603GC Gas Utility Saw Shop Manual

Transcription

1 603GC Gas Utility Saw Shop Manual

2

3 603GC SHOP MNUL TBLE OF TITLE CONTENTS SECTION SECTION TITLE PGE NUMBER SHOP MNUL USE 2 1 TOOLS 3 2 SW SPECIFICTIONS 4 3 SERIL NUMBER LOCTION 5 4 SPRE PRTS DIGRM (TORQUE ND LOCTITE ) 6 5 IR INTKE 19 6 SPRK PLUG 21 7 CLUTCH & RIM SPROCKET 23 8 STRTER SYSTEM 27 9 WLLWLKER CYLINDER COVER MUFFLER CRBURETOR CYLINDER & PISTON WTER HOSE IGNITION COIL FLYWHEEL FRONT HNDLE FUEL TNK CRNKCSE BR STUDS TENSIONER CRBURETOR TUNING IDLE SPEED DJUSTMENT TROUBLESHOOTING DIGRMS TROUBLESHOOTING: FUEL SYSTEM LEKS TROUBLESHOOTING: CRNKCSE LEKS 80 PPENDIX 1. SPRK PLUG REFERENCE GUIDE 81

4 SHOP MNUL TITLE USE 603GC SHOP MNUL Shop Manual Use This manual contains all the technical information necessary for carrying out repairs on the 603GC 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 lways 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. ssemble screws and nuts into appropriate subgroups. When reassembling, clean all parts carefully, lubricate moving parts and replace all oil seals, o-rings, 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. complete tool kit for ICS cut-off saws is available from ICS. Detailed carburetor maintenance and overhaul information is available in Walbro s Diaphragm Carburetor Service Manual. Walbro can be contacted at or by calling

5 603GC SHOP MNUL 1. TOOLS Gas Saw Service Tool Kit - P/N KEY P/N DESCRIPTION SERVICE TOOL KIT SCRENCH, 13-19mm PRESSURE GUGE BULB COIL/FLYWHEEL TIMING SHIM CYLINDER SSEMBLY CLMPS & PISTON STOP MIN BERING DRIVER TOOL SHOCK BSORBER TOOL SPRK TESTER FLYWHEEL PULLER TOOL LIMITER CP REMOVL TOOL ELECTRONIC TCHOMETER INDUCTION SEL FLNGE W/ SCREWS EXHUST SEL FLNGE W/ SCREWS TUNING SCREWDRIVER 3

6 2. SPECIFICTIONS 603GC SHOP MNUL Specifications Engine Type Displacement Horsepower Engine Speed Weight Cutting Depth Dimensions Carburetor ir Filtration Starter Ignition Clutch Fuel Mix Ratio Fuel Capacity Water Supply Noise Level Vibration Level 2-Stroke Single Cylinder ir Cooled 3.9 cu. in. (64 cc) 4.2 hp ( rpm 12,500 ± 500 rpm, electronically governed idle 18.5 lbs. (8.4 kg) with bar and chain Up to 9 inches (23 cm) 18 inches (45 cm) length 11.5 inches (29 cm) height 10 inches (25 cm) width Walbro diaphragm HD-225 Canister, polyester Dust and water shielded Electronic speed governing, water sealed Three-weight, single spring, centrifugal 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. (0.18 gal / 0.68 lit) minute run time Minimum 20 psi (1.5 bar) meter 11.0 m/s Spark Plug TYPE Champion RCJ-7Y (for spark plug reference guide see page 81) Spark Plug Gap Sprocket Type 0.02 inches (0.5 mm) 8-tooth rim sprocket 4

7 603GC SHOP MNUL 3. SERIL # LOCTION 3 603GC Cut-Off serial number series. 5

8 4. SPRE PRTS DIGRM 603GC SHOP MNUL 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 603GC Replacement Parts Price List. CYLINDER & PISTON SSEMBLY TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 6 WRIST PIN NEEDLE BERING CYLINDER BLOCK BOLT & WSHER X CYLINDER BSE GSKET SPRK PLUG COMPLETE CYLINDER & PISTON SSEMBLY WSHER SCREW PLUG DECOMPRESSION VLVE

9 603GC SHOP MNUL 4. SPRE PRTS DIGRM CRNKCSE SSEMBLY TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 1 CRNKCSE PLUG CRNKCSE CRNKCSE DOWEL PIN CHOKE LEVER BR MOUNTING STUD CRNKCSE GROMMET WSHER BR MOUNT PD COVER PLTE CRNKCSE GSKET CHOKE LEVER BUSHING CRNKCSE BOLT X SCREW, 5 X 50mm X CRNKCSE TENSIONER CRNKSHFT BERING FUEL LINE GROMMET

