ICS 603GC, Service Manual

Page 1: ...F N 518537 Oct 07 2007 ICS Blount Inc 603GC SERVICE MANUAL...

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Page 3: ...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 HAND...

Page 4: ...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 reassemblin...

Page 5: ...G SHIM 4 71543 CYLINDER ASSEMBLY CLAMPS PISTON STOP 5 73462 MAIN BEARING DRIVER TOOL 6 71546 SHOCK ABSORBER TOOL 7 71547 SPARK TESTER 8 71548 FLYWHEEL PULLER TOOL 9 71550 LIMITER CAP REMOVAL TOOL 10 7...

Page 6: ...h Carburetor Walbro diaphragm HDA 225 Air Filtration Canister polyester Starter Dust and water shielded Ignition Electronic speed governing water sealed Clutch Three weight single spring centrifugal F...

Page 7: ...F N 518537 Oct 07 2007 ICS Blount Inc TITLE 603GC SERVICE MANUAL 5 3 SERIAL LOCATION 3 603GC Cut Off serial number series...

Page 8: ...not related to the key numbers in the 603GC Replacement Parts Price List KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 6 WRIST PIN NEEDLE BEARING 505403 11 CYLINDER BLOCK BOLT WASHER 1 1 95...

Page 9: ...CRANKCASE DOWEL PIN 73281 4 CHOKE LEVER 505409 5 BAR MOUNTING STUD 509555 6 CRANKCASE GROMMET 505408 7 WASHER 73897 9 BAR MOUNT PAD COVER PLATE 505467 12 CRANKCASE GASKET 505440 13 CHOKE LEVER BUSHIN...

Page 10: ...PIN NEEDLE BEARING 505403 7 CRANKSHAFT ASSEMBLY 505397 KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 8 CLUTCH SPRING 505434 10 CRANKCASE SEAL RETAINER 505423 11 CRANKSHAFT SEAL 505381 14 C...

Page 11: ...TITE PART NUMBER Nm in lbs 242 1 MUFFLER SUPPORT BRACKET SCREW 0 9 78 X 73885 2 SERRATED WASHER 73327 3 MUFFLER SUPPORT BRACKET 505392 4 MUFFLER MOUNTING SCREW 1 0 87 73883 5 SCREW 0 4 35 71482 6 WASH...

Page 12: ...INTAKE MANIFOLD 505383 21 CARBURETOR PULSE TUBE 73898 32 CARBURETOR SPRING 73888 36 WASHER 73897 38 CARBURETOR ATTACHMENT SCREW 0 5 43 X 73902 49 OUTER INTAKE MANIFOLD FLANGE SCREW 0 4 35 X 73901 54...

Page 13: ...REW 0 9 78 X 73982 10 WASHER 73897 11 FRONT HANDLE BOLT 0 8 69 X 73983 12 FRONT HANDLE 505424 13 FUEL FILTER 73459 14 FUEL LINE 73375 15 FUEL CAP O RING 73448 16 TRIGGER LOCKOUT LEVER 73987 17 TRIGGER...

Page 14: ...E MANUAL 12 4 SPARE PARTS DIAGRAM KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 31 FLYWHEEL SHROUD 505438 45 FLYWHEEL 505399 48 NUT 3 0 260 73891 51 WAVE WASHER 73911 57 PLAIN WASHER 73912...

Page 15: ...WASHER 4 5mm 73285 40 SPARK PLUG CAP SPRING KIT 73241 41 SPARK PLUG SPRING 73917 43 IGNITION TOGGLE CABLE 73919 44 IGNITION COIL 505426 47 SWITCH IGNITION TOGGLE 73237 53 SCREW 0 7 61 X 73914 56 PLAI...

Page 16: ...6 26 STARTER ROPE HANDLE 505514 27 STARTER ROPE 508854 30 STARTER PULLEY SCREW 0 6 52 X 73907 34 RECOIL HOUSING SCREW 505380 35 STARTER PULLEY WASHER 73905 37 STARTER ROPE PULLEY 508857 42 STARTER ASS...

