613GC SM_4-8-05.indd

613GC Cut-Off SawShop Manual

SHOP MANUAL TITLE USE613GC SHOP MANUALShop Manual UseThis manual contains all the technical information necessary for carrying out repairs on the613GC cut-off saw. For safe, efficient work, it is of prime importance that the values indicatedbe adhered to. Routine periodic maintenance is covered in the operator’s manual included witheach cut-off 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 appropriatesubgroups.• When reassembling, clean all parts carefully, lubricate moving parts and replace all oil seals,orings, 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 ®cut-off saws is available from ICS ® .• Detailed carburetor maintenance and overhaul information is available in Walbro’sDiaphragm Carburetor Service Manual. Walbro can be contacted at http:\\www.walbro.comor by calling 1.989.872.2131.2Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL1. TOOLSGas Saw Service Tool Kit - P/N 717001 2 3 4 56 7 8 9 1011 12 13 14 1516 17 18 19P/N DESCRIPTION1 71521 SCRENCH2 71541 PRESSURE GAUGE BULB3 71542 COIL/FLYWHEEL TIMING SHIM4 71543 CYLINDER ASSEMBLY CLAMPS & PISTON STOP5 71546 613 SHOCK ABSORBER TOOL6 71547 SPARK TESTER7 71548 613 FLYWHEEL DISASSEMBLY TOOL8 71550 LIMITER CAP REMOVAL TOOL9 71565 ELECTRONIC TACHOMETER10 71569 613GC INDUCTION SEAL FLANGE W/ SCREWS11 71570 613GC EXHAUST SEAL FLANGE W/SCREWS12 71573 TUNING SCREWDRIVER13 73410 633GC FLYWHEEL PULLER14 73425 633GC FUEL PRESSURE CAP15 73428 613GC & 633GC MAIN BEARING DRIVER TOOL16 73429 633 MAIN BEARING SPACING TOOL17 73430 633GC SHOCK ABSORBER TOOL18 73431 633GC INTAKE PORT COVER TOOL19 73432 633GC EXHAUST PORT COVER TOOLCopyright © 2005 ICS, Blount Inc.3

2. SPECIFICATIONS613GC SHOP MANUALSPECIFICATIONSEngine TypeDisplacementHorsepowerEngine SpeedChain SpeedWeightCutting DepthDimensionsCarburetorAir FiltrationStarterIgnitionClutchFuel Mix RatioFuel CapacityWater SupplyNoise LevelVibration Level2-Stroke Single Cylinder Air Cooled4.9 cu. in. (80.7 cc)5.7 hp (4.2 kW) @ 9000 rpm12,000 ± 500 rpm, electronically governed2800-3200 rpm @ idle5300 fpm (27 m/s), free running4000 fps (20 m/s), in the cut21 lbs. (9.5 kg) with bar and chainUp to 12 inches (30 cm)18 inches (45 cm) length11.5 inches (29 cm) height10 inches (25 cm) widthWalbro diaphragm WJ-85BDry nylonDust and water shieldedElectronic speed governing, water sealedThree-weight, single spring, centrifugal25:1 gasoline to oil with brand name gasoline and ICS ® 2-strokeengine oil, or other high quality 2-stroke engine oil for air cooledengines.0.23 gal (0.88 liter)15-18 minute run timeMinimum 20 psi (1.5 bar)100 dB @ 1 meter10.5 m/sSpark Plug TYPE Champion RCJ-7Y (for spark plug reference guide see page 78)Spark Plug GapSprocket Type0.02 inches (0.5 mm)8-tooth rim sprocket4Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL4. SPARE PARTS DIAGRAMTORQUE LOCTITE ®KEYDESCRIPTIONNm in-lbs. 242PART NUMBER1 REAR MANIFOLD CLAMP 738672 REAR MANIFOLD 738683 WRIST PIN NEEDLE BEARING 738694 COMPLETE PISTON/CYLINDER ASSEMBLY 714135 CYLINDER BASE GASKET ASSEMBLY 714126 SPARK PLUG 2.8 243 731997 CYLINDER TO MUFFLER GASKET 738819 CARBURETOR ATTACHMENT SCREW WASHER 7332710 MUFFLER ASSEMBLY 7141111 CYLINDER BLOCK BOLT 1.1 95 X 7387412 MUFFLER MOUNTING SCREW 1.0 87 7388313 CARBURETOR PULSE TUBE 7389814 MUFFLER SUPPORT BRACKET 7388415 MUFFLER SUPPORT BRACKET SCREW 0.9 78 7388516 COMPLETE CARBURETOR WJ-85B 7176217 INTAKE MANIFOLD FLANGE SCREW 0.4 35 X 7390118 WASHER 7325019 CARBURETOR SUPPORT BRACKET 7389520 DECOMPRESSION VALVE 1.3 113 7164221 INTAKE MANIFOLD FLANGE 7394722 INTAKE MANIFOLD 7173523 CARBURETOR PULSE TUBE PROTECTOR 7388824 WASHER 7389725 CARBURETOR ATTACHMENT SCREW 0.5 43 7390226 SCREW 0.4 35 X 7386627 SCREW GUIDE 0.6 52 7389928 MUFFLER DEFLECTOR 7148129 SCREW 0.4 35 71482Copyright © 2005 ICS, Blount Inc.7