10 4. SPRE PRTS DIGRM 603GC SHOP MNUL CLUTCH & CRNKCSE SSEMBLY TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 8 CLUTCH SPRING CRNKCSE SEL RETINER CRNKSHFT SEL CLUTCH SPCER CLUTCH CLUTCH SPCER INSIDE CLUTCH BERING T RIM SPROCKET KIT OUTER CRNKCSE SEL BODY SCREW X WVE WSHER, 4.5mm CLUTCH CUP WITH SPLINED DPTOR TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 1 CRNKSHFT SEL FLYWHEEL SIDE CRNKSHFT BERING CRNKSHFT SEL CRNKSHFT BUSHING X WRIST PIN NEEDLE BERING CRNKSHFT SSEMBLY

11 603GC SHOP MNUL 4. SPRE PRTS DIGRM MUFFLER SSEMBLY TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 1 MUFFLER SUPPORT BRCKET SCREW X SERRTED WSHER MUFFLER SUPPORT BRCKET MUFFLER MOUNTING SCREW SCREW WSHER MUFFLER DEFLECTOR MUFFLER SSEMBLY CYLINDER-TO-MUFFLER GSKET

12 4. SPRE PRTS DIGRM 603GC SHOP MNUL CRBURETOR SSEMBLY KEY DESCRIPTION TORQUE LOCTITE PRT NUMBER Nm in lbs SCREW X INTKE MNIFOLD CLMP INTKE MNIFOLD CRBURETOR PULSE TUBE CRBURETOR SPRING WSHER CRBURETOR TTCHMENT SCREW X OUTER INTKE MNIFOLD FLNGE SCREW X CRBURETOR MOUNTING BRCKET CRBURETOR OUTER INTKE MNIFOLD FLNGE OUTER INTKE MNIFOLD DJUSTMENT GUIDE BRETHER TUBE BODY

13 603GC SHOP MNUL 4. SPRE PRTS DIGRM FUEL TNK & HNDLE SSEMBLY TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 1 FUEL TNK RER HNDLE HLF SCREW THROTTLE LEVER FUEL CP SSEMBLY, WITH OUTER SEL RIING SHOCK BSORBER WITH SCREW BRETHER TUBE BODY SCREW X WSHER FRONT HNDLE BOLT X FRONT HNDLE FUEL FILTER FUEL LINE FUEL CP O-RING TRIGGER LOCKOUT LEVER TRIGGER LOCKOUT LEVER SPRING BUMPER, SHOCK BSORBER, FUEL TNK TOP FUEL BRETHER COMPLETE RER HNDLE SHOCK BSORBER TUBE CLMP, WITH TBS BRETHER TUBE ELBOW TUBE CLMP, NO TBS FUEL BRETHER, REMOTE RUBBER WTER DEFLECTOR SHOCK BSORBER

14 4. SPRE PRTS TITLE DIGRM 603GC SHOP MNUL FLYWHEEL SSEMBLY TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 31 FLYWHEEL SHROUD FLYWHEEL NUT WVE WSHER PLIN WSHER STRTER PWL SSEMBLY

15 603GC SHOP MNUL 4. SPRE PRTS DIGRM IGNITION SSEMBLY TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 39 WVE WSHER, 4.5mm SPRK PLUG CP & SPRING KIT SPRK PLUG SPRING IGNITION TOGGLE CBLE IGNITION COIL SWITCH, IGNITION TOGGLE SCREW X PLIN WSHER IGNITION TOGGLE SWITCH NUT IGNITION TOGGLE PLTE ON/OFF SWITCH GROUND CONNECTION PLTE

16 4. SPRE PRTS DIGRM 603GC SHOP MNUL STRTER SSEMBLY TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 1 SCREW X STRTER ROPE HNDLE STRTER ROPE STRTER PULLEY SCREW X RECOIL HOUSING SCREW STRTER PULLEY WSHER STRTER ROPE PULLEY STRTER SSEMBLY STRTER COIL SPRING & HOUSING STRTER CSE PLTE STRTER SSEMBLY CP

17 603GC SHOP MNUL 4. SPRE PRTS DIGRM IR FILTER SSEMBLY TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 1 CYLINDER COVER IR FILTER CNISTER, POLY IR FILTER COVER SSEMBLY, 3 SCREW FILTER COVER SCREW FILTER SUPPORT FILTER COVER GSKET CYLINDER COVER SCREW X PREFILTER PLSTIC, SECONDRY FILTER IR FILTER FLNGE FILTER SUPPORT SCREW X FILTER CNISTER GSKET O-RING TUBE CLMP, NO TBS COMPENSTOR TUBE BRETHER GROMMET THROTTLE SSEMBLY O-RING, IR FILTER WSHER

