613GC SERVICE MANUAL F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL SECTION TABLE OF TITLE CONTENTS SECTION TITLE PAGE NUMBER SHOP MANUAL USE 2 1 TOOLS 3 2 SAW SPECIFICATIONS 4 3 SERIAL NUMBER LOCATION 5 4 SPARE PARTS DIAGRAM (TORQUE AND LOCTITE®) 6 5 AIR INTAKE 15 6 SPARK PLUG 17 7 CLUTCH & RIM SPROCKET 19 8 STARTER SYSTEM 23 9 WALLWALKER 29 10 CYLINDER COVER 31 11 MUFFLER 34 12 CARBURETOR 36 13 CYLINDER & PISTON 38 14 WATER HOSE 47 15 IGNITION COIL 49 16 FLYWHEEL 51 17 BOTTOM GUARD 53 18 FRONT
SHOP MANUAL TITLE USE 613GC SERVICE MANUAL 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. General Shop Rules • Always use the right tools for the job, otherwise components may be damaged.
613GC SERVICE MANUAL 1.
2. SPECIFICATIONS TITLE 613GC SERVICE MANUAL Specifications Engine Type 2-Stroke Single Cylinder Air Cooled Displacement 4.9 cu. in. (80.7 cc) Horsepower 5.7 hp (4.2 kW) @ 9000 rpm Engine Speed 12,000 ± 500 rpm, electronically governed 2800-3200 rpm @ idle Chain Speed 5300 fpm (27 m/s), free running 4000 fps (20 m/s), in the cut Weight 21 lbs. (9.5 kg) with bar and chain Cutting Depth Up to 12 inches (30 cm) Dimensions 18 inches (45 cm) length 11.
613GC SERVICE MANUAL 3. SERIAL TITLE # LOCATION 3 613GC Cut-Off serial number series. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
4. SPARE PARTS TITLE DIAGRAM 613GC 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 613GC Replacement Parts Price List. 6 TORQUE Nm in‑lbs.
613GC SERVICE MANUAL KEY 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 4. SPARE PARTS TITLE DIAGRAM TORQUE Nm in‑lbs.
4. SPARE PARTS TITLE DIAGRAM KEY 1 2 3 4 5 6 7 KEY 1 2 3 4 5 6 7 8 9 10 11 8 613GC SERVICE MANUAL TORQUE Nm in‑lbs. DESCRIPTION CRANKSHAFT SEAL FLYWHEEL SIDE CRANKSHAFT BEARING CRANKSHAFT FLYWHEEL WOODRUFF KEY CRANKSHAFT ASSEMBLY WRIST PIN NEEDLE BEARING CLUTCH SIDE MAIN BEARING SEAL-INSIDE CRANKSHAFT BUSHING 73877 73209 73878 71410 73869 73289 71452 TORQUE Nm in‑lbs.
613GC SERVICE MANUAL KEY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 DESCRIPTION GUARD FLAP WALLWALKER® LEVER ARM GUARD FLAP CLAMP WASHER WALLWALKER® LEVER ARM SCREW GUARD FLAP SCREW GUARD FLAP WASHER GUARD FLAP SPACER WATER HOSE GASKET FITTING RING NUT WATER HOSE O-RING WATER SHUT-OFF VALVE FITTING WATER HOSE HOSE CLAMP HOSE HANGER WATER HOSE COVER WATER HOSE SCREW FITTING COPPER WASHER WATER TANK CAP FUEL CAP O-RING TUBE FITTING FITTING O-RING HOSE HANGER BUTTON F/N 71537
4. SPARE PARTS TITLE DIAGRAM 613GC SERVICE MANUAL TORQUE Nm in‑lbs.
613GC SERVICE MANUAL KEY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DESCRIPTION SIDE COVER INSERT, TOP SIDE COVER NUT CHAIN COVER CAP MOUNTING NUT WALLWALKER® SIDE ARM WASHER WALLWALKER® SIDE ARM SCREW SCREW SIDE COVER PLATE LOWER GUARD SIDE COVER INSERT, BOTTOM REAR SIDE COVER INSERT, TOP REAR SIDE COVER GROMMET SIDE COVER ASSEMBLY, COMPLETE F/N 71537 Oct 07 4. SPARE PARTS TITLE DIAGRAM TORQUE Nm in‑lbs. 1.2 104 0.3 26 © 2007 ICS, Blount Inc.