4. SPARE PARTS DIAGRAM613GC SHOP MANUALTORQUE LOCTITE ®KEYDESCRIPTIONNm in-lbs. 242PART NUMBER1 CRANKSHAFT SEAL FLYWHEEL SIDE 738772 CRANKSHAFT BEARING 732093 CRANKSHAFT FLYWHEEL WOODRUFF KEY 738784 CRANKSHAFT ASSEMBLY 714105 WRIST PIN NEEDLE BEARING 738696 CLUTCH SIDE MAIN BEARING SEAL-INSIDE 732897 CRANKSHAFT BUSHING 71452TORQUE LOCTITE ®KEYDESCRIPTIONNm in-lbs. 242PART NUMBER1 OUTER CRANKCASE SEAL CLUTCH SIDE 739312 OUTER CRANKCASE SEAL BODY 739493 OUTER CRANKCASE SEAL BODY SCREW 0.3 26 739404 WASHER 732855 CLUTCH SPACER WASHER 739456 8T RIM SPROCKET KIT 709497 CLUTCH NEEDLE BEARING 739398 613GC CLUTCH DRUM ASSEMBLY 715209 CLUTCH SPACER WASHER, INSIDE 7394110 CLUTCH 3.4 295 7141911 CLUTCH SPRING 739438Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL4. SPARE PARTS DIAGRAMTORQUE LOCTITE ®KEYDESCRIPTIONNm in-lbs. 242PART NUMBER1 GUARD FLAP 715342 WALLWALKER ® LEVER ARM 715323 GUARD FLAP CLAMP 715314 WASHER 739515 WALLWALKER ® LEVER ARM SCREW 0.5 43 X 714786 GUARD FLAP SCREW 0.5 43 X 714797 GUARD FLAP WASHER 714838 GUARD FLAP SPACER 714809 WATER HOSE GASKET 7146910 FITTING 7146711 RING NUT 7145712 WATER HOSE O-RING 7146813 WATER SHUT-OFF VALVE 7145814 FITTING 7145415 WATER HOSE 7145516 HOSE CLAMP 7146517 HOSE HANGER 7146118 WATER HOSE COVER 7146419 WATER HOSE SCREW 2.0 174 7146320 FITTING 7145321 COPPER WASHER 7145622 WATER TANK CAP 7392323 FUEL CAP O-RING 7344824 TUBE 7145925 FITTING 7147026 FITTING 7147127 O-RING 7147228 HOSE HANGER BUTTON 71744Copyright © 2005 ICS, Blount Inc.9

4. SPARE PARTS DIAGRAM613GC SHOP MANUALTORQUE LOCTITE ®KEYDESCRIPTIONNm in-lbs. 242PART NUMBER1 FUEL LINE GROMMET (CRANKCASE) 733902 CRANKCASE ASSEMBLY, LEFT HALF 717363 CRANKCASE DOWEL PIN 732814 CRANKSHAFT BEARING 732095 CRANKCASE ASSEMBLY, RIGHT HALF 717477 CHOKE LEVER SPLIT PIN 739278 CRANKCASE GASKET 739349 CRANKCASE BOLT 0.8 69 X 7393010 WASHER 7389711 BOTTOM COVER 7395012 BAR MOUNT PAD SPACER 7174013 COVER GUARD MOUNTING BOLT 0.8 69 X 7339714 SCREW (CRANKCASE) 0.5 43 X 7337915 BAR MOUNTING STUD 1.2 104 7393316 SCREW 0.8 69 7328417 BAR MOUNT PAD COVER PLATE 7173818 PREMIUM TENSIONER KIT (REPLACES 73283), ASSEMBLY 7393519 TENSIONER SCREW RETAINER 7393620 CHOKE LEVER 7392821 CRANKCASE GROMMET, RIGHT SIDE 7174122 CHOKE LEVER BUSHING 7395510Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL4. SPARE PARTS DIAGRAMTORQUE LOCTITE ®KEYDESCRIPTIONNm in-lbs. 242PART NUMBER1 SIDE COVER INSERT, TOP 717432 SIDE COVER NUT 1.2 104 739583 CHAIN COVER CAP 714624 MOUNTING NUT 733675 WALLWALKER® SIDE ARM 715336 WASHER 739517 WALLWALKER® SIDE ARM SCREW 5073558 SCREW 0.3 26 X 714879 SIDE COVER PLATE 7144710 LOWER GUARD 7395711 SIDE COVER INSERT, BOTTOM REAR 7397212 SIDE COVER INSERT, TOP REAR 7394813 SIDE COVER GROMMET 7331014 SIDE COVER ASSEMBLY, COMPLETE 71420Copyright © 2005 ICS, Blount Inc.11

4. SPARE PARTS TITLE DIAGRAM613GC SHOP MANUAL12Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL4. SPARE PARTS DIAGRAMTORQUE LOCTITE ®KEYDESCRIPTIONNm in-lbs. 242PART NUMBER1 CYLINDER COVER ASSEMBLY, WITH AIR INTAKE 717542 AIR FILTER CANNISTER, POLYESTER 717523 AIR FILTER COVER ASSEMBLY, 3 SCREW 717534 FILTER COVER SCREW 739925 FILTER SUPPORT 733386 FILTER COVER GASKET 717567 SCREW, CYLINDER COVER, LONG, SOCKET HEAD X X X 717718 PREFILTER PLASTIC, SECONDARY FILTER 733369 AIR FILTER FLANGE 7175810 FILTER SUPPORT SCREW 0.3 26 X 7333711 FILTER CANNISTER GASKET 7333512 O-RING 7147213 TUBE CLAMP, NO TABS 7176014 COMPENSATOR TUBE 7177515 BREATHER GROMMET 7176316 THROTTLE ASSEMBLY 7175017 O-RING, AIR FILTER 73331Copyright © 2005 ICS, Blount Inc.13