18 4. SPRE PRTS DIGRM 603GC SHOP MNUL WTER DELIVERY SYSTEM TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 1 HOSE CLMP WTER HOSE WTER HOSE COVER HOSE HNGER WTER SHUT-OFF VLVE WTER HOSE O-RING RING NUT FITTING WTER HOSE GSKET FITTING FITTING

19 603GC SHOP MNUL 4. SPRE PRTS DIGRM SIDE COVER SSEMBLY TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER 9 SIDE COVER SIDE COVER NUT GURD FLP NUT SCREW GURD FLP MOUNTING BRCKET (BCK) GURD FLP MOUNTING BRCKET (FRONT) GURD FLP SCREW GURD FLP RUBBER BUMPER, COVER SCREW SIDE COVER PLTE SIDE COVER GSKET MOUNTING NUT RUBBER WLLWLKER FITTING X BOLT

20 4. SPRE PRTS DIGRM 603GC SHOP MNUL CRBURETOR REPIR KIT TORQUE LOCTITE KEY DESCRIPTION Nm in lbs. 242 PRT NUMBER BOVE CRBURETOR WLBRO HD CRBURETOR REPIR KIT

21 603GC SHOP MNUL 5 This section covers the disassembly, inspection, and assembly air induction system. 5. IR TITLE INTKE 5.1 Loosen the air filter cover screws and remove air filter cover. 5.2 Remove air filter from cover. Inspect air filter. B Replace if necessary (P/N 71752). 5.3 Remove secondary filter from air filter mount. B Clean secondary filter with cleaning solution and a nylon brush. Let dry and reinstall. 19

22 5. IR TITLE INTKE 5.4 Inspect air filter cover gasket. Replace if permanently depressed or hard due to slurry. 5.5 Inspect filter cannister gasket. B Clean. Replace if necessary. 603GC SHOP MNUL 5.6 Secure air filter mount screws (3) using Loctite

23 603GC SHOP MNUL 6 This section covers the removal, inspection, and installation of the spark plug. 6. SPRK TITLEPLUG 6.1 Remove the spark boot taking care not to pry or damage the wire. 6.2 Clean area around the spark plug to prevent debris from entering the cylinder. 6.3 Remove the spark plug. 6.4 Inspect the spark plug for proper size, gap and condition. If dirty, clean with a wire brush as shown. 21

24 B 6. SPRK TITLEPLUG Gap if necessary to 0.02 (0.5 mm). NOTE: If the spark plug must be replaced refer to the Spark Plug Reference Guide on page 81 to select the correct replacement plug. 603GC SHOP MNUL 6.5 ssemble in the reverse order. Make sure the plug boot is seated completely. 22

25 603GC SHOP MNUL 7 This section covers clutch removal, rim sprocket removal, inspection, and assembly. Refer to sections 5 and 6 if needed. 7. CLUTCH & TITLE RIM SPROCKET 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. 23

26 7. CLUTCH & TITLE RIM SPROCKET 7.4 Remove all drive components. 603GC SHOP MNUL 7.5 Inspect the clutch shoes for wear. Replace if the shoe has less than 0.04 (1 mm) of material, as shown. 7.6 Inspect spring for cracks. 24

27 603GC SHOP MNUL 7.7 ssemble clutch. Insert top edge of clutch shoe over spring as shown. 7. CLUTCH & TITLE RIM SPROCKET B Snap clutch shoe into place. 7.9 Inspect the rim sprocket for wear. Replace if the rim sprocket teeth are worn to points, as shown on right. 25

28 7. CLUTCH & TITLE RIM SPROCKET 7.10 Clean and assemble. B C Clean all parts in solvent. Grease clutch cup bearing with a water proof grease (ICS P/N 70885). ssemble clutch spacer washer, bearing, clutch cup with rim sprocket, and inside clutch spacer washer. 603GC SHOP MNUL 7.11 Install clutch. Tighten firmly. Left hand threads 26

29 603GC SHOP MNUL 8 This section covers the removal of the starter cover, replacement of the starter rope, and replacement of the recoil spring. 8. STRTER TITLE 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. B C Pull 4-6 (10-15 cm) of rope out. Line rope up with notch on pulley. To release pulley, slowly rotate pulley counterclockwise until spring pressure is released. Use thumb as a brake. 8.5 Remove rubber screw seal. 27

30 8. STRTER TITLE 8.6 Remove starter pulley. Remove pulley screw. 603GC SHOP MNUL 8.7 Inspect coil spring. Replace if spring hook is damaged. ttempting 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. 28

