUAL 13.20 Install cylinder Lubricate cylinder bore with ICS ® 2-stroke oil. Compress rings with ring compression tool. Slide cylinder onto piston, pushing ring compression tool down. 13.21 Install cylinder. Remove ring compression tool.
Page 47 613GC SHOP MANUAL 13. CYLINDER & PISTON TITLE 13.23 Install rear manifold. Lubricate rear manifold with ICS ® 2-stroke oil. Push rear manifold onto cylinder intake. Align rear manifold seam with cylinder and crankcase seam. 13.24 Install rear manifold clamp.
Page 48 Make sure rear manifold lip is flat. 13.28 Install carburetor base screws. Use blue Loctite on 3 screws without ® ground wire. Make sure to include stop switch wire. Torque to 35 in-lbs. (3.9 Nm). © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 49: Water Hose
14.1 Loosen hose clamp screw. 14.2 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. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 50 14. WATER HOSE TITLE 613GC SHOP MANUAL 14.6 Release water tank cap from water tank tube. Depress orange fitting as shown. 14.7 Assemble in the reverse order. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 51: Ignition Coil
Remove starter flywheel shroud by unhooking wires. 15.2 Remove ignition coil screws, wave washers and plain washers. 15.3 Remove ignition coil. 15.4 Inspect. Look for cracks/missing insulation. Clean flywheel magnets and coil if rusty. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 52 26 in-lbs. (2.9 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. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 53: 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 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 54 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. Torque nut to 217 in-lbs. (24.5 Nm). © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 55: Bottom Guard
17. BOTTOM GUARD TITLE This section covers the removal inspection, and installation of the bottom guard. Remove bottom guard screws and split washers. Inspect bottom guard. Replace if damaged. Assemble in reverse order F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 56: Front Handle
Remove front handle screws on right side. 18.2 Remove front handle screws on bottom. 18.3 Install front handle. Roll front handle into place. Install front handle screws (4). Use blue Loctite ® Torque to 69 in-lbs. (7.8 Nm). © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 57: Fuel Tank
19.1 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. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 58 2 bottom vibration isolators on the clutch side (circled). 19.4 Remove vibration isolators from fuel tank (6) if necessary. 19.5 Assemble in reverse order. NOTE: During assembly be careful to avoid kinking the fuel line. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 59: Crankcase
20. CRANKCASE TITLE This section covers the disassembly, 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. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 60 Tap with mallet. NOTE: A nut should always be placed on a threaded shaft when pounding or pressing on it. 20.5 Remove the flywheel side crankcase seal with 1/2” (13 mm) socket. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 61 20.7 Remove crankshaft from the clutch-side crankcase tap crankshaft with a plastic mallet. Suspend above work surface. Tap with plastic mallet. 20.8 Remove the bearing from the flywheel side of crankshaft. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 62 20.10 Clean mating crankcase faces. 20.11 Heat crankcase halves to 150° F. 20.12 Install bearing into crankcase halves. 20.13 Tap with bearing driver and mallet. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 63 20. CRANKCASE TITLE 20.14 Repeat with other half. 20.15 Install crankshaft into clutch side of case. 20.16 Place clutch side crank case seal on crankshaft. Tap lightly with bearing driver and mallet. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 64 20. CRANKCASE TITLE 613GC SHOP MANUAL 20.17 Coat crankcase gasket with ICS ® 2-stroke engine oil. 20.18 Align crankcase gasket on flywheel side crankcase pins. 20.19 Place crankcase halves together and align crankcase pins. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 65 ® Torque to 69 in-lbs. (7.8 Nm). NOTE: The 3 remaining crankcase bolts will be installed during the completion of the saw assembly. 20.22 Install flywheel side crankcase seal – tap with bearing driver and mallet. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 66 20. CRANKCASE TITLE 613GC SHOP MANUAL 20.23 Trim crankcase gasket flush. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 67: Bar Studs
Attempt to remove the inside nut which should pull out the bar stud. Repeat on second bar stud. 21.2 Remove bar pad. Remove sealing o-ring. 21.3 Assemble in reverse order. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 68: Tensioner
NOTE: Saws with serial #’s lower than 0482421700 are not equipped with a bar mount pad cover plate. 22.2 Unscrew tensioner to remove. Remove tensioner pin. Remove tensioner screw keeper. 22.3 Assemble in reverse order. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 69: 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 F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 70 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. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 71 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. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 72 23. CARBURETOR TUNING TITLE 613GC SHOP MANUAL 23.9 When the carburetor is adjusted correctly set the limiter caps as shown with a 1/4” straight blade screwdriver. L = vertical H = horizontal © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 73: Idle Speed Adjustment
Make sure the chain is properly tensioned. Turn T screw clockwise until chain begins to move Back T screw out ½ turn. 24.2 If chain turns at idle: Back T screw out until chain stops moving. F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 74: 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. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 75 • Repair or replace fuel tank carburetor? • Plugged fuel tank breather. breather. Is the flywheel key • Loose flywheel. • Replace key and reinstall flywheel. sheared? F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 76: Troubleshooting: Fuel System Leaks
Test the main fuel pick-up tube for leaks. Install the pressure gauge and bulb. Pressurize the tube to 7 psi (0.5 bar). If the pressure does not maintain, separate the fuel line from the carburetor. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 78 If the pressure does not reduce to 0 psi, disassemble or replace the breather. Clean the parts with solvent or fuel. Assemble in reverse order. Make sure that the spring taper is oriented in the correct direction. © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 79: Troubleshooting: Crankcase Leaks
(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 F/N 71537 Jan O8 © 2008 ICS, Blount Inc.
Page 80: Appendix
1 The Spark Plug Reference Guide is to be used as a guide only. When trying a plug from a different manufacturer, perform a plug check to be sure that the plug will work. Spark Plug Reference Guide ICS Resistor Champion Resistor NGK Resistor 514770 RCYJ4 BPMR8Y © 2008 ICS, Blount Inc. F/N 71537 Jan O8...
Page 81: Engine Rebuild Tips
613GC SHOP MANUAL APPENDIX 613GC Engine Rebuild Tips ALWAYS SET THE CARBURETOR JETS TO FACTORY SETTING WHEN REPLACING OR COMPLETE REBUILD BECOMES NECESSARY – See page 67 for factory recommended settings A replacement carburetor is not set correctly from factory. (DO NOT adjust the carburetor for maximum rpm. Adjusting the carburetor for maximum rpm will cause engine damage).
Page 82 603GC SERVICE MANUAL ICS, Blount Inc. 4909 SE International Way Portland, Oregon 97222 TEL 800‑321‑1240 FAX 503‑653‑4393 icsbestway.com © 2008 ICS, Blount Inc. F/N 71537 Jan O8...

ICS 613GC Service Manual

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