4. SPARE PARTS DIAGRAM613GC SHOP MANUALTORQUE LOCTITE ®KEYDESCRIPTIONNm in-lbs. 242PART NUMBER1 FUEL TANK ASSEMBLY (REQUIRES P/N 71739) 714212 REAR HANDLE HALF 739753 SCREW 0.1 9 739764 THROTTLE LEVER 717495 FUEL CAP ASSEMBLY, WITH OUTER SEAL RING 717396 FUEL CAP O-RING 734487 FUEL FILTER 734598 TRIGGER LOCKOUT LEVER 739879 TRIGGER LOCKOUT LEVER SPRING 739880 WASHER 7389711 SCREW 0.9 78 X 7398212 SHOCK ABSORBER 0.4 35 7398013 TUBE CLAMP, WITH TABS 7158814 FUEL LINE 7337515 SHOCK ABSORBER, REAR HANDLE 7174516 BUMPER, SHOCK ABSORBER, FUEL TANK TOP 7327017 FRONT HANDLE BOLT 0.8 69 X 7398318 FRONT HANDLE 7142219 FUEL BREATHER COMPLETE 7174820 WATER DEFLECTOR, BOTTOM 7176621 BREATHER TUBE BODY 7175122 BREATHER TUBE ELBOW 7175923 FUEL BREATHER, REMOTE 7176124 BREATHER TUBE EXTENSION 7177725 TUBE CLAMP, NO TABS 7176014Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL5 This section covers thedisassembly, inspection, andassembly air induction system.5. AIR TITLE INTAKE5.1 Loosen the air filter cover screws andremove air filter cover.5.2 Remove air filter from cover.A Inspect air filter.B Replace if necessary5.3 Clean filter with cleaning solution anda nylon brush.ABClean filter with cleaning solution andwater.Let dry and reinstall.Copyright © 2005 ICS, Blount Inc.15

TITLE5. AIR INTAKE5.4 Inspect air filter cover gasket.AReplace if permanently depressed orhard due to slurry.5.5 Inspect filter cannister gasket.ABClean.Replace if necessary.613GC SHOP MANUAL5.6 Secure air filter mount screws.16Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL6 This section covers the removal,inspection, and installation ofthe spark plug.6. SPARK TITLEPLUG6.1 Remove the spark plug lead.6.2 Clean area around the spark plugto prevent debris from entering thecylinder.6.3 Remove the spark plug.6.4 Inspect the spark plug.AIf dirty, clean with a wire brush asshown.Copyright © 2005 ICS, Blount Inc.17

B6. SPARK TITLEPLUGGap if necessary to 0.02” (0.5 mm).NOTE: If the spark plug must bereplaced refer to the Spark PlugReference Guide on page 78 toselect the correct replacementplug.613GC SHOP MANUAL6.5 Assemble in the reverse order.AMake sure the plug boot is seatedcompletely.18Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL7 This section covers clutchremoval, rim sprocket removal,inspection, and assembly. Referto sections 5 and 6 if needed.7.1 Insert piston stop tool into spark plughole.7. CLUTCH & TITLE RIM SPROCKET7.2 Pull starter handle until piston stopsagainst tool.7.3 Remove clutch.Left hand threads – rotateclockwise to loosen.NOTE: If an impact wrench is availablesteps 7.1 and 7.2 do not have tobe performed.Copyright © 2005 ICS, Blount Inc.19

7. CLUTCH & TITLE RIM SPROCKET7.4 Remove all drive components.613GC SHOP MANUAL7.5 Inspect the clutch shoes for ear.AReplace if the shoe has less than0.04” (1 mm) of material, as shown.7.6 Inspect spring for cracks.20Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL7.7 Assemble clutch shoes as shown.7. CLUTCH & TITLE RIM SPROCKET7.8 Finish installation of clutch shoe asshown.7.9 Inspect the rim sprocket for wear.AReplace if the rim sprocket teeth areworn to points, as shown on right.Copyright © 2005 ICS, Blount Inc.21

7. CLUTCH & TITLE RIM SPROCKET7.10 Clean and assemble.ABCClean all parts in solvent.Grease clutch cup bearing with awater proof grease(ICS ® P/N 70885).Assemble clutch spacer washer,bearing, clutch cup with rim sprocket,and inside clutch spacer washer.613GC SHOP MANUAL7.11 Install clutch.A Tighten firmlyLeft hand threads22Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL8 This section covers theremoval of the starter cover,replacement of the starter rope,and replacement of the recoilspring.8. STARTER TITLE8.1 Remove starter cover screws.8.2 Remove starter cover assembly fromsaw.8.3 Remove starter cord shield screws.8.4 Relieve spring tension.ABCPull 4-6” of rope out.Line rope up with notch on pulley.Slowly rotate pulley counterclockwiseuntil spring pressure is released. Usethumb as a brake.8.5 Remove starter pulley screw andwasher.NOTE: Hold starter cover firmly.Copyright © 2005 ICS, Blount Inc.23

8. STARTER TITLE8.6 Remove starter pulley.613GC SHOP MANUAL8.7 Inspect coil spring.AReplace if spring hook is damaged.Attempting to re-bend the springhook may cause the hook to breakoff.BCarefully remove coil spring andhousing to prevent spring fromunwinding.8.8 Lubricate with light weight oil.8.9 Replace parts carefully.24Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL8.10 Inspect pulley spring catch.A Clean with cleaning solution.B Replace if worn or broken.8. STARTER TITLE8.11 Install starter rope and tie knot.8.12 Install pulleyABWind rope onto pulley clockwiseleaving 4-6” out.Make sure that the pulley springcatch is in the spring hook.8.13 Install center screw.A Use blue Loctite ® .BTorque to 26 in-lbs. (2.9 Nm).Copyright © 2005 ICS, Blount Inc.25

