613GC
SERVICE MANUAL
F/N 71537 Oct 07
© 2007 ICS, Blount Inc.
613GC SERVICE MANUAL
TABLE OFCONTENTS
PAGE NUMBER
SECTION
SECTION TITLE
SHOP MANUAL USE
TOOLS
2
1
2
3
SAW SPECIFICATIONS
SERIAL NUMBER LOCATION
SPARE PARTS DIAGRAM (TORQUE AND LOCTITE®)
AIR INTAKE
4
3
5
4
6
5
15
17
19
23
29
31
34
36
38
47
49
51
53
54
55
57
65
66
67
71
72
74
77
6
SPARK PLUG
7
CLUTCH & RIM SPROCKET
STARTER SYSTEM
WALLWALKER
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
CYLINDER COVER
MUFFLER
CARBURETOR
CYLINDER & PISTON
WATER HOSE
IGNITION COIL
FLYWHEEL
BOTTOM GUARD
FRONT HANDLE
FUEL TANK
CRANKCASE
BAR STUDS
TENSIONER
CARBURETOR TUNING
IDLE SPEED ADJUSTMENT
TROUBLESHOOTING DIAGRAMS
TROUBLESHOOTING: FUEL SYSTEM LEAKS
TROUBLESHOOTING: CRANKCASE LEAKS
APPENDIX
1. SPARK PLUG REFERENCE GUIDE
78
F/N 71537 Oct 07
© 2007 ICS, Blount Inc.
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SHOP MANUAL 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.
Use a plastic dead blow mallet to separate parts attached solidly to each other.
Mark mating parts as a reassembly reference.
Keep component parts together as a group. Assemble screws and nuts into appropriate
subgroups.
•
When reassembling, clean all parts carefully, lubricate moving parts and replace all oil seals,
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’s
or by calling 1.989.872.2131.
© 2007 ICS, Blount Inc.
F/N 71537 Oct 07
2
613GC SERVICE MANUAL
1.TOOLS
Gas Saw Service Tool Kit - P/N 71700
1
2
3
4
9
5
6
7
8
10
15
11
16
12
17
13
18
14
19
P/N
DESCRIPTION
1
2
71521
SCRENCH
71541
71542
71543
71546
71547
71548
71550
71565
71569
71570
71573
73410
PRESSURE GAUGE BULB
COIL/FLYWHEEL TIMING SHIM
3
4
CYLINDER ASSEMBLY CLAMPS & PISTON STOP
613 SHOCK ABSORBER TOOL
5
6
SPARK TESTER
7
613 FLYWHEEL DISASSEMBLY TOOL
LIMITER CAP REMOVAL TOOL
8
9
ELECTRONIC TACHOMETER
10
11
12
13
14
15
16
17
18
19
613GC INDUCTION SEAL FLANGE W/ SCREWS
613GC EXHAUST SEAL FLANGE W/SCREWS
TUNING SCREWDRIVER
633GC FLYWHEEL PULLER
73425
73428
73429
73430
73431
73432
633GC FUEL PRESSURE CAP
613GC & 633GC MAIN BEARING DRIVER TOOL
633 MAIN BEARING SPACING TOOL
633GC SHOCK ABSORBER TOOL
633GC INTAKE PORT COVER TOOL
633GC EXHAUST PORT COVER TOOL
F/N 71537 Oct 07
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2. SPECIFICATIONS
613GC SERVICE MANUAL
SPECIFICATIONS
Engine Type
2-Stroke Single Cylinder Air Cooled
4.9 cu. in. (80.7 cc)
Displacement
Horsepower
Engine Speed
5.7 hp (4.2 kW) @ 9000 rpm
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
Up to 12 inches (30 cm)
Cutting Depth
Dimensions
18 inches (45 cm) length
11.5 inches (29 cm) height
10 inches (25 cm) width
Carburetor
Air Filtration
Starter
Walbro diaphragm WJ-85B
Dry nylon
Dust and water shielded
Ignition
Electronic speed governing, water sealed
Three-weight, single spring, centrifugal
Clutch
Fuel Mix Ratio
25:1 gasoline to oil with brand name gasoline and ICS® 2-stroke
engine oil, or other high quality 2-stroke engine oil for air cooled
engines.