31 603GC SHOP MNUL 8.10 Inspect pulley spring catch. Clean with cleaning solution. B Replace if worn or broken. 8. STRTER TITLE 8.11 Install starter rope and tie knot Knot tying instructions: B C D Make a loop at the end of the pulley rope with the end of the rope crossing on top of the tail. Bring the end of the rope through the loop, creating a single loose knot. Pull the end of the rope down and in front of the tail. Send the end through the loop a second time, creating a double knot; cinch tight. C B D 29

32 8. STRTER TITLE 8.13 Install pulley. B Wind rope onto pulley clockwise leaving 4-6 out. Make sure that the pulley spring catch is in the spring hook Install center screw. Use Loctite 242. B Torque to 26 in-lbs. (2.9 Nm). 603GC SHOP MNUL 8.15 Wind the recoil spring. B C Line rope up with notch on pulley. Rotate the pulley with the rope clockwise 5 times. Untangle rope and release ssemble starter cord shield. 30

33 603GC SHOP MNUL 8.17 Remove starter pawl screws, pawls, spring, and plain washer Inspect and clean pawl components. B Inspect the components. Replace if necessary. Clean the components with a brush and solvent. 8. STRTER TITLE 8.19 ssemble components. B C Make sure the spring is in the correct position. Use Loctite 242 on the pawl screws. Torque to 60 in-lbs. (6.8 Nm) Install starter cover. Pull out cord 4-6. B Slowly release while placing cover to allow pawls to engage. 31

34 8. STRTER TITLE 8.21 Install starter cover screws. Use Loctite 242. B Torque to 60 in-lbs. (7 Nm). 603GC SHOP MNUL 32

35 603GC SHOP MNUL 9 This section covers the removal, inspection, and assembly of the rubber padded wallwalker and guard flap. 9. WLLWLKER TITLE 9.1 Inspect bumpers. Replace if worn. 9.2 Remove side cover assembly. 9.3 Remove cover plate. 9.4 Remove crankcase screws and wave washers. 33

36 9. WLLWLKER TITLE 9.5 Remove and inspect guard flap. Replace the flap if it is torn or damaged in any way. 603GC SHOP MNUL 9.6 Remove guard flap screws and washers. 9.7 Reassemble in the reverse order. Install crankcase screws and wave washers. B Use Loctite 242. C Torque to 70 in-lbs. (7.9 Nm). 34

37 603GC SHOP MNUL 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 5 and 17 if needed. 10. CYLINDER TITLE COVER 10.1 Remove the air filter mount screws. NOTE: May require heat to remove screws Remove the cylinder cover screws (3) Remove spark plug boot from cylinder cover taking care not to pry or damage the wire Remove fuel tank breather cap and clamp Partially remove intake manifold from cylinder cover Remove cylinder cover. Pull up on front. B 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. 35

38 10. CYLINDER TITLE COVER 10.7 Remove stop switch leads Inspect cylinder cover for damage. Replace if necessary. 603GC SHOP MNUL 10.9 Check filter cover gasket. Replace if necessary Check cylinder cover water seal. Replace if necessary. 36

39 603GC SHOP MNUL ssemble in reverse order. Reassemble stop switch leads. 10. CYLINDER TITLE COVER Make sure carburetor screw boot is in place Install cylinder cover. B Pull spark plug lead into slot in cylinder cover. Lubricate compensating tube (1) and fuel tank breather tube (2) with soapy water, guide through cylinder cover (Install compensating tube first). NOTE: Be careful to not pull tubes away from their point of connection. pproximately 3/4 of tube should protrude from cylinder cover. B (1) B (2) 37

40 C D E 10. CYLINDER COVER Push the cylinder cover down on the crankcase, guide intake manifold into cylinder cover. lign throttle linkage with cylinder cover and crankcase. Install the cylinder cover screws. Use Loctite 242. Torque to 35 in-lbs. (4.0 Nm). 603GC SHOP MNUL D Install air filter mount. B C Guide carburetor compensating tube through air filter mount. Make sure manifold sits flat over lip on cylinder cover. Install air filter mount screws (3) using Loctite 242. Torque to 43 in-lbs. (4.9 Nm) Install air filters and cover. Install pre-filter. B Install clean air filter. C Install air filter flange and tighten. D Install air filter cover and tighten. 38

41 603GC SHOP MNUL 11 This section covers the disassembly, inspection, and assembly of the muffler. Removal of the bumpers and cylinder cover is necessary. Refer to sections 9 and 10 if necessary. 11. MUFFLER 11.1 Remove muffler support screws Remove muffler screws (2) note there are two screws and serrated washers located inside the muffler Remove muffler and heat shield gasket. Replace any damaged components. 39

