660GC SERVICE MANUAL SECTION SECTION TITLE PAGE NUMBER SERVICE MANUAL USE TOOLS SAW SPECIFICATIONS SERIAL NUMBER LOCATION SPARE PARTS DIAGRAMS (TORQUE SPECS & LOCTITE APPLICATION) ® AIR INTAKE SPARK PLUG CLUTCH & RIM SPROCKET STARTER SYSTEM WALLWALKER ® CYLINDER COVER...
660GC 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 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, 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. A complete tool kit for ICS 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 http:\\www.walbro.com or by calling 1.989.872.2131.
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660GC SERVICE MANUAL 4. SPARE PARTS DIAGRAM FUEL TANK & HANDLE ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. REAR HANDLE HALF 548392 SCREW 73976 THROTTLE LEVER 71749 THROTTLE LINKAGE ASSEMBLY 71750 TRIGGER LOCKOUT LEVER SPRING 73988 TRIGGER LOCKOUT LEVER 73987 SHOCK ABSORBER 505387 SHOCK ABSORBER WITH SCREW 505658 REAR HANDLE SHOCK ABSORBER 505425 BUMPER, SHOCK ABSORBER, FUEL TANK TOP 73270 FUEL TANK 548391 FRONT HANDLE BOLT 73983 FRONT HANDLE...
660GC SERVICE MANUAL 10. CYLINDER COVER 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. 10.1 Remove the air filter mount screws. NOTE: May require heat to remove screws. 10.2 Remove the cylinder cover screws (3). 10.3 Remove spark plug boot from cylinder cover taking care not to pry or damage the wire. 10.4 Remove fuel tank breather cap and clamp. 10.5 Partially remove intake manifold from cylinder cover. 10.6 Remove cylinder cover. A Pull up on front. 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.
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660GC SERVICE MANUAL 13. CYLINDER & PISTON 13.23 Install rear manifold. A Apply lightweight grease on the inside lip of the rear manifold. B Push rear manifold onto cylinder intake. Align mold seams of intake boot with casting seams of the cylinder. 13.24 Install rear manifold clamp. A Torque to 11 in-lbs. (1 Nm). NOTE: Insure that the intake boot is properly installed. DO NOT OVER TIGHTEN INTAKE BOOT CLAMP. If over tightened, intake boot can tear, resulting in an air leak which will cause engine damage. 13.25 Install the pulse tube onto cylinder barb. 13.26 Install protective spring onto pulse tube.
660GC SERVICE MANUAL 24. DIAGRAMS This section provides several flowcharts to aid diagnosing common problems. CHECK POSSIBLE CAUSE REPAIR • Clean or replace the air filter. • Dirty or clogged air filter. • Inspect air intake system for water. The engine runs rough at • Water has been ingested. • Inspect fuel system for water. all speeds. • Loose or dirty spark plug. • Tighten, clean, or replace spark plug. A dirty air filter is the #1 reason for engine problems. • Operator is overworking • See Operator’s Manual. the saw. • See Carburetor Tuning section. • Carburetor mixture is • See Saw Specifications section. too lean.
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24. DIAGRAMS 660GC SERVICE MANUAL Saw Will Not Start CHECK POSSIBLE CAUSE REPAIR • Clean, rebuild or replace the • Dirty or broken recoil recoil starter. Does the engine crank? starter. • Inspect for internal damage such • Internal damage. as seized piston. • The ignition switch is • Move switch to “ON” and re-test. “OFF”. • Tighten connections or replace Is there spark? • Faulty ignition ground. ground wire. • Faulty spark plug lead. • Repair or replace spark plug lead.
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660GC SERVICE MANUAL 25. FUEL SYSTEM LEAKS D Plug one end of the main fuel pick-up tube. E Re-pressurize the tube to 7psi (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 has been isolated to the carburetor. Refer to the Walbro Diaphragm Carburetor Service Manual. 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. 25.4 Fuel tank breather is located inside the air filter compartment. 25.5 Testing the fuel tank breather. A Attach the pressure gauge and bulb to the fuel tank breather. Pressurize the tube to 7psi (0.5 bar). The pressure should reduce to nearly 0 psi (0 bar) over about 3 seconds.