Fuel Capacity
0.23 gal (0.88 liter)
15-18 minute run time
Water Supply
Noise Level
Minimum 20 psi (1.5 bar)
100 dB @ 1 meter
Vibration Level
Spark Plug TYPE
Spark Plug Gap
Sprocket Type
10.5 m/s
Champion RCJ-7Y (for spark plug reference guide see page 78)
0.02 inches (0.5 mm)
8-tooth rim sprocket
© 2007 ICS, Blount Inc.
F/N 71537 Oct 07
4
613GC SERVICE MANUAL
3. SERIAL#LOCATION
3 613GC Cut-Off serial number series.
F/N 71537 Oct 07
© 2007 ICS, Blount Inc.
5
4. SPARE PARTS 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.
TORQUE
LOCTITE®
KEY
DESCRIPTION
PART NUMBER
Nm
in‑lbs.
242
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
19
20
21
22
23
24
25
26
27
SCREW
STARTER ROPE HANDLE
STARTER ROPE
0.4
35
X
73866
505514
73904
73909
71451
73910
73913
73905
73907
71415
73908
73891
73911
73912
509163
509207
73914
73237
73919
73914
73285
73890
73241
73917
73920
71449
STARTER COIL SPRING & HOUSING
STARTER CASE PLATE
STARTER COIL SPRING & HOUSING SCREW
STARTER ROPE PULLEY
STARTER PULLEY WASHER
STARTER PULLEY SCREW
STARTER COVER ASSEMBLY
STARTER COVER AIR DEFLECTOR
NUT
0.6
3.0
52
X
260
WASHER
WAVE WASHER
FLYWHEEL ASSEMBLY
STARTER PAWL ASSEMBLY
SCREW
SWITCH, IGNITION TOGGLE
IGNITION TOGGLE CABLE
SCREW
WAVE WASHER
PLAIN WASHER
SPARK PLUG CAP
0.7
0.3
61
26
X
SPARK PLUG SPRING
IGNITION COIL WITH SPARK PLUG LEAD & PRIMARY
SWITCH GROUND CONNECTION PLATE
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613GC SERVICE MANUAL
4. SPARE PARTS DIAGRAM
TORQUE
Nm in‑lbs.
LOCTITE®
KEY
DESCRIPTION
PART NUMBER
242
1
2
3
4
5
6
7
9
REAR MANIFOLD CLAMP
REAR MANIFOLD
WRIST PIN NEEDLE BEARING
COMPLETE PISTON/CYLINDER ASSEMBLY
CYLINDER BASE GASKET ASSEMBLY
SPARK PLUG
CYLINDER TO MUFFLER GASKET
CARBURETOR ATTACHMENT SCREW WASHER
MUFFLER ASSEMBLY
73867
73868
73869
71413
71412
73199
73881
73327
71411
73874
73883
73898
73884
73885
71762
73901
73250
73895
71642
73947
71735
73888
73897
73902
73866
73899
71481
71482
2.8
243
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
CYLINDER BLOCK BOLT
1.1
1.0
95
87
X
X
MUFFLER MOUNTING SCREW
CARBURETOR PULSE TUBE
MUFFLER SUPPORT BRACKET
MUFFLER SUPPORT BRACKET SCREW
COMPLETE CARBURETOR WJ-85B
INTAKE MANIFOLD FLANGE SCREW
WASHER
CARBURETOR SUPPORT BRACKET
DECOMPRESSION VALVE
INTAKE MANIFOLD FLANGE
INTAKE MANIFOLD
CARBURETOR PULSE TUBE PROTECTOR
WASHER
CARBURETOR ATTACHMENT SCREW
SCREW
SCREW GUIDE
MUFFLER DEFLECTOR
0.9
0.4
78
35
1.3
113
0.5
0.4
0.6
43
35
52
X
SCREW
0.4
35
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4. SPARE PARTS DIAGRAM
613GC SERVICE MANUAL
TORQUE
Nm in‑lbs.
LOCTITE®
PART NUMBER
242
KEY
DESCRIPTION
1
2
3
4
5
6
7
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
LOCTITE®
PART NUMBER
242
KEY
DESCRIPTION
Nm
in‑lbs.