42 11.4 Install muffler. B C 11. MUFFLER Insert muffler screws and serrated washer (2) into muffler. Hold muffler screws in place with heat shield gasket. Thread muffler screws into cylinder, torque to 78 in-lbs. (9 Nm). 603GC SHOP MNUL 11.5 Install muffler support. B C D Install top 3 muffler support screws and serrated washer finger tight. Install bottom 2 muffler support screws with Loctite 242. Torque top screws to 78 in-lbs. (9 Nm). Torque bottom screws to 52 in-lbs. (6 Nm). 40

43 603GC SHOP MNUL 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 CRBURETOR NOTE: ll saws are equipped with carburetor model # HD Remove throttle linkage. Push trigger end out of rear handle. B Pivot linkage around. C Remove carburetor end of linkage from throttle rod tab on carburetor Remove fuel line from carburetor and support bracker Remove carburetor support bracket. Remove carburetor support screw (1) with #4 Torx or straight blade screwdriver. B Remove carburetor body screws (2). 41

44 12.4 Remove carburetor. B C 12. CRBURETOR Remove pulse tube. Remove carburetor jet cover. Remove carburetor from choke linkage. 603GC SHOP MNUL C B 12.5 ssemble in the reverse order. B Torque carburetor body screws to 43 in-lbs. (5 Nm). Torque supporter screw with Loctite 242 to 43 in-lbs. (5 Nm). 42

45 603GC SHOP MNUL 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. CYLINDER & PISTON NOTE: When replacing the 603GC cylinder and piston it is necessary to tune the carburetor prior to returning the saw to service (see section 22) Remove carburetor base screws. Remove carburetor base bracket from rear manifold. B Remove carburetor base bracket from pulse tube Remove pulse tube and protective spring from cylinder base. 43

46 13. CYLINDER & PISTON 13.3 Remove rear manifold clamp Remove rear manifold from cylinder. Inspect for holes and tears. 603GC SHOP MNUL 13.5 Remove cylinder screws (4) and wave washers Remove cylinder. Remove cylinder gasket and clean case. 44

47 603GC SHOP MNUL 13.7 Remove wrist pin retaining clips (2). 13. CYLINDER & PISTON 13.8 Press wrist pin out with an 8 mm deep socket Remove piston and inspect. Replace if damaged Remove wrist pin bearing. 45

48 13.11 ssemble cylinder gasket. B 13. CYLINDER & PISTON Oil gasket with ICS 2-stroke engine oil. Install and align holes and notch. 603GC SHOP MNUL Install wrist pin bearing in rod. Oil bearing with ICS 2-stroke engine oil Install rings. Install lower ring first for ease of installation. 46

49 603GC SHOP MNUL Ring orientation. NOTE: Make sure both piston ring end gaps are correctly oriented over their locating pins in the piston ring grooves. 13. CYLINDER & PISTON Install one wrist pin retaining clip Make sure wrist pin retaining clip is in the proper orientation. Improper installation may result in serious engine damage. NOTE: Never attempt to reuse wrist pin retaining clips or substitute wrist pins from another model or brand. Install two new retaining clips with their open ends facing either to the six o'clock (toward the crankcase) or twelve o'clock (toward the cylinder head) position. Each retaining clip should produce an audible "click" as it seats in its groove in the piston. 47

50 13. CYLINDER & PISTON 603GC SHOP MNUL Lube and partially install wrist pin lign piston in correct orientation. Make sure arrow points to exhaust port. EXHUST INTKE Install piston. B C D Oil piston with ICS 2-stroke oil. lign wrist pin with wrist pin bearing. Complete wrist pin installation. Install second wrist pin retaining clip. Make sure wrist pin retaining clip is in the proper orientation (see 13.16). 48

51 603GC SHOP MNUL Install cylinder. B C Lubricate cylinder bore with ICS 2 stroke oil. Compress rings with ring compression tool. Slide cylinder onto piston, pushing ring compression tool down. 13. CYLINDER & PISTON Install cylinder. B C Remove ring compression tool. Slide cylinder down piston and into crankcase. lign cylinder bolt holes with crankcase Install 4 cylinder screws and washers. Use Loctite 242. B Torque bolts to 95.5 in-lbs. (11 Nm). 49

52 13.23 Install rear manifold. B C 13. CYLINDER & PISTON pply lightweight grease on the inside lip of the rear manifold. Push rear manifold onto cylinder intake. lign mold seams of intake boot with casting seams of the cylinder. 603GC SHOP MNUL Install rear manifold clamp. Torque to 11 in-lbs. (1 Nm). NOTE: Insure that the intake boot is properly installed. DO NOT OVER TIGHTEN INTKE BOOT CLMP. If over tightened, intake boot can tear, resulting in an air leak which will cause engine damage Install protective spring onto pulse tube Install the pulse tube onto cylinder barb. 50

