ICS 695XL, Service Manual

Page 1: ...2017 ICS Blount Inc Specifications subject to change without notice REV19JUNE2017 P N 598901 695XL SERVICE MANUAL...

Page 2: ...SIONER 21 8 CLUTCH RIM SPROCKET 23 9 STARTER SYSTEM 28 10 CARBURETOR REMOVAL 33 11 MUFFLER 37 12 GUIDE BAR STUD 38 13 IGNITION MODULE 39 14 STOP SWITCH 40 15 WATER HOSE 42 16 CYLINDER PISTON DECOMPRES...

Page 3: ...se 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 approp...

Page 4: ...Piston Stop 9 546196 Wrist Pin Punch 10 546197 Cylinder Seal Exhaust 11 546198 Cylinder Seal Inlet Port 12 546289 Puller Sealing Ring 13 546292 Universal Puller 14 546293 Grip Plate 15 546294 Bearing...

Page 5: ...ignition Clutch Centrifugal three shoe three spring Fuel ratio 2 50 1 petrol to oil Fuel Capacity 1 liter 0 26 gallon Water Supply Requirement Minimum 1 5 bar 20 psi Water Flow Requirement Minimum 4lp...

Page 6: ...017 ICS Blount Inc Specifications subject to change without notice REV19JUNE2017 P N 598901 6 695XL SERVICE MANUAL 3 SERIAL NUMBER LOCATION 3 This section shows the single location of the serial numbe...

Page 7: ...SPARE PARTS DIAGRAM 4 This section covers spare parts STARTER ASSEMBLY Key Part No Description A1 544013 STARTER COVER ASSEMBLY A2 544127 STARTER PULLEY KIT A3 543974 SCREW A4 544021 RECOIL SPRING A5...

Page 8: ...Description B1 544030 STOP SWITCH SCREW B2 544031 STOP SWITCH B3 544032 STOP SWITCH CABLE B4 544033 SPARK PLUG CAP B5 544034 SPARK PLUG B6 544035 PROTECTIVE SLEEVE B7 544036 IGNITION MODULE B8 544038...

Page 9: ...07 SPACER C4 525496 695F4 FORCE4 SPROCKET C4 70949 695GC RIM SPROCKET C5 543909 CLUTCH CUP C6 543910 NEEDLE BEARING C7 543911 BAR BRACKET SCREW C8 543912 CRANK CASE BOLT C9 544130 WALLWALKER C10 54392...

Page 10: ...01 10 695XL SERVICE MANUAL SIDE COVER TENSIONER ASSEMBLY Key Part No Description D1 543899 SIDE COVER ASSEMBLY D2 543900 SIDE COVER NUT D3 543901 SIDE COVER NUT CIRCLIP D4 543902 TENSIONER COVER PLATE...

Page 11: ...43844 HEAT DEFLECTOR E4 543938 MUFFLER GASKET E5 543845 MUFFLER E6 543846 LOWER MUFFLER MOUNTING SCREW E7 543847 MUFFLER MOUNTING WASHER E8 576166 DECOMPRESSION VALVE E9 576165 CYLINDER BASE GASKET E1...

Page 12: ...RANKCASE ASSEMBLY F2 543930 CRANKCASE SCREW F3 543931 SEALING RING F4 543932 GUIDE BUSHING F5 543933 CRANKCASE GASKET F6 543934 MAIN BEARING F7 543935 RUBBER BUSHING F8 543936 GASKET KIT F9 543937 CYL...

Page 13: ...without notice REV19JUNE2017 P N 598901 13 695XL SERVICE MANUAL CRANKSHAFT ASSEMBLY Key Part No Description G1 543952 CRANKSHAFT ASSEMBLY G2 543934 MAIN BEARING G3 543953 CRANKSHAFT SHIELD G4 543949 N...

Page 14: ...BRACKET I6 544065 SCREW I7 544074 SEPARATOR PLATE I8 544075 CARBURETOR WALBRO RWJ 7 I9 544111 THROTTLE CABLE LEVER I10 576168 ADJUSTMENT GUIDE I11 544112 MANIFOLD BRACKET I12 544113 AIR INTAKE MANIFO...