4. SPARE PARTS TITLE DIAGRAM 12 613GC SERVICE MANUAL © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 4. SPARE PARTS TITLE DIAGRAM TORQUE Nm in‑lbs.
4. SPARE PARTS TITLE DIAGRAM KEY 1 2 3 4 5 6 7 8 9 0 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 14 613GC SERVICE MANUAL TORQUE Nm in‑lbs.
613GC SERVICE MANUAL 5 This section covers the disassembly, inspection, 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 5.3 TITLE 5. AIR INTAKE Clean filter with cleaning solution and a nylon brush. A Clean filter with cleaning solution and water. B Let dry and reinstall. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
5. AIR TITLE INTAKE 5.4 A 5.5 Inspect air filter cover gasket. Replace if permanently depressed or hard due to slurry. Inspect filter cannister gasket. A Clean. B Replace if necessary. 5.6 16 613GC SERVICE MANUAL Secure air filter mount screws. © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 6 This section covers the removal, inspection, and installation of the spark plug. 6.1 Remove the spark plug lead. 6.2 Clean area around the spark plug to prevent debris from entering the cylinder. 6.3 Remove the spark plug. 6.4 Inspect the spark plug. A 6. SPARK TITLEPLUG If dirty, clean with a wire brush as shown. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
6. SPARK TITLEPLUG B 613GC SERVICE MANUAL 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 78 to select the correct replacement plug. 6.5 A 18 Assemble in the reverse order. Make sure the plug boot is seated completely. © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 7 This section covers clutch removal, rim 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. 7. CLUTCH &TITLE RIM SPROCKET 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 Oct 07 © 2007 ICS, Blount Inc.
7. CLUTCH & TITLE RIM SPROCKET 7.4 Remove all drive components. 7.5 Inspect the clutch shoes for wear. A 7.6 20 613GC SERVICE MANUAL Replace if the shoe has less than 0.04” (1 mm) of material, as shown. Inspect spring for cracks. © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 7.7 Assemble clutch shoes as shown. 7.8 Finish installation of clutch shoe as shown. 7.9 Inspect the rim sprocket for wear. A 7. CLUTCH & TITLE RIM SPROCKET Replace if the rim sprocket teeth are worn to points, as shown on right. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
7. CLUTCH & TITLE RIM SPROCKET 7.10 613GC SERVICE MANUAL 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 inside clutch spacer washer. 7.11 Install clutch. A Tighten firmly Left hand threads 22 © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 8 This section covers the removal of the starter cover, replacement of the starter rope, and replacement 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” of rope out. B Line rope up with notch on pulley. C Slowly rotate pulley counterclockwise until spring pressure is released. Use thumb as a brake. 8.5 8.
8. STARTER TITLE 8.6 Remove starter pulley. 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 housing to prevent spring from unwinding. 8.8 Lubricate with light weight oil. 8.9 Replace parts carefully. 24 613GC SERVICE MANUAL © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 8.10 Inspect pulley spring catch. A Clean with cleaning solution. B Replace if worn or broken. 8.11 Install starter rope and tie knot. 8.12 Install pulley A Wind rope onto pulley clockwise leaving 4-6” out. B Make sure that the pulley spring catch is in the spring hook. 8.13 8. STARTER TITLE Install center screw. A Use blue Loctite®. B Torque to 26 in-lbs. (2.9 Nm). F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
8. STARTER TITLE 8.14 Wind the recoil spring. A Line rope up with notch on pulley. B Rotate the pulley with the rope clockwise 5 times. C Untangle rope and release. 8.15 Assemble starter cord shield. 8.16 Remove starter pawl screws, pawls, spring, and plain washer. 8.17 Inspect and clean pawl components. A Inspect the components. Replace if necessary. B Clean the components with a brush and solvent. 26 613GC SERVICE MANUAL © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 8.18 Assemble components A Make sure the spring is in the correct position. B Use blue Loctite® on the pawl screws. C Torque to 60 in-lbs. (6.8 Nm). 8.19 A 8.20 8. STARTER TITLE Wind the pawl spring. Use needle nose pliers to move the tail of the spring into position. Install starter cover. A Pull out cord 4-6”. B Slowly release while placing cover to allow pawls to engage. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
8. STARTER TITLE 8.21 Install starter cover screws. A Use blue Loctite®. B Torque to 60 in-lbs. (7 Nm). 28 613GC SERVICE MANUAL © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 9 This section covers the removal, inspection, and assembly of the WallWalker ® and guard flap. 9.1 Inspect WallWalker ® tip. A 9. WALLWALKER TITLE If the tip is worn, as shown, replace. 9.2 Remove crankcase screws and wave washers. 9.3 Remove WallWalker ® from saw. NOTE: On late model saws it is necessary to remove the bar plate prior to removing the crankcase screws. 9.4 Remove guard flap screws and washer. 9.5 Remove and inspect guard flap.