Page 17: ...EW 73992 5 FILTER SUPPORT 73338 6 FILTER COVER GASKET 71756 7 CYLINDER COVER SCREW 0 5 43 X 505429 8 PREFILTER PLASTIC SECONDARY FILTER 73336 9 AIR FILTER FLANGE 71758 10 FILTER SUPPORT SCREW 0 3 26 X...

Page 18: ...ART NUMBER Nm in lbs 242 1 HOSE CLAMP 71465 2 WATER HOSE 509488 3 WATER HOSE COVER 71464 4 HOSE HANGER 71461 5 WATER SHUT OFF VALVE 71458 6 WATER HOSE O RING 71468 7 RING NUT 71457 8 FITTING 71467 19...

Page 19: ...NUT 505468 12 SCREW 0 5 43 73982 13 GUARD FLAP MOUNTING BRACKET BACK 505490 14 GUARD FLAP MOUNTING BRACKET FRONT 505491 15 GUARD FLAP SCREW 71479 16 GUARD FLAP 505492 17 RUBBER BUMPER COVER 73310 18 S...

Page 20: ...c F N 518537 Oct 07 TITLE 603GC SERVICE MANUAL 18 4 SPARE PARTS DIAGRAM KEY DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 ABOVE CARBURETOR WALBRO HDA 225 517742 CARBURETOR REPAIR KIT 505441 CAR...

Page 21: ...and assembly 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...

Page 22: ...GC SERVICE MANUAL 20 5 AIR INTAKE 5 4 Inspect air filter cover gasket A Replace if permanently depressed or hard due to slurry 5 5 Inspect filter cannister gasket A Clean B Replace if necessary 5 6 Se...

Page 23: ...tion and installation of the spark plug 6 1 Remove the spark boot taking care not to pry or damage the wire 6 2 Clean area around the spark plug to prevent debris from entering the cylinder 6 3 Remove...

Page 24: ...AL 22 6 SPARK PLUG B Gap if necessary to 0 02 0 5 mm NOTE If the spark plug must be replaced refer to the Spark Plug Reference Guide on page 81 to select the correct replacement plug 6 5 Assemble in t...

Page 25: ...sprocket removal inspection and assembly Refer to sections 5 and 6 if needed 7 1 Insert piston stop tool into spark plug hole 7 2 Pull starter handle until piston stops against tool 7 3 Remove clutch...

Page 26: ...37 Oct 07 TITLE 603GC SERVICE MANUAL 24 7 CLUTCH RIM SPROCKET 7 4 Remove all drive components 7 5 Inspect the clutch shoes for wear A Replace if the shoe has less than 0 04 1 mm of material as shown 7...

Page 27: ...RVICE MANUAL 25 7 CLUTCH RIM SPROCKET 7 7 Assemble clutch A Insert top edge of clutch shoe over spring as shown B Snap clutch shoe into place 7 9 Inspect the rim sprocket for wear A Replace if the rim...

Page 28: ...ROCKET 7 10 Clean and assemble A Clean all parts in solvent B Grease clutch cup bearing with a water proof grease ICS P N 70885 C Assemble clutch spacer washer bearing clutch cup with rim sprocket and...

Page 29: ...ment of the recoil spring 8 1 Remove starter cover screws 8 2 Remove starter cover assembly from saw 8 3 Remove starter cord shield screws 8 4 Relieve spring tension A Pull 4 6 10 15 cm of rope out B...

Page 30: ...pulley A Remove pulley screw 8 7 Inspect coil spring A Replace if spring hook is damaged Attempting to re bend the spring hook may cause the hook to break off B Carefully remove coil spring and housin...

Page 31: ...stall starter rope and tie knot 8 12 Knot tying instructions A Make a loop at the end of the pulley rope with the end of the rope crossing on top of the tail B Bring the end of the rope through the lo...