53 603GC SHOP MNUL Install carburetor base. B C Slip pulse tube into carburetor base. Slip rear manifold into carburetor base. Make sure rear manifold lip is flat. 13. CYLINDER & PISTON Install carburetor base screws. Use Loctite 242 on screws (3). B C Make sure to include stop switch wire on front screw. Torque to 35 in-lbs. (4 Nm). 51

54 14. WTER HOSE 14 This section covers water hose and side cover. 603GC SHOP MNUL 14.1 Inspect water hose and side cover. Replace if damaged ssemble in reverse order Remove water hose connector from side cover. B Remove clamp and hose from fitting. Unthread fitting from side cover Inspect side cover for damage. Replace if necessary. 52

55 603GC SHOP MNUL 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. IGNITION COIL 15.1 Remove starter flywheel shroud by unhooking wires Remove ignition coil screws, wave washers and plain washers Remove ignition coil Inspect ignition coil. B Look for: Cracks Missing insulation Wear marks in wire Clean flywheel magnets and coil if rusty. 53

56 15. IGNITION COIL 15.5 Install Ignition coil. 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 Loctite 242. Holding shim, rotate flywheel magnet around to coil. E Torque ignition coil screws to 26 in lbs. (3 Nm). F Remove shim, rotate flywheel to check clearance Install flywheel shroud Route yellow ignition stop switch wire through crankcase into carburetor chamber. 603GC SHOP MNUL 15.8 Complete ignition wire routing. 54

57 603GC SHOP MNUL 16 This section covers the removal, inspection, and installation of the flywheel. Removal of spark plug and the starter is required. Refer to sections 6 and 8 if necessary. 16. FLYWHEEL 16.1 Insert piston stop Remove flywheel nut, wave washer, and plain washer Screw on flywheel removal tool finger tight. Unscrew tool 1 ½ turns leaving approximately 1/8 inch (5 mm) space between tool and flywheel. 55

58 16. FLYWHEEL 16.4 Using pliers, hold saw up by magnet counterweight Strike flywheel removal tool with a ball peen hammer. The flywheel should release from crankshaft Inspect and clean flywheel. Replace if any of the fins are broken. 603GC SHOP MNUL 16.7 Inspect cast woodruff key inside the flywheel. NOTE: Key is cast into flywheel Install flywheel, plain washer, wave washer, and flywheel nut. Torque nut to 217 in-lbs. (25 Nm). 56

59 603GC SHOP MNUL 17 This section covers the removal, inspection, and installation of the front handle. 17. FRONT HNDLE 17.1 Remove front handle screws on right side Remove front handle screws on bottom Install front handle. Roll front handle into place. B Install front handle screws (4). C Use Loctite 242. D Torque to 69 in-lbs. (8 Nm). 57

60 18. FUEL TNK 18 This section covers the disassembly, inspection, and assembly of the vibration isolaters, fuel tank, and rear handle. 603GC SHOP MNUL 18.1 Remove vibration isolator screws (2) and wave washers on clutch side of saw Remove vibration isolator screws (2) and wave washers on flywheel side of saw. 58

61 603GC SHOP MNUL 18.3 Separate crankcase and fuel tank. NOTE: Saws have a rubber water deflector connected to the 2 bottom vibration isolators on the clutch side (circled). 18. FUEL TNK 18.4 Remove vibration isolators (4) from fuel tank if necessary ssemble in reverse order. NOTE: During assembly be careful to avoid kinking the fuel line. 59

62 19. CRNKCSE 19 This section covers the disassembly, inspection, and assembly of the crankcase seals and crankshaft bearings. 603GC SHOP MNUL 19.1 Remove outer crankshaft seal housing screws and wave washers Remove crankcase bolts (5). 60

63 603GC SHOP MNUL 19.3 Heat the flywheel side crankcase with heat gun for 5 minutes, approximately 150 F (65.5 C). 19. CRNKCSE 19.4 Remove the flywheel side crankcase tap crankshaft with plastic mallet. Suspend above work surface. B Tap with mallet. NOTE: nut should always be placed on a threaded shaft when pounding or pressing on it Remove the flywheel side crankcase seal with 1/2 (13 mm) socket. 61

64 19. CRNKCSE 19.6 Disassembly of crankcase. Heat the clutch side crankcase with heat gun to 150 F (65.5 C). 603GC SHOP MNUL 19.7 Remove crankshaft from the clutch side crankcase tap crankshaft with a plastic mallet. Suspend above work surface. B Tap with plastic mallet Remove the bearing from the flywheel side of crankshaft. 62

65 603GC SHOP MNUL 19.9 Remove the bearing, seal, and bushing from the clutch side of crankshaft. 19. CRNKCSE ssembly of crankcase. Clean mating crankcase faces Heat crankcase halves to 150 F Install bearing into crankcase halves Tap with bearing driver and mallet. 63