1
2
3
4
5
6
7
8
9
OUTER CRANKCASE SEAL CLUTCH SIDE
OUTER CRANKCASE SEAL BODY
OUTER CRANKCASE SEAL BODY SCREW
WASHER
CLUTCH SPACER WASHER
8T RIM SPROCKET KIT
CLUTCH NEEDLE BEARING
613GC CLUTCH DRUM ASSEMBLY
CLUTCH SPACER WASHER, INSIDE
CLUTCH
73931
73949
73940
73285
73945
70949
73939
71520
73941
71419
73943
0.3
26
10
11
3.4
295
CLUTCH SPRING
© 2007 ICS, Blount Inc.
F/N 71537 Oct 07
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613GC SERVICE MANUAL
4. SPARE PARTS DIAGRAM
TORQUE
LOCTITE®
PART NUMBER
242
KEY
DESCRIPTION
Nm
in‑lbs.
1
2
3
4
GUARD FLAP
71534
71532
71531
73951
WALLWALKER® LEVER ARM
GUARD FLAP CLAMP
WASHER
5
6
7
8
WALLWALKER® LEVER ARM SCREW
GUARD FLAP SCREW
GUARD FLAP WASHER
GUARD FLAP SPACER
WATER HOSE GASKET
FITTING
0.5
0.5
43
43
X
X
71478
71479
71483
71480
71469
71467
71457
71468
71458
71454
71455
71465
71461
71464
71463
71453
71456
73923
73448
71459
71470
71471
71472
71744
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
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
2.0
174
FITTING
FITTING
O-RING
HOSE HANGER BUTTON
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4. SPARE PARTS DIAGRAM
613GC SERVICE MANUAL
TORQUE
LOCTITE®
PART NUMBER
242
KEY
DESCRIPTION
Nm
in‑lbs.
1
2
3
4
5
FUEL LINE GROMMET (CRANKCASE)
73390
71736
73281
73209
71747
73927
73934
CRANKCASE ASSEMBLY, LEFT HALF
CRANKCASE DOWEL PIN
CRANKSHAFT BEARING
CRANKCASE ASSEMBLY, RIGHT HALF
CHOKE LEVER SPLIT PIN
CRANKCASE GASKET
7
8
9
CRANKCASE BOLT
WASHER
BOTTOM COVER
BAR MOUNT PAD SPACER
COVER GUARD MOUNTING BOLT
SCREW (CRANKCASE)
BAR MOUNTING STUD
SCREW
BAR MOUNT PAD COVER PLATE
PREMIUM TENSIONER KIT (REPLACES 73283), ASSEMBLY
TENSIONER SCREW RETAINER
CHOKE LEVER
CRANKCASE GROMMET, RIGHT SIDE
CHOKE LEVER BUSHING
0.8
69
X
73930
73897
73950
71740
73397
73379
73933
73284
71738
73935
73936
73928
71741
73955
10
11
12
13
14
15
16
17
18
19
20
21
22
0.8
0.5
1.2
0.8
69
43
104
69
X
X
© 2007 ICS, Blount Inc.
F/N 71537 Oct 07
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613GC SERVICE MANUAL
4. SPARE PARTS DIAGRAM
TORQUE
LOCTITE®
PART NUMBER
242
KEY
DESCRIPTION
Nm
in‑lbs.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
SIDE COVER INSERT, TOP
SIDE COVER NUT
CHAIN COVER CAP
MOUNTING NUT
WALLWALKER® SIDE ARM
WASHER
WALLWALKER® SIDE ARM SCREW
SCREW
SIDE COVER PLATE
71743
73958
71462
73367
71533
73951
507355
71487
71447
73957
73972
73948
73310
71420
1.2
104
0.3
26
X
LOWER GUARD
SIDE COVER INSERT, BOTTOM REAR
SIDE COVER INSERT, TOP REAR
SIDE COVER GROMMET
SIDE COVER ASSEMBLY, COMPLETE
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4. SPARE PARTS DIAGRAM
613GC SERVICE MANUAL
© 2007 ICS, Blount Inc.