Page 15: ...scription J1 544060 FILTER COVER REAR SCREW J2 544061 FILTER COVER FRONT SCREW J3 576167 PLUG may be required on older 695GC F4 models J4 544062 FILTER COVER J5 544063 AIR INTAKE INSERT J6 544064 AIR...

Page 16: ...CLAMP K11 543971 FUEL FILTER K12 544990 TANK VENT ELBOW K13 544122 TANK VENT K14 543972 REAR HANDLE GROUND SUPPORT K15 543973 PURGE BULB K16 543974 REAR HANDLE SCREW K17 543975 THROTTLE CABLE ASSEMBL...

Page 17: ...AMP WATER HOSE L5 544001 CLAMP WATER HOSE VALVE SIDE L6 544002 FRONT HANDLE L7 544003 SHOCK ABSORBER FRONT HANDLE L8 543981 SCREW SHOCK ABSORBERS L9 544008 CLIP FRONT HANDLE L10 544009 SCREW FRONT HAN...

Page 18: ...N 598901 18 695XL SERVICE MANUAL 5 This section covers the removal inspection and assembly of the air intake 5 2 Loosen air filter screw Inspect air filter for dirt or damage Replace with P N 544064...

Page 19: ...XL SERVICE MANUAL 6 This section covers the removal inspection and installation of the spark plug 6 1 Remove the spark plug cap 6 2 Remove the spark plug 6 3 Inspect spark plug If it s dirty clean wit...

Page 20: ...subject to change without notice REV19JUNE2017 P N 598901 20 695XL SERVICE MANUAL 6 SPARK PLUG 6 4 Gap if necessary to 0 20 0 5mm 6 5 Assemble in reverse order ensuring that the spark plug is properly...

Page 21: ...e cover nut removal inspection and assembly 7 1 Loosen side cover nut Remove side cover Remove tensioner plate screws and tensioner plate 7 2 Remove tensioner assembly Note the orientation of the tens...

Page 22: ...to change without notice REV19JUNE2017 P N 598901 22 695XL SERVICE MANUAL 7 SIDE COVER TENSIONER 7 4 Inspect side cover nut and circlip Replace if damaged Circlip can be removed with a large flathead...

Page 23: ...lutch removal rim sprocket removal inspection and assembly Refer to sections 5 and 6 if necessary Rim sprocket removal procedure 8 1 Using flat head screwdriver remove retaining ring Use caution when...

Page 24: ...CE MANUAL 8 3 Inspect rim sprocket and replace if necessary P N 70949 Replace if the rim sprocket teeth are worn to points as shown on right 8 4 Rim sprocket assembly Assemble in reverse order 8 5 Rem...

Page 25: ...E2017 P N 598901 25 695XL SERVICE MANUAL 8 6 Clutch removal Remove clutch cup rim sprocket first 8 7 Insert piston stop tool into spark plug hole 8 8 Remove clutch with clutch tool P N 546659 Rotate c...

Page 26: ...ERVICE MANUAL 8 CLUTCH RIM SPROCKET 8 10 Inspect clutch shoes P N 543927 CHECK I can t find this p n in the RPPL for excessive wear or damage 8 9 Clutch is marked with arrow off for direction of remov...

Page 27: ...of the screwdriver or rod This will cause the spring hook to detach Push the spring out Repeat with the remaining two springs 8 14 Fit clutch shoes Slide the spring into the narrower section of the cl...

Page 28: ...is section covers the removal of the starter cover replacement of the starter rope and replacement of the recoil spring 9 1 Loosen 4 starter cover screws 9 2 Remove starter cover from the power cutter...

Page 29: ...19JUNE2017 P N 598901 29 695XL SERVICE MANUAL 9 5 Pulley removal from spring 9 4 Rotate pulley shaft counter clockwise allowing pulley to unwind using rope as a brake 9 6 Remove the center screw and c...

Page 30: ...knot 9 7 Note the orientation of the parts for re installation 9 8 A Lift pulley from spring housing NOTE the spring catch and spring hook must be aligned during installation arrows B Remove the two...

Page 31: ...L 9 12 Tension pulley Wind rope onto pulley clockwise leaving 6 8 in 15 20 cm of rope out Ensure the pulley spring catch is installed on the spring hook 9 10 Assemble in reverse order 9 11 Install the...

Page 32: ...s and seat cover Tighten side cover screws 9 14 Rope must fully retract into starter cover 9 13 Insert the rope into the pulley notch Wind rope clockwise around pulley shaft 3 4 times Then pull starte...