8. STARTER TITLE8.14 Wind the recoil spring.ABCLine rope up with notch on pulley.Rotate the pulley with the ropeclockwise 5 times.Untangle rope and release.613GC SHOP MANUAL8.15 Assemble starter cord shield.8.16 Remove starter pawl screws, pawls,spring, and plain washer.8.17 Inspect and clean pawl components.ABInspect the components. Replace ifnecessary.Clean the components with a brushand solvent.26Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL8.18 Assemble componentsABCMake sure the spring is in the correctposition.Use blue Loctite ® on the pawl screws.Torque to 60 in-lbs. (6.8 Nm).8. STARTER TITLE8.19 Wind the pawl spring.AUse needle nose pliers to move thetail of the spring into position.8.20 Install starter cover.A Pull out cord 4-6”.BSlowly release while placing cover toallow pawls to engage.Copyright © 2005 ICS, Blount Inc.27

8. STARTER TITLE8.21 Install starter cover screws.A Use blue Loctite ® .B Torque to 60 in-lbs. (7 Nm).613GC SHOP MANUAL28Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL9 This section covers the removal,inspection, and assembly of theWallWalker ® and guard flap.9. WALLWALKERTITLE9.1 Inspect WallWalker ® tip.AIf the tip is worn, as shown, replace.9.2 Remove crankcase screws and wavewashers.9.3 Remove WallWalker ® from saw.NOTE: On late model saws it isnecessary to remove the barplate prior to removing thecrankcase screws.9.4 Remove guard flap screws andwasher.9.5 Remove and inspect guard flap.AReplace the flap if it is torn ordamaged in any way.Copyright © 2005 ICS, Blount Inc.29

9. WALLWALKERTITLE9.6 Reassemble in the reverse order.AInstall crankcase screws and wavewashers.B Use blue Loctite ® .CTorque to 70 in-lbs. (7.9 Nm).613GC SHOP MANUAL30Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL10 This section covers thedisassembly and assembly ofthe cylinder cover. Removal ofthe air intake components andfront handle is necessary. Referto sections 1 and 14 if needed.10. CYLINDER TITLE COVER10.1 Remove the air filter mount screws.10.2 Remove the cylinder cover screws (3).10.3 Remove spark plug lead from cylindercover.10.4 Remove fuel tank breather cap andclamp.10.5 Partially remove intake manifold fromcylinder cover.10.6 Remove cylinder cover.ABCDPull up on front.Push intake manifold through hole.Make sure throttle linkage isdisengaged from cylinder cover.Guide fuel breather tube andcompensator tube through cylindercover.Copyright © 2005 ICS, Blount Inc.31

10. CYLINDER TITLE COVER10.7 Remove stop switch leads.10.8 Inspect cylinder cover for damage.A Replace if necessary.613GC SHOP MANUAL10.9 Check cylinder cover water seal andfilter cover gasket are in place and ingood condition.AReplace if necessary.10.10 Reassemble stop switch leads.10.11 Make sure carburetor screw boot is inplace.10.12 Lubricate compensating tube and fueltank breather tube with soapy water,guide through cylinder cover (Installcompensating tube first).NOTE: Be careful as to not pulltubes away from their point ofconnection. Approximately 3/4”of tube should protrude fromcylinder cover.32Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL10.13 Install cylinder cover.ABCDEPull spark plug lead into slot incylinder cover.Align throttle linkage with cylindercover and crankcase.Push the cylinder cover down on thecrankcase, guide intake manifold intocylinder cover.Install the cylinder cover screws. Useblue Loctite ® . Torque to 35 in-lbs.(4.0 Nm).Install fuel tank breather and clamp.10. CYLINDER TITLE COVER10.14 Install air filter mount.AGuide carburetor compensating tubethrough air filter mount. Make suremanifold sits flat over lip on cylindercover.B Install air filter mount screws (3)using blue Loctite ® .CTorque to 43 in-lbs. (4.9 NM).10.15 Install air filters and cover.A Install pre-filterB Install clean air filterC Install air filter flange and tightenD Install air filter cover and tightenCopyright © 2005 ICS, Blount Inc.33

11. MUFFLER TITLE11 This section covers thedisassembly, inspection,and assembly of the muffler.Removal of the WallWalker ®and cylinder cover is necessary.Refer to sections 7 and 10 ifnecessary.613GC SHOP MANUAL11.1 Remove muffler support screws.11.2 Remove muffler screws and serratedwashers located inside the muffler.11.3 Remove muffler and heat shieldgasket.AReplace any damaged components.34Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL11.4 Install muffler.ABCInsert muffler screws and serratedwasher (2) into muffler.Hold muffler screws in place withheat shield gasket.Thread muffler screws into cylinder,torque to 78 in-lbs. (9 Nm).11. MUFFLER TITLE11.5 Install muffler support.ABCDInstall top 3 muffler support screwsand serrated washer finger tight.Install bottom 2 muffler supportscrews with blue Loctite ® .Torque top screws to 78 in-lbs.(9 Nm).Torque bottom screws to 52 in-lbs.(6 Nm).Copyright © 2005 ICS, Blount Inc.35