F/N 71537 Oct 07
12
613GC SERVICE MANUAL
4. SPARE PARTS DIAGRAM
TORQUE
LOCTITE®
PART NUMBER
242
KEY
DESCRIPTION
Nm
in‑lbs.
1
2
3
4
5
CYLINDER COVER ASSEMBLY, WITH AIR INTAKE
AIR FILTER CANNISTER, POLYESTER
AIR FILTER COVER ASSEMBLY, 3 SCREW
FILTER COVER SCREW
FILTER SUPPORT
FILTER COVER GASKET
71754
71752
71753
73992
73338
71756
6
7
8
9
SCREW, CYLINDER COVER, LONG, SOCKET HEAD
PREFILTER PLASTIC, SECONDARY FILTER
AIR FILTER FLANGE
FILTER SUPPORT SCREW
FILTER CANNISTER GASKET
O-RING
TUBE CLAMP, NO TABS
COMPENSATOR TUBE
BREATHER GROMMET
THROTTLE ASSEMBLY
X
X
X
X
71771
73336
71758
73337
73335
71472
71760
71775
71763
71750
73331
10
11
12
13
14
15
16
17
0.3
26
O-RING, AIR FILTER
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4. SPARE PARTS DIAGRAM
613GC SERVICE MANUAL
TORQUE
LOCTITE®
PART NUMBER
242
KEY
DESCRIPTION
Nm
in‑lbs.
1
2
3
4
5
6
7
8
9
FUEL TANK ASSEMBLY (REQUIRES P/N 71739)
REAR HANDLE HALF
SCREW
THROTTLE LEVER
FUEL CAP ASSEMBLY, WITH OUTER SEAL RING
FUEL CAP O-RING
FUEL FILTER
TRIGGER LOCKOUT LEVER
TRIGGER LOCKOUT LEVER SPRING
WASHER
71421
73975
73976
71749
71739
73448
73459
73987
73988
73897
0.1
9
0
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
SCREW
SHOCK ABSORBER
0.9
0.4
78
35
X
X
73982
73980
71588
73375
71745
73270
73983
71422
71748
71766
71751
71759
71761
71777
71760
TUBE CLAMP, WITH TABS
FUEL LINE
SHOCK ABSORBER, REAR HANDLE
BUMPER, SHOCK ABSORBER, FUEL TANK TOP
FRONT HANDLE BOLT
FRONT HANDLE
FUEL BREATHER COMPLETE
WATER DEFLECTOR, BOTTOM
BREATHER TUBE BODY
BREATHER TUBE ELBOW
FUEL BREATHER, REMOTE
BREATHER TUBE EXTENSION
TUBE CLAMP, NO TABS
0.8
69
© 2007 ICS, Blount Inc.
F/N 71537 Oct 07
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613GC SERVICE MANUAL
5. AIR INTAKE
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.
Inspect air filter.
A
B
Replace if necessary
5.3
Clean filter with cleaning solution and
a nylon brush.
A
B
Clean filter with cleaning solution and
water.
Let dry and reinstall.
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5. AIRINTAKE
613GC SERVICE MANUAL
5.4
Inspect air filter cover gasket.
A
Replace if permanently depressed or
hard due to slurry.
5.5
Inspect filter cannister gasket.
Clean.
A
B
Replace if necessary.
5.6
Secure air filter mount screws.
© 2007 ICS, Blount Inc.
F/N 71537 Oct 07
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613GC SERVICE MANUAL
6. SPARKPLUG
6
This section covers the removal,
inspection, and installation of
the spark plug.
6.1
6.2
Remove the spark plug lead.
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
If dirty, clean with a wire brush as
shown.
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6. SPARKPLUG
613GC SERVICE MANUAL
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 78 to
select the correct replacement
plug.
6.5
Assemble in the reverse order.
A
Make sure the plug boot is seated
completely.
© 2007 ICS, Blount Inc.
F/N 71537 Oct 07
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613GC SERVICE MANUAL
7. CLUTCH &RIMSPROCKET
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.
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.
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7. CLUTCH &RIMSPROCKET
613GC SERVICE MANUAL
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.
7.6
Inspect spring for cracks.