9. WALLWALKER TITLE 9.6 Reassemble in the reverse order. A Install crankcase screws and wave washers. B Use blue Loctite®. C Torque to 70 in-lbs. (7.9 Nm). 30 613GC SERVICE MANUAL © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 10 This section covers the disassembly and assembly of the cylinder cover. Removal of the air intake components and front handle is necessary. Refer to sections 1 and 14 if needed. 10.1 Remove the air filter mount screws. 10.2 Remove the cylinder cover screws (3). 10.3 Remove spark plug lead from cylinder cover. 10.4 Remove fuel tank breather cap and clamp. 10.5 Partially remove intake manifold from cylinder cover. 10.6 Remove cylinder cover. A Pull up on front.
10. CYLINDER TITLE COVER 10.7 Remove stop switch leads. 10.8 Inspect cylinder cover for damage. A 10.9 A 613GC SERVICE MANUAL Replace if necessary. Check cylinder cover water seal and filter cover gasket are in place and in good condition. Replace if necessary. 10.10 Reassemble stop switch leads. 10.11 Make sure carburetor screw boot is in place. 10.12 Lubricate compensating tube and fuel tank breather tube with soapy water, guide through cylinder cover (Install compensating tube first).
613GC SERVICE MANUAL 10. CYLINDER TITLE COVER 10.13 Install cylinder cover. A Pull spark plug lead into slot in cylinder cover. B Align throttle linkage with cylinder cover and crankcase. C Push the cylinder cover down on the crankcase, guide intake manifold into cylinder cover. D Install the cylinder cover screws. Use blue Loctite®. Torque to 35 in-lbs. (4.0 Nm). E Install fuel tank breather and clamp. 10.14 Install air filter mount.
11. MUFFLER TITLE 11 This section covers the disassembly, inspection, and assembly of the muffler. Removal of the WallWalker ® and cylinder cover is necessary. 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. A 34 613GC SERVICE MANUAL Replace any damaged components. © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 11.4 Install muffler. A Insert muffler screws and serrated washer (2) into muffler. B Hold muffler screws in place with heat shield gasket. C Thread muffler screws into cylinder, torque to 78 in-lbs. (9 Nm). 11.5 11. MUFFLER TITLE Install muffler support. A Install top 3 muffler support screws and serrated washer finger tight. B Install bottom 2 muffler support screws with blue Loctite®. C Torque top screws to 78 in-lbs. (9 Nm). D Torque bottom screws to 52 in-lbs.
12. CARBURETOR TITLE 12 This section covers the removal and installation of the carburetor. Removal of the air intake components and cylinder cover is required. Please refer to sections 5 and 10 or 11 if necessary. Carburetor tuning is covered in section 23. 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. 12.2 Remove choke lever split pin. 12.3 Remove choke lever. 12.
613GC SERVICE MANUAL 12.5 Remove carburetor support screw (1) with #4 Torx or straight blade screwdriver. 12.6 Remove carburetor body screws (2). 12.7 Remove fuel line. 12.8 Remove pulse tube. 12.9 Remove carburetor compensator tube on top of carburetor. 12. CARBURETOR TITLE 12.10 Assemble in the reverse order. A Torque carburetor body screws to 43 in-lbs. (5 Nm). B Torque supporter screw with blue Loctite® to 43 in-lbs. (5 Nm). F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
13. CYLINDER TITLE& PISTON 13 This section covers the disassembly, inspection and assembly of the cylinder, piston and related components. Removal of several component groups is required. Refer to sections 5, 6, 10, and 12 if necessary. 13.1 Remove carburetor base screws. A Remove carburetor base from rear manifold. B Remove carburetor base from pulse tube. 13.