12. CARBURETORTITLE12 This section covers theremoval and installation of thecarburetor. Removal of the airintake components and cylindercover is required. Please referto sections 5 and 10 or 11 ifnecessary. Carburetor tuning iscovered in section 23.613GC SHOP MANUALNOTE: All saws are equipped withcarburetor model # WJ-85A.12.1 Remove throttle linkage.ABCPush trigger end out of rear handle.Pivot linkage around.Remove carburetor end of linkagefrom throttle rod tab on carburetor.12.2 Remove choke lever split pin.12.3 Remove choke lever.12.4 Remove adjustment screw boot.36Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL12.5 Remove carburetor support screw (1)with #4 Torx or straight bladescrewdriver.12.6 Remove carburetor body screws (2).12. CARBURETORTITLE12.7 Remove fuel line.12.8 Remove pulse tube.12.9 Remove carburetor compensatortube on top of carburetor.12.10 Assemble in the reverse order.ABTorque carburetor body screws to43 in-lbs. (5 Nm).Torque supporter screw with blueLoctite ® to 43 in-lbs. (5 Nm).Copyright © 2005 ICS, Blount Inc.37

13. CYLINDER TITLE& PISTON13 This section covers thedisassembly, inspection andassembly of the cylinder, pistonand related components.Removal of several componentgroups is required. Refer tosections 5, 6, 10, and 12 ifnecessary.613GC SHOP MANUALNOTE: When replacing the 613GC cylinderand piston it is necessary to tune thecarburetor prior to returning the saw toservice (see section 23).13.1 Remove carburetor base screws.ABRemove carburetor base from rearmanifold.Remove carburetor base from pulsetube.13.2 Remove pulse tube and protectivespring from cylinder base.38Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL13.3 Remove rear manifold clamp.13.4 Remove rear manifold from cylinder.A Inspect for holes and tears.13. CYLINDER TITLE& PISTON13.5 Remove cylinder screws (4) andwave washers.13.6 Remove cylinder.ARemove cylinder gasket and cleancase.Copyright © 2005 ICS, Blount Inc.39

13. CYLINDER TITLE& PISTON13.7 Remove wrist pin retaining clips (2).613GC SHOP MANUAL13.8 Press wrist pin out with an 8 mmdeep socket.13.9 Remove piston and inspect. Replaceif damaged.13.10 Remove wrist pin bearing.40Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL13.11 Cylinder gasketABOil gasket with ICS ® 2-strokeengine oil.Install and align holes and notch.13. CYLINDER TITLE& PISTON13.12 Install wrist pin bearing in rod.AOil bearing with ICS ® 2-strokeengine oil.13.13 Install rings.Copyright © 2005 ICS, Blount Inc.41

13. CYLINDER TITLE& PISTON13.14 Ring orientation.613GC SHOP MANUAL13.15 Install one wrist pin retaining clip.13.16 Make sure wrist pin retaining clip is inthe proper orientation.Improper installation may resultin serious engine damage.42Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL13.17 Partially install wrist pin.13. CYLINDER TITLE& PISTON13.18 Align piston in correct orientation.EXHAUSTINTAKE13.19 Install piston.ABCDOil piston with ICS ® 2-stroke oil.Align wrist pin with wrist pin bearing.Complete wrist pin installation.Install second wrist pin retaining clipMake sure wrist pin retainingclip is in the proper orientation(see 13.16).Copyright © 2005 ICS, Blount Inc.43

13. CYLINDER TITLE& PISTON13.20 Install cylinderA Lubricate cylinder bore with ICS ®2-stroke oil.BCCompress rings with ringcompression tool.Slide cylinder onto piston, pushingring compression tool down.613GC SHOP MANUAL13.21 Install cylinder.ABCRemove ring compression tool.Slide cylinder down piston and intocrankcase.Align cylinder bolt holes withcrankcase.13.22 Install 4 cylinder screws andwashers.A Use blue Loctite ® .BTorque bolts to 95.5 in-lbs. (11 Nm)44Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL13.23 Install rear manifold.A Lubricate rear manifold with ICS ®2-stroke oil.BCPush rear manifold onto cylinderintake.Align rear manifold seam withcylinder and crankcase seam.13. CYLINDER TITLE& PISTON13.24 Install rear manifold clamp.ATorque to 11 in-lbs. (1 Nm)13.25 Install protective spring onto pulsetube.13.26 Install the pulse tube onto cylinderbarb.Copyright © 2005 ICS, Blount Inc.45

13. CYLINDER TITLE& PISTON13.27 Install carburetor base.ABCSlip pulse tube into carburetor base.Slip rear manifold into carburetorbase.Make sure rear manifold lip is flat.613GC SHOP MANUAL13.28 Install carburetor base screws.ABCUse blue Loctite ® on 3 screws withoutground wire.Make sure to include stop switchwire.Torque to 35 in-lbs. (4 Nm).46Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL14 This section covers water hoseand water tank cap.14. WATER TITLEHOSE14.1 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.Copyright © 2005 ICS, Blount Inc.47

14. WATER TITLEHOSE14.6 Release water tank cap from watertank tube.ADepress orange fitting as shown.14.7 Assemble in the reverse order.613GC SHOP MANUAL48Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL15 This section covers the removal,inspection, and installation ofthe ignition coil. Removal ofthe starter is required. Refer tosection 8 if necessary.15. IGNITION TITLE COIL15.1 Remove starter flywheel shroud byunhooking wires.15.2 Remove ignition coil screws, wavewashers and plain washers.15.3 Remove ignition coil.15.4 Inspect.ABLook for cracks/missing insulation.Clean flywheel magnets and coil ifrusty.Copyright © 2005 ICS, Blount Inc.49