© 2007 ICS, Blount Inc.
F/N 71537 Oct 07
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613GC SERVICE MANUAL
7. CLUTCH &RIMSPROCKET
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
Replace if the rim sprocket teeth are
worn to points, as shown on right.
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7. CLUTCH &RIMSPROCKET
613GC SERVICE MANUAL
7.10 Clean and assemble.
A
B
Clean all parts in solvent.
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
© 2007 ICS, Blount Inc.
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613GC SERVICE MANUAL
8. STARTER
8
This section covers the
removal of the starter cover,
replacement of the starter rope,
and replacement of the recoil
spring.
8.1
8.2
Remove starter cover screws.
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
Remove starter pulley screw and
washer.
NOTE: Hold starter cover firmly.
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8. STARTER
613GC SERVICE MANUAL
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
8.9
Lubricate with light weight oil.
Replace parts carefully.
© 2007 ICS, Blount Inc.
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613GC SERVICE MANUAL
8. STARTER
8.10 Inspect pulley spring catch.
A
B
Clean with cleaning solution.
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 Install center screw.
A
B
Use blue Loctite®.
Torque to 26 in-lbs. (2.9 Nm).
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8. STARTER
613GC SERVICE MANUAL
8.14 Wind the recoil spring.
A
B
Line rope up with notch on pulley.
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.
© 2007 ICS, Blount Inc.
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613GC SERVICE MANUAL
8. STARTER
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 Wind the pawl spring.
A
Use needle nose pliers to move the
tail of the spring into position.
8.20 Install starter cover.
A
B
Pull out cord 4-6”.
Slowly release while placing cover to
allow pawls to engage.
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8. STARTER
613GC SERVICE MANUAL
8.21 Install starter cover screws.
A
B
Use blue Loctite®.
Torque to 60 in-lbs. (7 Nm).
© 2007 ICS, Blount Inc.
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613GC SERVICE MANUAL
9. WALLWALKER
9
This section covers the removal,
inspection, and assembly of the
WallWalker® and guard flap.
9.1
Inspect WallWalker® tip.
A
If the tip is worn, as shown, replace.
9.2
9.3
Remove crankcase screws and wave
washers.
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
9.5
Remove guard flap screws and
washer.
Remove and inspect guard flap.
A
Replace the flap if it is torn or
damaged in any way.
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9. WALLWALKER
613GC SERVICE MANUAL
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).
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613GC SERVICE MANUAL
10. CYLINDER COVER
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
B
Pull up on front.
Push intake manifold through hole.
C Make sure throttle linkage is
disengaged from cylinder cover.
D Guide fuel breather tube and
compensator tube through cylinder
cover.
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10. CYLINDER COVER
613GC SERVICE MANUAL
10.7 Remove stop switch leads.
10.8 Inspect cylinder cover for damage.
A
Replace if necessary.
10.9 Check cylinder cover water seal and
filter cover gasket are in place and in
good condition.
A
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).
NOTE: Be careful as to not pull
tubes away from their point of
connection. Approximately 3/4”
of tube should protrude from
cylinder cover.
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613GC SERVICE MANUAL
10. CYLINDER 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.
A
Guide carburetor compensating tube
through air filter mount. Make sure
manifold sits flat over lip on cylinder
cover.
B
Install air filter mount screws (3) using
blue Loctite®.
C Torque to 43 in-lbs. (4.9 NM).
10.15 Install air filters and cover.
A
B
Install pre-filter
Install clean air filter
C Install air filter flange and tighten
D Install air filter cover and tighten
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11. MUFFLER
613GC SERVICE MANUAL
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
Replace any damaged components.
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613GC SERVICE MANUAL
11. MUFFLER
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 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.
(6 Nm).
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12. CARBURETOR
613GC SERVICE MANUAL
12
This section covers the
NOTE: All saws are equipped with
carburetor model # WJ-85A.
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
B
Push trigger end out of rear handle.
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.
12.4 Remove adjustment screw boot.
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613GC SERVICE MANUAL
12. CARBURETOR
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.
12.10 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).
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13. CYLINDER& PISTON
613GC SERVICE MANUAL
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.