613GC SERVICE MANUAL 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 13. CYLINDER TITLE& PISTON Remove cylinder gasket and clean case. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
13. CYLINDER TITLE& PISTON 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. 613GC SERVICE MANUAL 13.10 Remove wrist pin bearing. 40 © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 13. CYLINDER TITLE& PISTON 13.11 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 rings. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
13. CYLINDER TITLE& PISTON 613GC SERVICE 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. 42 © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 13. CYLINDER TITLE& PISTON 13.17 Partially install wrist pin. 13.18 Align piston in correct orientation. EXHAUST INTAKE 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 second wrist pin retaining clip Make sure wrist pin retaining clip is in the proper orientation (see 13.16). F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
13. CYLINDER TITLE& PISTON 613GC SERVICE MANUAL 13.20 Install cylinder A Lubricate cylinder bore with ICS® 2‑stroke oil. B Compress rings 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 Align cylinder bolt holes with crankcase. 13.22 Install 4 cylinder screws and washers. A Use blue Loctite®. B Torque bolts to 95.5 in-lbs.
613GC SERVICE MANUAL 13. CYLINDER TITLE& PISTON 13.23 Install rear manifold. A Lubricate rear manifold with ICS® 2‑stroke oil. B Push rear manifold onto cylinder intake. C Align rear manifold seam with cylinder and crankcase seam. 13.24 Install rear manifold clamp. A Torque to 11 in-lbs. (1 Nm) 13.25 Install protective spring onto pulse tube. 13.26 Install the pulse tube onto cylinder barb. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
13. CYLINDER TITLE& PISTON 613GC SERVICE MANUAL 13.27 Install carburetor 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 blue Loctite® on 3 screws without ground wire. B Make sure to include stop switch wire. C Torque to 35 in-lbs. (4 Nm). 46 © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 14 This section covers water hose and water tank cap. 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 Oct 07 14. WATER TITLEHOSE © 2007 ICS, Blount Inc.
14. WATER TITLEHOSE 14.6 A 14.7 48 613GC SERVICE MANUAL Release water tank cap from water tank tube. Depress orange fitting as shown. Assemble in the reverse order. © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 15 This section covers the removal, inspection, and installation of the ignition coil. Removal 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 ignition coil. 15.4 Inspect. A Look for cracks/missing insulation. B Clean flywheel magnets and coil if rusty. F/N 71537 Oct 07 15. IGNITION TITLE COIL © 2007 ICS, Blount Inc.
15. IGNITION TITLE COIL 15.5 A B C E F Install Ignition coil. Place ignition coil shim (0.012”) on magnet counterweight side of flywheel. Set ignition coil in place. Install ignition coil screws, wave washers, and plain washers with blue Loctite®. Holding shim, rotate flywheel magnet around to coil. Torque ignition coil screws to 26 in‑lbs. (3 Nm). Remove shim, rotate flywheel to check clearance. 15.6 Install flywheel shroud 15.
613GC SERVICE MANUAL 16 This section covers the removal, inspection, and installation of the flywheel. Removal of the starter and spark plug 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 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 Oct 07 16. FLYWHEEL TITLE © 2007 ICS, Blount Inc.
16. FLYWHEEL TITLE 16.4 Using pliers, hold saw up by magnet counterweight. 16.5 Strike flywheel 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 woodruff key. 16.8 Install flywheel, plain washer, wave washer, and flywheel nut. A 52 613GC SERVICE MANUAL Torque nut to 217 in-lbs. (25 Nm). © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 17 17. BOTTOM TITLEGUARD This section covers the removal inspection, and installation of the bottom guard. A Remove bottom guard screws and split washers. B Inspect bottom guard. C Replace if damaged. D Assemble in reverse order F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
18. FRONT TITLE HANDLE 18 This section covers the removal, inspection, and installation of the front handle. 18.1 Remove front handle screws on right side. 18.2 Remove front handle screws on bottom. 18.3 Install front handle. A Roll front handle into place. B Install front handle screws (4). C Use blue Loctite®. D Torque to 69 in-lbs. (8 Nm). 54 613GC SERVICE MANUAL © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 19 This section covers the disassembly, inspection, and assembly of the vibration isolaters, fuel tank, and rear handle. 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 Oct 07 19. FUEL TITLETANK © 2007 ICS, Blount Inc.