15. IGNITION TITLE COIL15.5 Install Ignition coil.A Place ignition coil shim (0.012”)on magnet counterweight side offlywheel.B Set ignition coil in place.C Install ignition coil screws, wavewashers, and plain washers with blueLoctite ® .Holding shim, rotate flywheel magnetaround to coil.E Torque ignition coil screws to26 in-lbs. (3 Nm).F Remove shim, rotate flywheel tocheck clearance.15.6 Install flywheel shroud15.7 Route yellow ignition stop switch wirethrough crankcase into carburetorchamber.613GC SHOP MANUAL15.8 Complete ignition wire routing.50Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL16 This section covers the removal,inspection, and installationof the flywheel. Removal ofthe starter and spark plug isrequired. Refer to sections 6and 8 if necessary.16. FLYWHEEL TITLE16.1 Insert piston stop.16.2 Remove flywheel nut, wave washer,and plain washer.16.3 Screw on flywheel removal tool fingertight. Unscrew tool 1 ½ turns leavingapproximately 1/8 inch (5 mm) spacebetween tool and flywheel.Copyright © 2005 ICS, Blount Inc.51

16. FLYWHEEL TITLE16.4 Using pliers, hold saw up by magnetcounterweight.16.5 Strike flywheel removal tool witha ball peen hammer. The flywheelshould release from crankshaft.16.6 Inspect and clean flywheel. Replaceif any of the fins are broken.613GC SHOP MANUAL16.7 Inspect woodruff key.16.8 Install flywheel, plain washer, wavewasher, and flywheel nut.ATorque nut to 217 in-lbs. (25 Nm).52Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL17 This section covers the removalinspection, and installation ofthe bottom guard.17. BOTTOM TITLEGUARDABCDRemove bottom guard screws andsplit washers.Inspect bottom guard.Replace if damaged.Assemble in reverse orderCopyright © 2005 ICS, Blount Inc.53

18. FRONT TITLE HANDLE18 This section covers the removal,inspection, and installation ofthe front handle.613GC SHOP MANUAL18.1 Remove front handle screws on rightside.18.2 Remove front handle screws onbottom.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).54Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL19 This section covers thedisassembly, inspection, andassembly of the vibrationisolaters, fuel tank, and rearhandle.19. FUEL TITLETANK19.1 Remove vibration isolator screws andwave washers on clutch side of saw.19.2 Remove vibration isolator screws andwave washers on flywheel side ofsaw.Copyright © 2005 ICS, Blount Inc.55

19. FUEL TITLETANK19.3 Separate crankcase and fuel tank.NOTE: Saws have a rubber waterdeflector connected to the2 bottom vibration isolators onthe clutch side (circled).613GC SHOP MANUAL19.4 Remove vibration isolators from fueltank (6) if necessary.19.5 Assemble in reverse order.NOTE: During assembly be careful toavoid kinking the fuel line.56Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL20 This section covers thedisassembly, inspection, andassembly of the crankcaseseals and crankshaft bearings.20. CRANKCASETITLE20.1 Remove outer crankshaft sealhousing screws and wave washers.20.2 Remove crankcase bolts.Copyright © 2005 ICS, Blount Inc.57

20. CRANKCASETITLE20.3 Heat the flywheel side crankcasewith heat gun for 5 minutes,approximately 150° F (65.5° C).613GC SHOP MANUAL20.4 Remove the flywheel side crankcase– tap crankshaft with plastic mallet.ABSuspend above work surface.Tap with mallet.NOTE: A nut should always be placedon a threaded shaft whenpounding or pressing on it.20.5 Remove the flywheel side crankcaseseal with 1/2” (13 mm) socket.58Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL20.6 Heat the clutch side crankcase withheat gun to 150° F (65.5° C).20. CRANKCASETITLE20.7 Remove crankshaft from theclutch-side crankcase tap crankshaftwith a plastic mallet.ABSuspend above work surface.Tap with plastic mallet.20.8 Remove the bearing from theflywheel side of crankshaft.Copyright © 2005 ICS, Blount Inc.59

20. CRANKCASETITLE20.9 Remove the bearing, seal, andbushing from the clutch side ofcrankshaft.613GC SHOP MANUAL20.10 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.60Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL20.14 Repeat with other half.20. CRANKCASETITLE20.15 Install crankshaft into clutch side ofcase.20.16 Place clutch side crank case seal oncrankshaft.ATap lightly with bearing driver andmallet.Copyright © 2005 ICS, Blount Inc.61

20. CRANKCASETITLE613GC SHOP MANUAL20.17 Coat crankcase gasket with ICS ®2-stroke engine oil.20.18 Align crankcase gasket on flywheelside crankcase pins.20.19 Place crankcase halves together andalign crankcase pins.62Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL20.20 Assemble crankcase halves – tapwith bearing driver and mallet.20. CRANKCASETITLE20.21 Install main crankcase bolts.A Use blue Loctite ® .BTorque to 69 in-lbs. (8 Nm).NOTE: The 3 remaining crankcasebolts will be installed during thecompletion of the saw assembly.20.22 Install flywheel side crankcase seal– tap with bearing driver and mallet.Copyright © 2005 ICS, Blount Inc.63