NOTE: When replacing the 613GC cylinder
and piston it is necessary to tune the
carburetor prior to returning the saw to
service (see section 23).
13.1 Remove carburetor base screws.
A
Remove carburetor base from rear
manifold.
B
Remove carburetor base from pulse
tube.
13.2 Remove pulse tube and protective
spring from cylinder base.
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613GC SERVICE MANUAL
13. CYLINDER& PISTON
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 cylinder gasket and clean
case.
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13. CYLINDER& PISTON
613GC SERVICE MANUAL
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 pin bearing.
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613GC SERVICE MANUAL
13. CYLINDER& 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.
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13. CYLINDER& 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.
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613GC SERVICE MANUAL
13. CYLINDER& PISTON
13.17 Partially install wrist pin.
13.18 Align piston in correct orientation.
EXHAUST
INTAKE
13.19 Install piston.
A
B
Oil piston with ICS® 2-stroke oil.
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).
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13. CYLINDER& 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
B
Remove ring compression tool.
Slide cylinder down piston and into
crankcase.
C Align cylinder bolt holes with
crankcase.
13.22 Install 4 cylinder screws and
washers.
A
B
Use blue Loctite®.
Torque bolts to 95.5 in-lbs. (11 Nm)
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613GC SERVICE MANUAL
13. CYLINDER& 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.
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13. CYLINDER& PISTON
613GC SERVICE MANUAL
13.27 Install carburetor base.
A
B
Slip pulse tube into carburetor base.
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).
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613GC SERVICE MANUAL
14. WATERHOSE
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.
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14. WATERHOSE
613GC SERVICE MANUAL
14.6 Release water tank cap from water
tank tube.
A
Depress orange fitting as shown.
14.7 Assemble in the reverse order.
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613GC SERVICE MANUAL
15. IGNITION COIL
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
B
Look for cracks/missing insulation.
Clean flywheel magnets and coil if
rusty.
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15. IGNITION COIL
613GC SERVICE MANUAL
15.5 Install Ignition coil.
A
Place ignition coil shim (0.012”)
on magnet counterweight side of
flywheel.
B
Set ignition coil in place.
C Install ignition coil screws, wave
washers, and plain washers with blue
Loctite®.
Holding shim, rotate flywheel magnet
around to coil.
E
F
Torque ignition coil screws to
26 in-lbs. (3 Nm).
Remove shim, rotate flywheel to
check clearance.
15.6 Install flywheel shroud
15.7 Route yellow ignition stop switch wire
through crankcase into carburetor
chamber.
15.8 Complete ignition wire routing.
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613GC SERVICE MANUAL
16. FLYWHEEL
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.
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16. FLYWHEEL
613GC SERVICE MANUAL
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
Torque nut to 217 in-lbs. (25 Nm).
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613GC SERVICE MANUAL
17. BOTTOMGUARD
17
This section covers the removal
inspection, and installation of
the bottom guard.
A
B
Remove bottom guard screws and
split washers.
Inspect bottom guard.
C Replace if damaged.
D Assemble in reverse order
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18. FRONTHANDLE
613GC SERVICE MANUAL
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
B
Roll front handle into place.
Install front handle screws (4).
C Use blue Loctite®.
D Torque to 69 in-lbs. (8 Nm).
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613GC SERVICE MANUAL
19. FUELTANK
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.
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19. FUELTANK
613GC SERVICE MANUAL
19.3 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.
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613GC SERVICE MANUAL
20. CRANKCASE
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.
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20. CRANKCASE
613GC SERVICE MANUAL
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
B
Suspend above work surface.
Tap with mallet.
NOTE: A nut should always be placed
on a threaded shaft when
pounding or pressing on it.
20.5 Remove the flywheel side crankcase
seal with 1/2” (13 mm) socket.
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613GC SERVICE MANUAL
20. CRANKCASE
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
B
Suspend above work surface.
Tap with plastic mallet.
20.8 Remove the bearing from the
flywheel side of crankshaft.
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20. CRANKCASE
613GC SERVICE MANUAL
20.9 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.
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613GC SERVICE MANUAL
20. CRANKCASE
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.
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20. CRANKCASE
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.
