ICS 660GC User manual

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC

SERVICE MANUAL

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

1

SECTION SECTION TITLE PAGE NUMBER

SERVICE MANUAL USE 2

1 TOOLS 3

2 SAW SPECIFICATIONS 4

3 SERIAL NUMBER LOCATION 5

4 SPARE PARTS DIAGRAMS

(TORQUE SPECS & LOCTITE

®

APPLICATION) 6

5 AIR INTAKE 19

6 SPARK PLUG 21

7 CLUTCH & RIM SPROCKET 23

8 STARTER SYSTEM 27

9 WALLWALKER

®

33

10 CYLINDER COVER 35

11 MUFFLER 39

12 CARBURETOR 41

13 CYLINDER & PISTON 43

14 WATER HOSE 52

15 IGNITION COIL 53

16 FLYWHEEL 55

17 FRONT HANDLE 57

18 FUEL TANK 58

19 CRANKCASE 60

20 BAR STUDS & BAR PAD 68

21 CHAIN TENSIONER 69

22 CARBURETOR TUNING 70

23 IDLE SPEED ADJUSTMENT 74

24 TROUBLESHOOTING DIAGRAMS 75

25 TROUBLESHOOTING FUEL SYSTEM LEAKS 77

26 TROUBLESHOOTING CRANKCASE LEAKS 80

APPENDIX

1. SPARK PLUG REFERENCE GUIDE 81

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

2

ServiceManualUse

Thismanualcontainsallthetechnicalinformationnecessaryforcarryingoutrepairsonthe

660GC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.

General Shop Rules

• Alwaysusetherighttoolsforthejob,otherwisecomponentsmaybedamaged.

• 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

appropriatesubgroups.

• Whenreassembling,cleanallpartscarefully,lubricatemovingpartsandreplace

alloilseals,o-rings,gaskets,washersandself-lockingnuts.

• For best results, use only original ICS

®

replacement parts.

General Recommendations

• Someproceduresinthismanualrequiretheuseofspecialtools.Acompletetoolkit

forICS

®

sawsisavailablefromICS

®

.

• DetailedcarburetormaintenanceandoverhaulinformationisavailableinWalbro’s

DiaphragmCarburetorServiceManual.Walbrocanbecontactedathttp:\\www.walbro.com

orbycalling1.989.872.2131.

SERVICE MANUAL USE

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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Key # Part No. Description MSRP

1 71521 Scrench13-19mm $10.55

2 71541 PressureGaugeBulb $47.40

3 71542 Coil/FlywheelTimingShim $5.25

4 71543 CylinderAssemblyClamps&PistonStop $10.55

5 73462 MainBearingDriverTool $38.65

6 71546 ShockAbsorberTool $22.15

7 71547 SparkTester $46.35

8 71548 FlywheelDisassemblyTool $31.45

9 71550 LimiterCapPuller $89.25

10 71565 ElectronicTachometer $240.00

11 71573 TuningScrewdriver $10.55

NotShown 71625 CarburetorTuningKit $99.95

NotShown 505882 2-StrokeOil,25:1Mix,5.2oz(158ml)(6-Pack) $18.00

NotShown 505883 2-StrokeOil,25:1Mix,5.2oz(158ml)(24-Pack) $55.00

1. TOOLS

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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EngineType 2-strokeSingleCylinderAirCooled

Displacement 3.9cu-in(64cc)

Horsepower 4.2HP(3.1kw)@9,500RPM

Torque 32in-lbs(3.6Nm)@6,000RPM

EngineSpeed

11,500+/-500rpm(max)

2,800-3,200rpm(idle)

Weight

18.2lbs(8.3kg)withoutguidebarand

diamondchain

CutDepth Upto10inches(25.4cm)

Dimensions

17inches(44cm)length

10inches(25.5cm)height

11.6inches(29.5cm)width

AirFilter WaterResistantPolyester

Carburetor WalbroHDA225

Starter DustandWaterresistant

Ignition

Specialwaterresistantelectronic

ignition

Clutch Centrifugalthreeshoe,singlespring

FuelMixratio 25:1(4%)

FuelCapacity 0.26gallons(1Liter)

WaterSupply Minimum20psi(1.5bar)

WaterFlow Minimum2gpm(8lpm)

NoiseLevel 101dBat3ft(1m)

VibrationLevel

6.2m/s

2

(fronthandle)

7.3m/s

2

(rearhandle)

EngineBreak-inPeriod

Onetank,withoutcutting,cycling

throttle

SparkPlug

ChampionCJ7Y,BoschBWS7F,or

NGKBPMR7A.

Electrodegap.020in(0.5mm)

SPECIFICATIONS

2. SPECIFICATIONS

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

5

3 660GCserialnumberseries.

3. SERIAL # LOCATION

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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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

660GCReplacementPartsPriceList.