20. CRANKCASETITLE20.23 Trim crankcase gasket flush.613GC SHOP MANUAL64Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL21 This section covers the removaland installation of the bar studsand bar pad.21. BAR STUDS TITLE& BAR PADNOTE: On saws with Serial #’sbeginning 0482421700 and071XXXXXXX, it is necessary toremove the bar mount pad coverplate first.21.1 Remove bar studs.ABCDRemove side cover.Install side cover nuts, flange toflange and tighten together.Attempt to remove the inside nutwhich should pull out the bar stud.Repeat on second bar stud.21.2 Remove bar pad.A Remove sealing o-ring.21.3 Assemble in reverse order.Copyright © 2005 ICS, Blount Inc.65

22. CHAIN TITLE TENSIONER22 This section covers the removaland installation of the chaintensioner.613GC SHOP MANUAL22.1 Remove bar plate to expose thechain tensioner.NOTE: Saws with serial #’s lower than0482421700 are not equippedwith a bar mount pad coverplate.22.2 Unscrew tensioner to remove.A Remove tensioner pin.B Remove tensioner screw keeper.22.3 Assemble in reverse order.66Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL23. CARBURETOR TITLE TUNING23 This section covers carburetor tuning. Included in this section are basic settings,idle speed adjustment, and complete adjustment.The carburetor on a new saw is set at the factory for optimal performance and complianceto EPA Phase 1 emmissions standards. However, minor adjustments may berequired in certain conditions, such as high elevation.A replacement carburetor is not set correctly from the factory. Use the tuning instructionsin this manual to adjust carburetor to factory-recommended settings. (DO NOTadjust the carburetor for maximum rpm. Adjusting the carburetor for maximum rpmwill cause engine damage).Always set the carburetor jets to factory settings when replacement or completerebuild becomes necessary.NOTES:• These cut-off saws are equipped with an electronic speed limiter, as part ofthe ignition system. This will prevent the saw from going above 12,500 rpm.Attempting to set the carburetor mixture to increase the speed or power beyondthis limit may seriously damage the engine.• Always check the air filter, pre filter, fuel filter, and spark plug before makingcarburetor tunings and clean or replace if necessaryCopyright © 2005 ICS, Blount Inc.67

23. CARBURETOR TITLE TUNING23.1 Basic Setting -H = 1 3/4 turns from closedL = 1 1/4 turns from closed613GC SHOP MANUALRPM Settings for saws.NOTE: Saw tuned without bar and chain installed.Idle Speed = 3,000 ± 500 rpmFull Throttle = 11,000 ± 500 rpmComplete carburetor readjustment.23.2 Remove limiter capABCDLook into adjustment screw hole.Observe orientation of the releaseslots on the adjustment screw limitercap.Insert the limiter cap puller bladesinto the release slots.Firmly hold the tool shaft whilescrewing in the puller screw untilthe screw head is against the pullershaft.Unscrew the puller screw.68Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL23.3 Using a 5/64” straight bladescrewdriver, gently turn theadjustment screws clockwise untilcompletely closed.23.4 Set the adjustment screws at theBasic Setting:H = 1 3/4 turns from closedL = 1 1/4 turns from closedThe side cover must be heldtightly in place with the sidecover nuts, using a bar and nochain. Failure to do so may resultin personal injury.23. CARBURETOR TITLE TUNING23.5 Start the saw and warm up theengine.23.6 With a tachometer check the sawrpm, with no bar and chain:ABIdle = 3,000 ± 300 rpmIf the idle rpm does not fall into thisrang, adjust the T screw, clockwise toraise RPM, counterclockwise to lowerRPM.23.7 With a tachometer check the saw fullthrottle rpm, with no bar and chain:ATarget = 11,000 ± 500 rpm23.8 If the full throttle rpm falls below thisrange, turn the H screw in (clockwise)1/16 th of a turn at a time.APulse the throttle to help stabilize thesystem.Do not hold the saw at maxrpm for more than 5 seconds orcylinder damage could occur.Copyright © 2005 ICS, Blount Inc.69

23. CARBURETOR TITLE TUNING23.9 When the carburetor is adjustedcorrectly set the limiter caps asshown with a 1/4” straight bladescrewdriver.ABL = verticalH = horizontal613GC SHOP MANUAL70Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL24 This section covers idle speedadjustment.24. IDLE SPEED TITLE ADJUSTMENT24.1 If engine stops while idling:ABCMake sure the chain is properlytensioned.Turn T screw clockwise until chainbegins to moveBack T screw out ½ turn.24.2 If chain turns at idle:ABack T screw out until chain stopsmoving.Copyright © 2005 ICS, Blount Inc.71