66 19. CRNKCSE Repeat with other half. 603GC SHOP MNUL Install crankshaft into clutch side of case Place clutch side crankcase seal on crankshaft. Tap lightly with bearing driver and mallet. 64

67 603GC SHOP MNUL Coat crankcase gasket with ICS 2 stroke engine oil. 19. CRNKCSE lign crankcase gasket on flywheel side crankcase pins Place crankcase halves together and align crankcase pins. 65

68 19. CRNKCSE ssemble crankcase halves tap with bearing driver and mallet. 603GC SHOP MNUL Install crankcase bolts. Use Loctite 242. B Torque to 69 in-lbs. (8 Nm) Install flywheel side crankcase seal tap with bearing driver and mallet. 66

69 603GC SHOP MNUL ssemble in reverse order Install outer crankshaft seal housing with 3 bolts and use Loctite CRNKCSE Trim crankcase gasket flush. 67

70 20. BR STUDS & BR PD 20 This section covers the removal and installation of the bar studs and bar pad. 603GC SHOP MNUL 20.1 On 603GC saws: NOTE: This requires the removal of the piston and cylinder, and to split the crankcase. (Refer to section 13 &19 for detailed instructions) Remove side cover. B Remove bar pad cover. C Split the crankcase. D E Press out bar studs. ssemble in reverse order. 68

71 603GC SHOP MNUL 21 This section covers the removal and installation of the chain tensioner. 21. CHIN TENSIONER 21.1 Remove bar plate to expose the chain tensioner Unscrew tensioner to remove. Remove tensioner pin. B Remove tensioner screw keeper ssemble in reverse order. NOTE: The tensioner is intended to perform as a fuse in high load or sudden impact situations. P/N

72 22. CRBURETOR TUNING 603GC SHOP MNUL 22 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 compliance to EP Phase 1 emmissions standards. However, minor adjustments may be required in certain conditions, such as high elevation. replacement carburetor is not set correctly from the factory. Use the tuning instructions in this manual to adjust carburetor to factory-recommended settings. (DO NOT adjust the carburetor for maximum rpm. djusting the carburetor for maximum rpm will cause engine damage). lways set the carburetor jets to factory settings when replacement or complete rebuild becomes necessary. 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. ttempting to set the carburetor mixture to increase the speed or power beyond this limit may seriously damage the engine. lways check the air filter, pre filter, fuel filter, and spark plug before making carburetor tunings and clean or replace if necessary 70

73 603GC SHOP MNUL 22.1 Basic Setting - H = 1 turn from closed L = 1 turn from closed 22. CRBURETOR TUNING RPM Settings for saws. NOTE: Saw tuned without bar and chain installed. Idle Speed = 3,000 ± 500 rpm Full Throttle = 12,500 ± 500 rpm Complete carburetor readjustment Remove limiter cap. B C D Look into adjustment screw hole. Observe orientation of the release slots on the adjustment screw limiter cap. Insert the limiter cap puller blades into the release slots. Firmly hold the tool shaft while screwing in the puller screw until the screw head is against the puller shaft. Unscrew the puller screw. 71

74 22. CRBURETOR TUNING 22.3 Using a 5/64 straight blade screwdriver, gently turn the adjustment screws clockwise until completely closed Set the adjustment screws at the Basic Setting: H = 1 turns from closed L = 1 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. 603GC SHOP MNUL 22.5 Start the saw and warm up the engine With a tachometer check the saw rpm, with bar and no chain: B Idle = 3,000 ± 300 rpm If the idle rpm does not fall into this range, adjust the T screw, clockwise to raise RPM, counterclockwise to lower RPM With a tachometer check the saw full throttle rpm, with no bar and chain: Target = 11,000 ± 500 rpm 22.8 If the full throttle rpm falls below this range, turn the H screw in (clockwise) 1/16 th of a turn at a time. 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. 72

75 603GC SHOP MNUL 22.9 When the carburetor is adjusted correctly set the limiter caps as shown with a 1/4 straight blade screwdriver. L = vertical B H = horizontal 22. CRBURETOR TUNING 73

76 23. IDLE SPEED DJUSTMENT 23 This section covers idle speed adjustment. 603GC SHOP MNUL 23.1 If engine stops while idling: B C Make sure the chain is properly tensioned. Turn T screw clockwise until chain begins to move. Back T screw out ½ turn If chain turns at idle: Back T screw out until chain stops moving. 74