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 SPARKPLUG 27.5 243 73199

2 CYLINDERBOLT 10.7 95 X 73874

3 DECOMPRESSIONVALVE 12.8 113 71642

4 CYLINDERBASEGASKET 505439

5 COMPLETECYLINDER&PISTONASSEMBLY 505428

6 WRISTPINNEEDLEBEARING 505403

CYLINDER&PISTONASSEMBLY

2

6

4

3

5

4. SPARE PARTS DIAGRAM

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 CRANKCASEPLUG 505407

2 TANKPLUG 512461

3 CRANKCASE 537665

4 CRANKCASEDOWELPIN 73281

5 FUELLINEGROMMET 505627

6 CRANKCASEGROMMET 505408

7 CRANKSHAFTBEARING 505375

8 BARMOUNTINGSTUD 509555

9 TENSIONER 505393

10 BARMOUNTPADCOVERPLATE 505467

11 SCREW,5X50mm 4.9 43 X 509709

12 WASHER 73897

13 CRANKCASEBOLT 7.9 69 X 73930

14 CRANKCASEGASKET 505440

15 CHOKELEVERBUSHING 73955

16 CHOKELEVER 505409

CRANKCASEASSEMBLY

2

6

5

8

7

4

3

9

10

16

15

14 13

12

11

7

4. SPARE PARTS DIAGRAM

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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4. SPARE PARTS DIAGRAM

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 CRANKSHAFTSEAL 505381

2 CRANKSHAFTBEARING 505375

3 CRANKSHAFTASSEMBLY 505397

4 WRISTPINNEEDLEBEARING 505403

5 CRANKSHAFTBUSHING X 509487

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 CRANKSHAFTRETAINERSEAL 540139

2 CRANKCASESEALRETAINER 505423

3 WASHER 73285

4 BOLT 2.9 26 X 73940

5 CLUTCHSPACER 505421

6 CLUTCHBEARING 505378

7 8TRIMSPROCKETKIT 70949

8 CLUTCHCUPWITHSPLINEDADAPTOR 505422

9 CLUTCHSPACERINSIDE 505436

10 CLUTCH 33.3 295 505442

11 CLUTCHSPRING 505434

CLUTCH&CRANKCASEASSEMBLY

1

11

10

9

86

7

5

4

3

2

1

5

1

2

3

2

4

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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4. SPARE PARTS DIAGRAM

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 CYLINDER-TO-MUFFLERGASKET 505385

2 MUFFLER 537692

3 MUFFLERSCREW&WASHER 8.8 78 548518f

4 LOWERMUFFLERSCREW 5.8 52 73866

MUFFLERASSEMBLY

3

4

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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4. SPARE PARTS DIAGRAM

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 SCREW 4.9 43 505469

2 WASHER 73897

3 OUTERINTAKEMANIFOLD 507427

4 OUTERINTAKEMANIFOLDFLANGESCREW 4.9 43 X 73901

5 OUTERINTAKEMANIFOLDFLANGE 505384

6 COMPENSATORTUBE 505382

7 CARBURETORSPRING 73888

8 CARBURETOR,WALBRO 517742

9 PULSETUBE 71751

10 CARBURETORMOUNTINGBRACKET 505411

11 SCREW 4.0 35 X 73866

12 ADJUSTMENTGUIDE 505391

13 INTAKEMANIFOLD 505383

14 INTAKEMANIFOLDCLAMP 1.0 11 73867

CARBURETORASSEMBLY

1

9

7

8

6

4

5

2

3

10

14

13

12

11

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

11

4. SPARE PARTS DIAGRAM

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 REARHANDLEHALF 548392

2 SCREW 1.0 9 73976

3 THROTTLELEVER 71749

4 THROTTLELINKAGEASSEMBLY 71750

5 TRIGGERLOCKOUTLEVERSPRING 73988

6 TRIGGERLOCKOUTLEVER 73987

7 SHOCKABSORBER 4.0 35 505387

8 SHOCKABSORBERWITHSCREW 4.0 35 505658

9 REARHANDLESHOCKABSORBER 505425

10 BUMPER,SHOCKABSORBER,FUELTANKTOP 73270

11 FUELTANK 548391

12 FRONTHANDLEBOLT 7.8 69 X 73983

13 FRONTHANDLE 548483

14 WASHER 73897

15 SCREW 8.8 78 X 73982

16 RUBBERWATERDEFLECTOR 505445

17 FUELBREATHERCOMPLETE 71748

18 FUELBREATHER,REMOTE 71761

19 FUELFILTERCLIP 71588

20 TUBECLAMP 71760

21 BREATHERTUBEELBOW 71759

22 BREATHERTUBEBODY 71751

23 FUELLINE 73375

24 FUELFILTER 73459

25 FUELCAPO-RING 73448

26 FUELCAPASSEMBLY,WITHOUTERSEALRIING 71739

FUELTANK&HANDLEASSEMBLY

1

8

9

8

7

6

5

3

2

8

7

10

11

19

24

25

26

16

15

14

22

21

20

19

18

17

13

12

23

4

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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4. SPARE PARTS DIAGRAM