Page 32: ...e leaving 4 6 out B Make sure that the pulley spring catch is in the spring hook 8 14 Install center screw A Use Loctite 242 B Torque to 26 in lbs 2 9 Nm 8 15 Wind the recoil spring A Line rope up wit...

Page 33: ...n pawl components A Inspect the components Replace if necessary B Clean the components with a brush and solvent 8 19 Assemble components A Make sure the spring is in the correct position B Use Loctite...

Page 34: ...2007 ICS Blount Inc F N 518537 Oct 07 TITLE 603GC SERVICE MANUAL 32 8 STARTER 8 21 Install starter cover screws A Use Loctite 242 B Torque to 60 in lbs 7 Nm...

Page 35: ...UAL 33 9 WALLWALKER 9 This section covers the removal inspection and assembly of the rubber padded wallwalker and guard flap 9 1 Inspect bumpers A Replace if worn 9 2 Remove side cover assembly 9 3 Re...

Page 36: ...9 WALLWALKER 9 5 Remove and inspect guard flap A Replace the flap if it is torn or damaged in any way 9 6 Remove guard flap screws and washers 9 7 Reassemble in the reverse order A Install crankcase s...

Page 37: ...screws NOTE May require heat to remove screws 10 2 Remove the cylinder cover screws 3 10 3 Remove spark plug boot from cylinder cover taking care not to pry or damage the wire 10 4 Remove fuel tank b...

Page 38: ...3GC SERVICE MANUAL 36 10 CYLINDER COVER 10 7 Remove stop switch leads 10 8 Inspect cylinder cover for damage A Replace if necessary 10 9 Check filter cover gasket A Replace if necessary 10 10 Check cy...

Page 39: ...w boot is in place 10 13 Install cylinder cover A Pull spark plug lead into slot in cylinder cover B Lubricate compensating tube 1 and fuel tank breather tube 2 with soapy water guide through cylinder...

Page 40: ...e Loctite 242 Torque to 35 in lbs 4 0 Nm 10 14 Install air filter mount A Guide carburetor compensating tube through air filter mount Make sure manifold sits flat over lip on cylinder cover B Install...

Page 41: ...the muffler Removal of the bumpers and cylinder cover is necessary Refer to sections 9 and 10 if necessary 11 1 Remove muffler support screws 11 2 Remove muffler screws 2 note there are two screws an...

Page 42: ...ffler screws in place with heat shield gasket C Thread muffler screws into cylinder torque to 78 in lbs 9 Nm 11 5 Install muffler support A Install top 3 muffler support screws and serrated washer fin...

Page 43: ...uning is covered in section 22 12 1 Remove throttle linkage A Push trigger end out of rear handle B Pivot linkage around C Remove carburetor end of linkage from throttle rod tab on carburetor NOTE All...

Page 44: ...Remove carburetor A Remove pulse tube B Remove carburetor jet cover C Remove carburetor from choke linkage 12 5 Assemble in the reverse order A Torque carburetor body screws to 43 in lbs 5 Nm B Torqu...

Page 45: ...required Refer to sections 5 6 10 and 12 if necessary 13 1 Remove carburetor base screws A Remove carburetor base bracket from rear manifold B Remove carburetor base bracket from pulse tube 13 2 Remo...

Page 46: ...C SERVICE MANUAL 44 13 3 Remove rear manifold clamp 13 4 Remove rear manifold from cylinder A Inspect for holes and tears 13 5 Remove cylinder screws 4 and wave washers 13 6 Remove cylinder A Remove c...

Page 47: ...ount Inc TITLE 603GC SERVICE MANUAL 45 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 pi...

Page 48: ...Assemble cylinder gasket A Oil gasket with ICS 2 stroke engine oil B Install and align holes and notch 13 12 Install wrist pin bearing in rod A Oil bearing with ICS 2 stroke engine oil 13 13 Install r...