77 603GC SHOP MNUL 24. DIGRMS 24 This section provides several flowcharts to aid diagnosing common problems. CHECK POSSIBLE CUSE REPIR The engine runs rough at all speeds. YES 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 spark plug. dirty air filter is the #1 reason for engine problems. The engine is overheating. YES Operator is overworking the saw. Carburetor mixture is too lean. Incorrect fuel/oil ratio. Flywheel fins are clogged. ir deflector is missing. Cylinder fins are clogged. See Operator s Manual. See Carburetor Tuning section. See Saw Specifications section. Clean flywheel fins with wire brush. 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 tank breather. Replace pulse tube. Uneven idle or engine may run away. YES ir leak at intake boot, cylinder gasket, or crankcase gasket. Faulty carburetor diaphragm. Inspect air intake boot. Pressure test crankcase. Replace carburetor. Diamond chain moves at idle. YES Idle speed too high. Broken clutch spring. djust idle speed. Replace clutch spring. Excessive vibration. YES Damaged shock absorber. Damaged or broken flywheel fins. Bent crankshaft. Replace shock absorbers. Replace flywheel. Replace crankshaft. 75

78 24. DIGRMS 603GC SHOP MNUL Saw Will Not Start CHECK POSSIBLE CUSE REPIR Does the engine crank? NO Dirty or broken recoil starter. Internal damage. Clean, rebuild or replace the recoil starter. Inspect for internal damage such as seized piston. YES Is there spark? YES Is the spark plug firing properly? YES NO NO The ignition switch is OFF. Faulty ignition ground. Faulty spark plug lead. Faulty ignition coil. Plug is soaked with fuel. The plug is fouled or gapped improperly. Plug is internally faulty or the wrong type. Move switch to ON and re-test. Tighten connections or replace ground wire. Repair or replace spark plug lead. Replace ignition coil. Dry plug, expel excess fuel from cylinder and crankcase. Clean and re-gap the plug to inch (0.05 mm). Replace with the correct plug see Spark Plug Reference Guide. Insure cylinder compression is above 125 psi. NO Loose spark plug. If below 125 psi excess wear on the piston, cylinder, rings. Tighten plug and re-test. Replace piston and cylinder. YES Is the fuel fresh? Is the fuel mixed 50:1? NO Fuel is old, varnished, or contaminated. Empty tank and re-fill with fresh fuel of the correct mixture (25:1). YES Is the fuel reaching the carburetor? YES NO 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 too much fuel reaching the carburetor? YES Carburetor is tuned incorrectly. Plugged fuel tank breather. Refer to Carburetor Tuning section. Repair or replace fuel tank breather. NO Is the flywheel key sheared? YES Loose flywheel. Replace key and reinstall flywheel. 76

79 603GC SHOP MNUL 25 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. 25. FUEL SYSTEM LEKS 25.1 Remove and inspect the fuel filter. 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. B C Connect tube to the pressure gauge and to the fuel line. Pressurize the tube to 7 psi (0.5 bar). If the pressure does not maintain, separate the fuel line from the carburetor. 77

80 D E F G 25. FUEL SYSTEM LEKS Plug one end of the main fuel pick-up tube. Re-pressurize the tube to 7 psi (0.5 bar). Replace the tube if pressure is not maintained. If the main fuel pick-up tube does maintain pressure, then the leak has been isolated to the carburetor. Refer to the Walbro Diaphragm Carburetor Service Manual. 603GC SHOP MNUL 25.3 The fuel tank breather stabilizes the pressure in the fuel tank preventing both excessive pressure, which could flood the engine, and negative pressure, which could starve the engine of fuel Fuel tank breather is located inside the air filter compartment Testing the fuel tank breather. B ttach the pressure gauge and bulb to the fuel tank breather. Pressurize the tube to 7 psi (0.4 bar). The pressure should reduce to nearly 0 psi (0 bar) over about 3 seconds. 78

81 603GC SHOP MNUL 25.6 If the pressure does not reduce to 0 psi, disassemble or replace the breather. B Disassemble by snapping off cap. Clean parts with solvent or fuel. 25. FUEL SYSTEM LEKS 25.7 ssemble in reverse order. B C Make sure duck bill opens easily. Make sure that the spring taper is oriented in the correct direction. ssemble by snapping cap in place. 79

82 26. CRNKCSE LEKS 26 This section covers testing the crankcase for leaks. leak in the crankcase can cause the engine not to run. 603GC SHOP MNUL 26.1 Install the intake seal flange. Plug cylinder pulse tube Install the exhaust seal flange Block one of the flange tubes with a rubber plug Install the pressure gauge and bulb Pressurize the crankcase to 7 psi (0.5 bar) 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. 80

83 603GC SHOP MNUL PPENDIX 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. SPRK PLUG REFERENCE GUIDE ICS RESISTOR CHMPION NGK RESISTOR BOSCH RESISTOR RESISTOR RCJ7Y BPMR7 WSR7F 81

84 603GC SHOP MNUL 82

85 ICS, Blount Inc SE International Way Portland, Oregon TEL FX p/n 71537