25. DIAGRAMS613GC SHOP MANUAL25 This section provides several flowcharts to aid diagnosing common problems.CHECK POSSIBLE CAUSE REPAIRThe engine runs rough atall speedsYES• Dirty or clogged air filter.• Water has been ingested.• Loose or dirty spark plug.• Clean or replace the air filter.• Inspect air intake sysetm for water.• Inspect fuel system for water.• Tighten, clean, or replace sparkplug.A dirty air filter is the #1 reason for engine problems.The engine is overheating.YES• Operator is overworkingthe saw.• Carburetor mixture is toolean.• Incorrect fuel/oil ratio.• Flywheel fins are clogged.• Air deflector is missing.• Cylinder fins are clogged• See Operator’s Manual.• See Carburetor Tuning section.• See Saw Specifications section.• Clean flywheel fins with wirebrush.• See Starter Cover section.• Clean cylinder fins.Poor acceleration.YES• Dirty or clogged air filter.• Clogged fuel filter.• Incorrect carburetor tune.• Plugged tank breather.• Blocked pulse tube.• Clean or replace the air filter.• Replace fuel filter.• See Carburetor Tuning section.• Repair or replace fuel tankbreather.• Replace pulse tube.Uneven idle or enginemay “run away”YES• Air leak at intake boot,cylinder gasket, orcrankcase gasket.• Faulty carburetordiaphragm.• Inspect air intake boot.• Pressure test crankcase.• Replace carburetor.Diamond chain movesat idle.YES• Idle speed too high.• Broken clutch spring.• Adjust idle speed.• Replace clutch spring.Excessive vibration.YES• Damaged shock absorber.• Damaged or brokenflywheel fins.• Bent crankshaft.• Replace shock absorbers• Replace flywheel.• Replace crankshaft.72Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL25. DIAGRAMSSaw Will Not StartCHECK POSSIBLE CAUSE REPAIRDoes the engine crank?NO• Dirty or broken recoilstarter.• Internal damage.• Clean, rebuild or replace the recoilstarter.• Inspect for internal damage suchas seized piston.YESIs there spark?YESIs the spark plug firingproperly?YESNONO• The ignition switch is“OFF”.• Faulty ignition ground.• Faulty spark plug lead.• Faulty ignition coil.• Plug is soaked with fuel.• The plug is fouled orgapped improperly.• Plug is internally faulty orthe wrong type.• Move switch to “ON” and re-test.• Tighten connections or replaceground wire.• Repair or replace spark plug lead.• Replace ignition coil.• Dry plug, expel excess fuel fromcylinder and crankcase.• Clean and re-gap the plug to0.020 inch (0.05 mm).• Replace with the correct plug –see Spark Plug Reference Guide.Insure cylindercompression is above125 psiNO• Loose spark plug.• If below 125 psi – excesswear on the piston,cylinder, rings.• Tighten plug and re-test.• Replace piston and cylinder.YESIs the fuel fresh?Is the fuel mixed 50:1NO• Fuel is old, varnished, orcontaminated.• Empty tank and re-fill with freshfuel of the correct mixture (25:1)YESIs the fuel reaching thecarburetor?YESNO• Clogged fuel filter.• Damaged fuel line.• Damaged pulse tube.• Plugged fuel tankbreather.• Replace fuel filter.• Replace fuel line.• Replace pulse tube.• Repair or replace fuel tankbreather.Is too much fuelreaching thecarburetor?YES• Carburetor is tunedincorrectly.• Plugged fuel tank breather.• Refer to Carburetor Tuningsection.• Repair or replace fuel tankbreather.NOIs the flywheel keysheared?YES• Loose flywheel.• Replace key and reinstall flywheel.Copyright © 2005 ICS, Blount Inc.73

26. FUEL SYSTEM TITLE LEAKS26 This section covers testing thefuel system for leaks. Enginestarvation can result from aleak or malfunction of any ofthe main components of thefuel system. The five maincomponents are the fuel tank,fuel tank breather, fuel filter,delivery tubes, and carburetor.613GC SHOP MANUAL26.1 Remove and inspect the fuel filter.AReplace the fuel filter if there is anyforeign material in the felt or theinternal screen.26.2 Test the main fuel pick-up tube forleaks.ABCInstall 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 thecarburetor.74Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUALDEFGPlug one end of the main fuel pick-uptube.Re-pressurize the tube to 7 psi(0.5 bar).Replace the tube if pressure is notmaintained.If the main fuel pick-up tube doesmaintain pressure, then the leak habeen isolated to the carburetor. Referto the Walbro Diaphragm CarburetorService Manual.26. FUEL SYSTEM TITLE LEAKS26.3 The fuel tank breather stabilizes thepressure in the fuel tank preventingboth excessive pressure, whichcould flood the engine, and negativepressure, which could starve theengine of fuel.26.4 Fuel tank breather is located insidethe air filter compartment.Copyright © 2005 ICS, Blount Inc.75

26. FUEL SYSTEM TITLE LEAKS26.5 Testing the fuel tank breather.ABAttach the pressure gauge and bulbto the main fuel pick-up tube at thecarburetor. Pressurize the tube to 4.5psi (0.3 bar).The pressure should reduce to nearly0 psi (0 bar) over about 3 seconds.613GC SHOP MANUAL26.6 If the pressure does not reduce to0 psi, disassemble or replace thebreather.ABCClean the parts with solvent or fuel.Assemble in reverse order.Make sure that the spring taper isoriented in the correct direction.76Copyright © 2005 ICS, Blount Inc.

613GC SHOP MANUAL27 This section covers testing thecrankcase for leaks. A leak inthe crankcase can cause theengine not to run.27. CRANKCASE TITLE LEAKS27.1 Install the intake seal flange.APlug cylinder pulse tube.27.2 Install the exhaust seal flange.27.3 Block one of the flange tubes with arubber 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 thesame, use soapy water to find theleak.NOTE: It is recommended that this testbe performed after an enginerebuildCopyright © 2005 ICS, Blount Inc.77

APPENDIX613GC SHOP MANUAL1 The Spark Plug Reference Guide is to be used as a guide only. When trying a plugfrom a different manufacturer, perform a plug check to be sure that the plug willwork.SPARK PLUG REFERENCE GUIDEICS RESISTOR CHAMPION NGK RESISTOR BOSCH RESISTORRESISTOR73199 RCJ7Y BPMR7A WSR7F78Copyright © 2005 ICS, Blount Inc.

ICS, Blount Inc. 4909 SE International Way Portland, Oregon 97222TEL 800-321-1240 FAX 503-653-4393www.icsbestway.comp/n 71537