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613GC SERVICE MANUAL
20. CRANKCASE
20.20 Assemble crankcase halves – tap
with bearing driver and mallet.
20.21 Install main crankcase bolts.
A
B
Use blue Loctite®.
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.
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20. CRANKCASE
613GC SERVICE MANUAL
20.23 Trim crankcase gasket flush.
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21. BAR STUDS& BAR PAD
21 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
B
Remove side cover.
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 Remove bar pad.
A
Remove sealing o-ring.
21.3 Assemble in reverse order.
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22. CHAINTENSIONER
613GC SERVICE MANUAL
22 This section covers the removal
and installation of the chain
tensioner.
22.1 Remove bar plate to expose the
chain tensioner.
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
B
Remove tensioner pin.
Remove tensioner screw keeper.
22.3 Assemble in reverse order.
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613GC SERVICE MANUAL
23. CARBURETOR TUNING
23 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. This will prevent the saw from going above 12,500 rpm.
Attempting to set the carburetor mixture to increase the speed or power beyond
this limit may seriously damage the engine.
• Always check the air filter, pre filter, fuel filter, and spark plug before making
carburetor tunings and clean or replace if necessary
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23. CARBURETOR TUNING
613GC SERVICE MANUAL
RPM Settings for saws.
23.1 Basic Setting -
H = 1 3/4 turns from closed
L = 1 1/4 turns from closed
NOTE: Saw tuned without bar and chain installed.
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.
C Firmly hold the tool shaft while
screwing in the puller screw until
the screw head is against the puller
shaft.
D Unscrew the puller screw.
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613GC SERVICE MANUAL
23. CARBURETOR TUNING
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:
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.
23.6 With a tachometer check the saw
rpm, with no bar and chain:
A
B
Idle = 3,000 ± 300 rpm
If the idle rpm does not fall into this
rang, adjust the T screw, clockwise to
raise RPM, counterclockwise to lower
RPM.
23.7 With a tachometer check the saw full
throttle rpm, with no bar and chain:
A
Target = 11,000 ± 500 rpm
23.8 If the full throttle rpm falls below this
range, turn the H screw in (clockwise)
1/16th of a turn at a time.
A
Pulse the throttle to help stabilize the
system.
Do not hold the saw at max
rpm for more than 5 seconds or
cylinder damage could occur.
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23. CARBURETOR TUNING
613GC SERVICE MANUAL
23.9 When the carburetor is adjusted
correctly set the limiter caps as
shown with a 1/4” straight blade
screwdriver.
A
B
L = vertical
H = horizontal
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613GC SERVICE MANUAL
24. IDLE SPEEDADJUSTMENT
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 If chain turns at idle:
A
Back T screw out until chain stops
moving.
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25. DIAGRAMS
613GC SERVICE MANUAL
25 This section provides several flowcharts to aid diagnosing common problems.
CHECK
POSSIBLE CAUSE
REPAIR
•
•
•
•
Clean or replace the air filter.
Inspect air intake sysetm for water.
Inspect fuel system for water.
Tighten, clean, or replace spark
plug.
•
•
•
Dirty or clogged air filter.
Water has been ingested.
Loose or dirty spark plug.
The engine runs rough at
all speeds
YES
A dirty air filter is the #1 reason for engine problems.
•
•
Operator is overworking
the saw.
•
•
•
•
See Operator’s Manual.
See Carburetor Tuning section.
See Saw Specifications section.
Clean flywheel fins with wire
brush.
Carburetor mixture is too
lean.
Incorrect fuel/oil ratio.
Flywheel fins are clogged.
Air deflector is missing.
Cylinder fins are clogged
The engine is overheating.
YES
•
•
•
•
•
•
See Starter Cover section.
Clean cylinder fins.
•
•
•
•
Clean or replace the air filter.
Replace fuel filter.
See Carburetor Tuning section.
Repair or replace fuel tank
breather.
•
•
•
•
•
Dirty or clogged air filter.
Clogged fuel filter.
Incorrect carburetor tune.
Plugged tank breather.
Blocked pulse tube.
Poor acceleration.
YES
YES
•
Replace pulse tube.
•
•
Air leak at intake boot,
cylinder gasket, or
crankcase gasket.