Page 33: ...s and front handle is required Refer to sections 5 15 if necessary 10 1 Remove air filter cover and air filter Refer to section 5 Remove 2 screws P N 544065 Lift cylinder cover off from the front of t...

Page 34: ...901 34 695XL SERVICE MANUAL 10 6 Remove fuel line check valve tube and carburetor 10 5 Remove flange screw P N 544072 Remove air intake manifold P N 544113 Inspect for damage 10 4 Remove 2 carburetor...

Page 35: ...ifications subject to change without notice REV19JUNE2017 P N 598901 35 695XL SERVICE MANUAL 10 7 Remove throttle cable from carburetor 10 8 Remove clutchside flange screw P N 544072 and screw P N 544...

Page 36: ...t Remove the flange bracket and flange from the inlet boot Note orientation of plate UP 10 10 Loosen clamp Inspect and replace inlet boot if damaged see section 16 2 Cylinder must be loosened in order...

Page 37: ...ch Remove 1 lower muffler mounting screw P N 543846 and muffler mounting washer P N 543847 11 This section covers the removal inspection and assembly of the muffler Removal of WallWalker and cylinder...

Page 38: ...d removal P N 544129 12 3 Inspect bar stud P N 544129 Replace if damaged Install in reverse order using Loctite 242 12 2 Using a 6 mm allen or hex head remove 2 bolts holding bar stud 12 This section...

Page 39: ...Removal of the starter is required Refer to section 8 if necessary 13 2 Remove 2 ignition module screws P N 544038 Remove ignition module P N 544036 Inspect and replace if damaged 13 3 Reassemble in...

Page 40: ...Blount Inc Specifications subject to change without notice REV19JUNE2017 P N 598901 40 695XL SERVICE MANUAL 14 STOP SWITCH 14 2 Remove screw P N 544030 14 1 Remove stop switch P N 544031 Disconnect c...

Page 41: ...ce REV19JUNE2017 P N 598901 41 695XL SERVICE MANUAL 14 4 Pull the right side out first Replace switch if damaged Install in reverse order Switch will snap back into place Use Loctite 242 only on screw...

Page 42: ...695XL SERVICE MANUAL 15 1 Inspect hose P N 543999 water pipe P N 543915 and water valve P N 543996 Replace if damaged 15 This section covers water hose and water tank cap 15 2 Release clip from water...

Page 43: ...der piston and related components Refer to section 5 10 if necessary 16 1 Remove outer shock absorber screw set aside for reassembly P N 543981 Loosen 4 cylinder screws P N 543942 16 2 Remove cylinder...

Page 44: ...without notice REV19JUNE2017 P N 598901 44 695XL SERVICE MANUAL 16 3 Remove wrist pin clip from each side of piston 16 4 Remove wrist pin using the wrist pin punch P N 543196 Remove piston and cylinde...

Page 45: ...o change without notice REV19JUNE2017 P N 598901 45 695XL SERVICE MANUAL 16 8 Note the ring locator pins 16 7 Install piston rings Install lower piston ring first 16 6 Inspect cylinder and piston P N...

Page 46: ...bricate crankcase gasket mating surface with ICS 2 stroke oil Install cylinder base gasket 16 11 Lubricate needle roller with ICS 2 stroke oil Insert into the connecting rod 16 9 Note ring orientation...

Page 47: ...ate wrist pin with ICS 2 stroke oil and partially install in the piston 16 13 Install wrist pin clip into opposite side of the piston Make sure wrist pin clip is in the proper orientation See 16 15 16...

Page 48: ...ide cylinder onto piston pushing ring tool down D Remove ring compressor E Slide cylinder onto piston and into the crankcase F Align cylinder bolt holes with crankcase Align cylinder screw with holes...

Page 49: ...HANDLE 17 2 Remove 2 screws from lower front handle P N 544009 17 1 Remove 2 screws P N 544012 and guard flap backing plate P N 544011 Inspect guard flap for damage P N 544010 replace if damaged Reass...

Page 50: ...17 P N 598901 50 695XL SERVICE MANUAL 17 4 Lift up crankcase and remove handle inspect and replace if damaged Install in reverse order Use Loctite 242 on all screws except shock absorber screw 17 3 Re...