Page 49: ...etaining clip is in the proper orientation Improper installation may result in serious engine damage NOTE Never attempt to reuse wrist pin retaining clips or substitute wrist pins from another model o...

Page 50: ...ect orientation A Make sure arrow points to exhaust port 13 19 Install piston A Oil piston with ICS 2 stroke oil B Align wrist pin with wrist pin bearing C Complete wrist pin installation D Install se...

Page 51: ...s with ring compression tool C Slide cylinder onto piston pushing ring compression tool down 13 21 Install cylinder A Remove ring compression tool B Slide cylinder down piston and into crankcase C Ali...

Page 52: ...eams of intake boot with casting seams of the cylinder 13 24 Install rear manifold clamp A Torque to 11 in lbs 1 Nm NOTE Insure that the intake boot is properly installed DO NOT OVER TIGHTEN INTAKE BO...

Page 53: ...base A Slip pulse tube into carburetor base B Slip rear manifold into carburetor base C Make sure rear manifold lip is flat 13 28 Install carburetor base screws A Use Loctite 242 on screws 3 B Make s...

Page 54: ...e and side cover 14 1 Inspect water hose and side cover A Replace if damaged 14 2 Assemble in reverse order 14 3 Remove water hose connector from side cover A Remove clamp and hose from fitting B Unth...

Page 55: ...emoval of the starter is required Refer to section 8 if necessary 15 1 Remove starter flywheel shroud by unhooking wires 15 2 Remove ignition coil screws wave washers and plain washers 15 3 Remove ign...

Page 56: ...e C Install ignition coil screws wave washers and plain washers with Loctite 242 Holding shim rotate flywheel magnet around to coil E Torque ignition coil screws to 26 in lbs 3 Nm F Remove shim rotate...

Page 57: ...f the flywheel Removal of spark plug and the starter is required Refer to sections 6 and 8 if necessary 16 1 Insert piston stop 16 2 Remove flywheel nut wave washer and plain washer 16 3 Screw on flyw...

Page 58: ...removal tool with a ball peen hammer The flywheel should release from crankshaft 16 6 Inspect and clean flywheel Replace if any of the fins are broken 16 7 Inspect cast woodruff key inside the flywhe...

Page 59: ...removal inspection and installation of the front handle 17 1 Remove front handle screws on right side 17 2 Remove front handle screws on bottom 17 3 Install front handle A Roll front handle into plac...

Page 60: ...ction covers the disassembly inspection and assembly of the vibration isolaters fuel tank and rear handle 18 1 Remove vibration isolator screws 2 and wave washers on clutch side of saw 18 2 Remove vib...

Page 61: ...d fuel tank NOTE Saws have a rubber water deflector connected to the 2 bottom vibration isolators on the clutch side circled 18 4 Remove vibration isolators 4 from fuel tank if necessary 18 5 Assemble...

Page 62: ...603GC SERVICE MANUAL 60 19 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...

Page 63: ...minutes approximately 150 F 65 5 C 19 4 Remove the flywheel side crankcase tap crankshaft with plastic mallet A Suspend above work surface B Tap with mallet NOTE A nut should always be placed on a th...

Page 64: ...rankcase Heat the clutch side crankcase with heat gun to 150 F 65 5 C 19 7 Remove crankshaft from the clutch side crankcase tap crankshaft with a plastic mallet A Suspend above work surface B Tap with...

Page 65: ...9 9 Remove the bearing seal and bushing from the clutch side of crankshaft 19 10 Assembly of crankcase A Clean mating crankcase faces 19 11 Heat crankcase halves to 150 F 19 12 Install bearing into cr...

Page 66: ...37 Oct 07 TITLE 603GC SERVICE MANUAL 64 19 14 Repeat with other half 19 15 Install crankshaft into clutch side of case 19 16 Place clutch side crankcase seal on crankshaft A Tap lightly with bearing d...