Faulty carburetor
diaphragm.
•
•
•
Inspect air intake boot.
Pressure test crankcase.
Replace carburetor.
Uneven idle or engine
may “run away”
Diamond chain moves
at idle.
•
•
Idle speed too high.
Broken clutch spring.
•
•
Adjust idle speed.
Replace clutch spring.
YES
YES
•
•
Damaged shock absorber.
Damaged or broken
flywheel fins.
•
•
•
Replace shock absorbers
Replace flywheel.
Replace crankshaft.
Excessive vibration.
•
Bent crankshaft.
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25. DIAGRAMS
REPAIR
Saw Will Not Start
CHECK
POSSIBLE CAUSE
•
•
Clean, rebuild or replace the recoil
starter.
Inspect for internal damage such
as seized piston.
•
•
Dirty or broken recoil
starter.
Internal damage.
Does the engine crank?
NO
YES
Is there spark?
YES
•
The ignition switch is
“OFF”.
Faulty ignition ground.
Faulty spark plug lead.
Faulty ignition coil.
•
•
Move switch to “ON” and re-test.
Tighten connections or replace
ground wire.
Repair or replace spark plug lead.
Replace ignition coil.
•
•
•
NO
NO
•
•
•
•
•
Dry plug, expel excess fuel from
cylinder and crankcase.
Clean and re-gap the plug to
0.020 inch (0.05 mm).
Replace with the correct plug –
see Spark Plug Reference Guide.
•
•
Plug is soaked with fuel.
The plug is fouled or
gapped improperly.
Plug is internally faulty or
the wrong type.
Is the spark plug firing
properly?
•
YES
•
•
Loose spark plug.
If below 125 psi – excess
wear on the piston,
cylinder, rings.
Insure cylinder
compression is above
125 psi
•
•
Tighten plug and re-test.
Replace piston and cylinder.
NO
NO
YES
Is the fuel fresh?
Is the fuel mixed 50:1
•
Fuel is old, varnished, or
contaminated.
•
Empty tank and re-fill with fresh
fuel of the correct mixture (25:1)
YES
•
•
•
•
Clogged fuel filter.
Damaged fuel line.
Damaged pulse tube.
Plugged fuel tank
breather.
•
•
•
•
Replace fuel filter.
Replace fuel line.
Replace pulse tube.
Repair or replace fuel tank
breather.
Is the fuel reaching the
carburetor?
NO
YES
•
•
Refer to Carburetor Tuning
section.
Repair or replace fuel tank
breather.
Is too much fuel
reaching the
carburetor?
•
•
Carburetor is tuned
incorrectly.
Plugged fuel tank breather.
YES
NO
Is the flywheel key
sheared?
•
Loose flywheel.
•
Replace key and reinstall flywheel.
YES
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26. FUEL SYSTEM LEAKS
613GC SERVICE MANUAL
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
Replace the fuel filter if there is any
foreign material in the felt or the
internal screen.
26.2 Test the main fuel pick-up tube for
leaks.
A
B
Install the pressure gauge and bulb.
Pressurize the tube to 7 psi (0.5 bar).
C If the pressure does not maintain,
separate the fuel line from the
carburetor.
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613GC SERVICE MANUAL
26. FUEL SYSTEM LEAKS
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.
26.3 The fuel tank breather stabilizes the
pressure in the fuel tank preventing
both excessive pressure, which
could flood the engine, and negative
pressure, which could starve the
engine of fuel.
26.4 Fuel tank breather is located inside
the air filter compartment.
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26. FUEL SYSTEM LEAKS
613GC SERVICE MANUAL
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
B
Clean the parts with solvent or fuel.
Assemble in reverse order.
C Make sure that the spring taper is
oriented in the correct direction.
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76
613GC SERVICE MANUAL
27. CRANKCASE LEAKS
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
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.
NOTE: It is recommended that this test
be performed after an engine
rebuild
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APPENDIX
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
CHAMPION
RESISTOR
RCJ7Y
NGK RESISTOR BOSCH RESISTOR
BPMR7A WSR7F
© 2007 ICS, Blount Inc.
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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.
F/N 71537 Oct 07
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