Page 51: ...ge without notice REV19JUNE2017 P N 598901 51 695XL SERVICE MANUAL 18 REAR HANDLE 18 1 Remove screw from rear handle P N 543974 18 2 Remove rear handle cover P N 543816 18 This section covers the remo...

Page 52: ...95XL SERVICE MANUAL 18 3 Remove throttle lock out P N 543815 by squeezing pulling up and out 18 5 Pull the throttle trigger and spring P N 543977 down from the rear handle 18 4 Remove throttle trigger...

Page 53: ...to change without notice REV19JUNE2017 P N 598901 53 695XL SERVICE MANUAL 18 7 Remove cable lever P N 543814 using needle nose pliers pulling up 18 6 Remove throttle cable P N 543975 See section 10 to...

Page 54: ...E2017 P N 598901 54 695XL SERVICE MANUAL 18 8 Remove throttle cable from cable lever using an awl or small punch 18 10 Inspect all throttle component parts Replace if damaged Reassemble in reverse ord...

Page 55: ...Remove fuel cap P N 543979 Inspect fuel cap and O ring Replace if damaged 19 3 Remove fuel filter Pull up on hose clamp P N 543970 Pull down on fuel filter 19 2 Remove fuel filter P N 543971 Use a sm...

Page 56: ...e if damaged or dirty Reassemble in reverse order 19 6 Remove the 2 shock absorber screws from the flywheel side of the power cut ter 19 5 Before separating the fuel tank from crankcase remove the fro...

Page 57: ...fuel tank from crankcase by pulling up on the crankcase while holding the fuel tank 19 9 Location of the tank vent on an assembled power cutter NOTE The breather assembly can be removed without remov...

Page 58: ...sing a small wedge insert between the crank case and fuel tank to create more space 19 11 Remove fuel cap and locate the fuel tank breather hole The hole is directly in line with the breather assembly...

Page 59: ...e REV19JUNE2017 P N 598901 59 695XL SERVICE MANUAL 19 13 Assemble the tank vent elbow and tank vent by pressing together 19 14 Insert the breather assembly by pressing directly over the elbow see arro...

Page 60: ...hange without notice REV19JUNE2017 P N 598901 60 695XL SERVICE MANUAL 19 15 Inspect the tank vent and replace if damaged Refer to troubleshooting section 25 if necessary 19 16 Inspect fuel tank for da...

Page 61: ...Front shock absorber P N 543983 B Clutch side shock absorber P N 543982 C Flywheel side shock absorber P N 543984 Inspect and replace if damaged Install in reverse order using Loctite 242 except Tank...

Page 62: ...ngage purge bulb 19 22 Reassemble in reverse order Check valve tube must be inserted back into channel and connected to fuel line with clip P N 543818 19 21 Inspect all components Replace if damaged C...

Page 63: ...case seal puller and punch 20 3 Seal removal A Insert T handle puller over the shaft B Apply downward pressure to the T handle and turn the barrel clockwise with a wrench to thread into the seal 20 2...

Page 64: ...e REV19JUNE2017 P N 598901 64 695XL SERVICE MANUAL 20 4 Turn the T handle until it presses against the shaft and pulls the seal from the crankcase 20 6 Lubricate the shaft with High Pressure Grease 20...

Page 65: ...ge without notice REV19JUNE2017 P N 598901 65 695XL SERVICE MANUAL 20 7 Install the new seal Use caution as seal slides over the threads 20 9 Repeat procedure for the flywheel side 20 8 Use the punch...

Page 66: ...20 10 Using soapy water on both sides perform a crankcase leak down test using pressure gauge and vacuum gauge 20 12 Crankcase separation The universal puller and grip plate are required to separate...

Page 67: ...ice REV19JUNE2017 P N 598901 67 695XL SERVICE MANUAL 20 13 Remove the shaft seals from both sides of the crankcase See seal removal 20 15 Attach universal puller and press out the crank shaft 20 14 In...

Page 68: ...7 P N 598901 68 695XL SERVICE MANUAL 20 16 Using the same process press out the other half from the flywheel side 20 18 If the bearing s remain on the shaft upon separation the bearing removal tool mu...