Page 67: ...nt Inc TITLE 603GC SERVICE MANUAL 65 19 17 Coat crankcase gasket with ICS 2 stroke engine oil 19 18 Align crankcase gasket on flywheel side crankcase pins 19 19 Place crankcase halves together and ali...

Page 68: ...SERVICE MANUAL 66 19 20 Assemble crankcase halves tap with bearing driver and mallet 19 21 Install crankcase bolts A Use Loctite 242 B Torque to 69 in lbs 8 Nm 19 22 Install flywheel side crankcase se...

Page 69: ...Oct 07 2007 ICS Blount Inc TITLE 603GC SERVICE MANUAL 67 19 23 Assemble in reverse order A Install outer crankshaft seal housing with 3 bolts and use Loctite 242 19 24 Trim crankcase gasket flush 19...

Page 70: ...n of the bar studs and bar pad 20 1 On 603GC saws NOTE This requires the removal of the piston and cylinder and to split the crankcase Refer to section 13 19 for detailed instructions A Remove side co...

Page 71: ...n of the chain tensioner 21 1 Remove bar plate to expose the chain tensioner 21 2 Unscrew tensioner to remove A Remove tensioner pin B Remove tensioner screw keeper 21 3 Assemble in reverse order NOTE...

Page 72: ...manual to adjust carburetor to factory recommended settings DO NOT adjust the carburetor for maximum rpm Adjusting the carburetor for maximum rpm will cause engine damage Always set the carburetor je...

Page 73: ...bserve orientation of the release slots on the adjustment screw limiter cap B Insert the limiter cap puller blades into the release slots C Firmly hold the tool shaft while screwing in the puller scre...

Page 74: ...ry 22 5 Start the saw and warm up the engine 22 6 With a tachometer check the saw rpm with bar and no chain A Idle 3 000 300 rpm B If the idle rpm does not fall into this range adjust the T screw cloc...

Page 75: ...7 2007 ICS Blount Inc TITLE 603GC SERVICE MANUAL 73 22 9 When the carburetor is adjusted correctly set the limiter caps as shown with a 1 4 straight blade screwdriver A L vertical B H horizontal 22 CA...

Page 76: ...on covers idle speed adjustment 23 1 If engine stops while idling A Make sure the chain is properly tensioned B Turn T screw clockwise until chain begins to move C Back T screw out turn 23 2 If chain...

Page 77: ...too high Broken clutch spring Excessive vibration YES Damaged shock absorber Damaged or broken flywheel fins Bent crankshaft Replace shock absorbers Replace flywheel Replace crankshaft Adjust idle sp...

Page 78: ...Fuel is old varnished or contaminated Empty tank 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 Tighten plug and re...

Page 79: ...re the fuel tank fuel tank breather fuel filter delivery tubes and carburetor 25 1 Remove and inspect the fuel filter A Replace the fuel filter if there is any foreign material in the felt or the inte...

Page 80: ...o Diaphragm Carburetor Service Manual 25 3 The fuel tank breather stabilizes the pressure in the fuel tank preventing both excessive pressure which could flood the engine and negative pressure which c...

Page 81: ...o 0 psi disassemble or replace the breather A Disassemble by snapping off cap B Clean parts with solvent or fuel 25 7 Assemble in reverse order A Make sure duck bill opens easily B Make sure that the...

Page 82: ...intake seal flange A Plug cylinder pulse tube 26 2 Install the exhaust seal flange 26 3 Block one of the flange tubes with a rubber plug 26 4 Install the pressure gauge and bulb 26 5 Pressurize the cr...

Page 83: ...k 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 CH...

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Page 86: ...2007 ICS Blount Inc F N 518537 Oct 07 ICS Blount Inc 4909 SE International Way Portland OR 97222 Tel 800 321 1240 Fax 503 653 4393 icsbestway com 603GC SERVICE MANUAL...