19. FUEL TITLETANK 19.3 613GC SERVICE MANUAL Separate crankcase and fuel tank. NOTE: Saws have a rubber water deflector connected to the 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. 56 © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 20 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 Oct 07 20. CRANKCASE TITLE © 2007 ICS, Blount Inc.
20. CRANKCASE TITLE 20.3 Heat the flywheel side crankcase with heat gun for 5 minutes, approximately 150° F (65.5° C). 20.4 Remove the flywheel side crankcase – tap crankshaft with plastic mallet. A Suspend above work surface. B Tap with mallet. 613GC SERVICE MANUAL NOTE: A nut should always be placed on a threaded shaft when pounding or pressing on it. 20.5 58 Remove the flywheel side crankcase seal with 1/2” (13 mm) socket. © 2007 ICS, Blount Inc.
3GC SERVICE MANUAL 20.6 Heat the clutch side crankcase with heat gun to 150° F (65.5° C). 20.7 Remove crankshaft from the clutch‑side crankcase tap crankshaft with a plastic mallet. A Suspend above work surface. B Tap with plastic mallet. 20.8 20. CRANKCASE TITLE Remove the bearing from the flywheel side of crankshaft. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
20. CRANKCASE TITLE 20.9 613GC SERVICE MANUAL Remove the bearing, seal, and bushing from the clutch side of crankshaft. 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. 60 © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 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. A Tap lightly with bearing driver and mallet. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
20. CRANKCASE TITLE 613GC SERVICE 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. 62 © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 20. CRANKCASE TITLE 20.20 Assemble crankcase halves – tap with bearing driver and mallet. 20.21 Install main crankcase bolts. A Use blue Loctite®. B Torque to 69 in-lbs. (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 Oct 07 © 2007 ICS, Blount Inc.
20. CRANKCASE TITLE 613GC SERVICE MANUAL 20.23 Trim crankcase gasket flush. 64 © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 21 21. BAR STUDS TITLE& BAR PAD This section covers the removal and installation of the bar studs and bar pad. NOTE: On saws with Serial #’s beginning 0482421700 and 071XXXXXXX, it is necessary to remove the bar mount pad cover plate first. 21.1 Remove bar studs. A Remove side cover. B Install side cover nuts, flange to flange and tighten together. C Attempt to remove the inside nut which should pull out the bar stud. D Repeat on second bar stud. 21.2 A 21.
22. CHAIN TITLE TENSIONER 22 This section covers the removal and installation of the chain tensioner. 22.1 Remove bar plate to expose the chain tensioner. 613GC SERVICE MANUAL NOTE: Saws with serial #’s lower than 0482421700 are not equipped with a bar mount pad cover plate. 22.2 Unscrew tensioner to remove. A Remove tensioner pin. B Remove tensioner screw keeper. 22.3 66 Assemble in reverse order. © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 23 TITLE TUNING 23. CARBURETOR This section covers carburetor tuning. Included in this section are basic settings, idle speed adjustment, and complete adjustment. The carburetor has been set at the factory for optimal performance and compliance to EPA Phase I emissions standards. However, minor adjustments may be required in certain conditions, such as high elevation. NOTES: • These cut-off saws are equipped with an electronic speed limiter, as part of the ignition system.
23. CARBURETOR TITLE TUNING 23.1 Basic Setting - 613GC SERVICE MANUAL RPM Settings for saws. H = 1 3/4 turns from closed NOTE: Saw tuned without bar and chain installed. L = 1 1/4 turns from closed Idle Speed = 3,000 ± 500 rpm Full Throttle = 11,000 ± 500 rpm Complete carburetor readjustment. 23.2 Remove limiter cap A Look into adjustment screw hole. Observe orientation of the release slots on the adjustment screw limiter cap. B Insert the limiter cap puller blades into the release slots.