Page 69: ...19JUNE2017 P N 598901 69 695XL SERVICE MANUAL 20 19 Install the bearing clamp and tighten nuts 20 21 Crankcase bearing tools These tools are required to remove the bearing from the crankcase 20 20 Ins...

Page 70: ...95XL SERVICE MANUAL 20 22 Heat crankcase halves to 150 F 65 5 C Use the shaft sleeve and soft mallet to tap out both bearings 20 24 Place the bearing on the bearing support plate Holding the bearing s...

Page 71: ...Place the screw with nut and washers through the crankcase support plate and thread into the bearing support plate 20 27 Bearing Tools Shaft Sleeve Shaft Mandrels 20 26 Hold the screw in place and tur...

Page 72: ...ce REV19JUNE2017 P N 598901 72 695XL SERVICE MANUAL 20 28 Bearing press kit 20 30 Slide the clutch side shaft through the bearing 20 29 Crankshaft install Secure clutch side crankcase face down so the...

Page 73: ...over the shaft against the crankcase Thread the M12 mandrel with the nut and washer until it bottoms Note REVERSE THREAD on the clutch side 20 33 Install the 2 crankcase guide pins 20 32 Hold mandrel...

Page 74: ...stroke oil and install the crankcase gasket 20 35 Lubricate and assemble the flywheel side of the crankcase using the same method with the M8 standard thread mandral Ensure the connecting rod does no...

Page 75: ...MANUAL 20 37 Tighten the screws to 106 124 in lbs 12 14 Nm using an x pattern 20 39 Install shaft seals refer to section 20 7 20 38 Cut the excess gasket over the cylinder port and carburetor area Ta...

Page 76: ...UAL 21 1 Carburetor tuning A Throttle screw B Low speed jet C High speed jet D Model number 21 3 Carburetor adjustment Tachometer is required for proper tuning of the power cutter 21 2 Tools required...

Page 77: ...basic setting H 1 1 2 turns from closed L 1 5 8 turns from closed Insert the tuning screw driver into the crankcase slot Note the H screw is on the right as seen in the picture 21 7 Turn the screws c...

Page 78: ...imum RPM for more than 5 seconds If the full throttle RPM falls below this range turn the H needle clockwise 1 16 of a turn at a time checking the RPM s at each interval NOTE pulse the throttle to sta...

Page 79: ...too high Broken clutch spring Excessive vibration Damaged shock absorber Damaged or broken flywheel fins Bent crankshaft Replace shock absorbers Replace flywheel Replace crankshaft Adjust idle speed...

Page 80: ...and re fill with fresh fuel of the correct mixture 50 1 Loose spark plug If below 125 psi excess wear on the piston cylinder rings and or improper fuel mixture Tighten plug and re test Replace piston...

Page 81: ...nction of any of the main components of the fuel system 24 3 Remove and inspect the fuel filter Replace the fuel filter if the filter is excessively dirty or there is foreign material stuck to it 24 2...

Page 82: ...rburetor 24 6 The fuel tank breather stabilizes the pressure in the fuel tank preventing both excessive pressure which could flood the engine and negative pressure which could starve the engine of fue...

Page 83: ...e to 4 5 psi 0 3 bar The pressure should reduce to nearly 0 psi 0 bar over a period of 3 seconds 24 10 Inspect the fuel purge circuit Inspect the purge bulb for leaks or damage Replace if damaged See...

Page 84: ...take plate from intake boot prior to installing intake seal flange A B 25 3 Securely plug or tape over the clutch needle roller lubrication port on the crankshaft Clutch cup and needle roller must be...

Page 85: ...eal flange Install the pressure gauge and pressurize the crankcase to 7 psi 0 5 bar If the pressure does not hold use soapy water to find the leak Note it is recommended to pressure test the engine af...

Page 86: ...CE MANUAL 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 show...

Page 87: ...s subject to change without notice REV19JUNE2017 P N 598901 87 695XL SERVICE MANUAL Gap if necessary to 0 02 0 5 mm Champion RCJ 6 or NGK BPMR7A Assemble in the reverse order Make sure the plug boot i...

Page 88: ...V19JUNE2017 P N 598901 695XL SERVICE MANUAL ICS Blount Inc 4909 SE International Way Portland OR 97222 USA Tel 800 321 1240 Fax 503 653 4393 ICS Blount Europe S A Rue Emile Francqui 5 1435 Mont Saint...