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 FLYWHEELSHROUD 548514

2 FLY WH EEL 548515

3 NUT 24.5 217 73891

4 WASHER 73911

5 WASHER 73912

6 STARTERPAWLASSEMBLY 6.8 60 508852

FLYWHEELASSEMBLY

1

6

5

4

3

2

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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4. SPARE PARTS DIAGRAM

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 IGNITIONTOGGLESWITCHNUT 73239

2 IGNITIONTOGGLEPLATEON/OFF 73238

3 IGNITIONTOGGLESWITCH 73237

4 TOGGLESWITCHCONNECTINGPLATE 71449

5 IGNITIONTOGGLECABLE 73919

6 SCREW 2.9 26 X 73914

7 WASHER 73285

8 WASHER 73890

9 SPARKPLUGBOOTW/SPRING 73241

10 SPARKPLUGSPRING 73917

11 IGNITIONCOILWITHSPARKPLUGLEAD&PRIMARY 505426

IGNITIONASSEMBLY

1

5

4

3

2

6

9

11

8

7

10

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 SCREW 6.8 60 73230

2 STARTERROPEHANDLE 505514

3 STARTERROPE 508854

4 STARTERASSEMBLY 537666

5 STARTERCASEPLATE 71451

6 RECOILHOUSINGSCREW 505380

7 STARTERPULLEYWASHER 73905

8 STARTERASSEMBLYCAP 508853

9 STARTERPULLEYSCREW 2.9 26 X 73907

10 STARTERROPEPULLEY 508857

11 STARTERCOILSPRING&HOUSING 73909

STARTERASSEMBLY

4. SPARE PARTS DIAGRAM

5

8

1

9

7

10

11

6

4

3

2

 ©2011ICS|Blount,Inc.Specicationsandpricingaresubjecttochangewithoutnotice.P/N550416REV06012011

660GC SERVICE MANUAL

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KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 AIRFILTERO-RING 73331

2 FILTERCOVERSCREW 4.0 35 73992

3 AIRFILTERCOVERASSEMBLY(WITH3SCREWS) 537661

4 AIRFILTERFLANGE 71758

5 AIRFILTERCANISTER,POLYESTER 71752

6 PREFILTERPLASTIC,SECONDARYFILTER 73336

7 WASHER 73897

8 CYLINDERCOVERSCREW 4.0 35 X 505429

9 FILTERSUPPORTSCREW 4.9 43 X 505437

10 FILTERSUPPORT 73338

11 CYLINDERCOVER 537660

12 O-RING 71472

13 COMPENSATORTUBE 505382

14 TUBECLAMP 71760

15 FILTERCOVERGASKET 71756

16 BREATHERGROMMET 71763

17 FILTERCANISTERGASKET 73335

AIRFILTERASSEMBLY

4. SPARE PARTS DIAGRAM

16

15

17

660GC SERVICE MANUAL

16

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 WATERHOSEGASKET 71469

2 FITTING 71467

3 RINGNUT 71457

4 WATERHOSEO-RING 71468

5 WATERSHUT-OFFVALVE 71458

6 FITTING 71466

7 FITTING 71454

8 HOSECLAMP 71465

9 WATERHOSE 509488

10 HOSEHANGER 71461

11 WATERHOSECOVER 71464

4. SPARE PARTS DIAGRAM

WATERDELIVERYSYSTEM

4

9

8

7

6

5

10

8

11

7

1

3

2

660GC SERVICE MANUAL

17

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 GUARDFLAPSCREW 71479

2 GUARDFLAPMOUNTINGBRACKET,FRONT 505491

3 GUARDFLAP 505492

NUT

5 GUARDFLAPMOUNTINGBRACKET,BACK 505490

6 GUARDFLAPNUT 505468

7 BOLT 73983

8 RUBBERBUMPER,COVER 73310

9 SIDECOVERGASKET 505417

10 MOUNTINGNUT 509852

11 RUBBERWALLWALKER 505493

12 SCREW 4.9 43 73982

13 SIDECOVERNUT 27.5 243 73958

14 SIDECOVER 537662

15 FITTING X 71454

16 SIDECOVERPLATE 505419

17 SCREW 71487

4. SPARE PARTS DIAGRAM

SIDECOVERASSEMBLY

1

9

8

7

6

5

3

2

10

16

15

14

13

12

11

4

17

660GC SERVICE MANUAL

18

4. SPARE PARTS DIAGRAM

KEY DESCRIPTION

TORQUE LOCTITE

®

PART NUMBER

Nm in‑lbs. 242

1 CARBURETORREPAIRKIT 548394

2 CARBURETORWALBRO

HDA-225 548393

CARBURETORREPAIRKIT

2

1

660GC SERVICE MANUAL

19

5. AIR INTAKE

5 Thissectioncoversthe

disassembly,inspection,and

assemblyoftheairinduction

system.

5.1 Loosen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(P/N71752).

5.3 Removesecondaryfilterfrom

airfiltermount.

A Cleansecondaryfilterwithcleaning

solutionandanylonbrush.

B Letdryandreinstall.

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ICS 660GC User manual

ICS 660GC User manual

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