613GC SERVICE MANUAL 23.3 Using a 5/64” straight blade screwdriver, gently turn the adjustment screws clockwise until completely closed. 23.4 Set the adjustment screws at the Basic Setting: 23. CARBURETOR TITLE TUNING H = 1 3/4 turns from closed L = 1 1/4 turns from closed The side cover must be held tightly in place with the side cover nuts, using a bar and no chain. Failure to do so may result in personal injury. 23.5 Start the saw and warm up the engine. 23.
23. CARBURETOR TITLE TUNING 23.9 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 70 613GC SERVICE MANUAL © 2007 ICS, Blount Inc.
613GC SERVICE MANUAL 24 This section covers idle speed adjustment. 24.1 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 ½ turn. 24.2 A 24. IDLE SPEED TITLE ADJUSTMENT If chain turns at idle: Back T screw out until chain stops moving. F/N 71537 Oct 07 © 2007 ICS, Blount Inc.
25. DIAGRAMS TITLE 25 613GC SERVICE MANUAL This section provides several flowcharts to aid diagnosing common problems. CHECK The engine runs rough at all speeds POSSIBLE CAUSE YES • • • Dirty or clogged air filter. Water has been ingested. Loose or dirty spark plug. REPAIR • • • • Clean or replace the air filter. Inspect air intake sysetm for water. Inspect fuel system for water. Tighten, clean, or replace spark plug. • • • • See Operator’s Manual. See Carburetor Tuning section.
613GC SERVICE MANUAL 25. DIAGRAMS TITLE Saw Will Not Start CHECK POSSIBLE CAUSE • Does the engine crank? NO • Dirty or broken recoil starter. Internal damage. REPAIR • • Clean, rebuild or replace the recoil starter. Inspect for internal damage such as seized piston. YES • Is there spark? NO • • • The ignition switch is “OFF”. Faulty ignition ground. Faulty spark plug lead. Faulty ignition coil. YES Is the spark plug firing properly? NO • • • Plug is soaked with fuel.
26. FUEL SYSTEM TITLE LEAKS 26 This section covers testing the fuel system for leaks. Engine starvation can result from a leak or malfunction of any of the main components of the fuel system. The five main components are the fuel tank, fuel tank breather, fuel filter, delivery tubes, and carburetor. 26.1 Remove and inspect the fuel filter. A 26.2 Replace the fuel filter if there is any foreign material in the felt or the internal screen. Test the main fuel pick-up tube for leaks.
613GC SERVICE MANUAL D Plug one end of the main fuel pick-up tube. E Re-pressurize the tube to 7 psi (0.5 bar). F Replace the tube if pressure is not maintained. G If the main fuel pick-up tube does maintain pressure, then the leak ha been isolated to the carburetor. Refer to the Walbro Diaphragm Carburetor Service Manual. 26.
26. FUEL SYSTEM TITLE LEAKS 26.5 Testing the fuel tank breather. A Attach the pressure gauge and bulb to the main fuel pick-up tube at the carburetor. Pressurize the tube to 4.5 psi (0.3 bar). B The pressure should reduce to nearly 0 psi (0 bar) over about 3 seconds. 26.6 If the pressure does not reduce to 0 psi, disassemble or replace the breather. A Clean the parts with solvent or fuel. B Assemble in reverse order. C Make sure that the spring taper is oriented in the correct direction.
613GC SERVICE MANUAL 27 This section covers testing the crankcase for leaks. A leak in the crankcase can cause the engine not to run. 27.1 Install the intake seal flange. A 27. CRANKCASE TITLE LEAKS Plug cylinder pulse tube. 27.2 Install the exhaust seal flange. 27.3 Block one of the flange tubes with a rubber plug. 27.4 Install the pressure gauge and bulb. 27.5 Pressurize the crankcase to 7 psi (0.5 bar). 27.6 If the pressure does not remain the same, use soapy water to find the leak.
APPENDIX TITLE 613GC SERVICE MANUAL 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 73199 78 CHAMPION RESISTOR RCJ7Y NGK RESISTOR BOSCH RESISTOR BPMR7A WSR7F © 2007 ICS, Blount Inc.
613GC 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.
