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ICS 660GC Service Manual

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660GC
SERVICE MANUAL
© 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011

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Summary of Contents for ICS 660GC

  • Page 1 660GC SERVICE MANUAL © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 2: Table Of Contents

    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...
  • Page 3: Service Manual Use

    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.
  • Page 4: Tools

    660GC SERVICE MANUAL 1. TOOLS Key # Part No. Description MSRP 71521 Scrench 13-19 mm $10.55 71541 Pressure Gauge Bulb $47.40 71542 Coil/Flywheel Timing Shim $5.25 71543 Cylinder Assembly Clamps & Piston Stop $10.55 73462 Main Bearing Driver Tool $38.65 71546 Shock Absorber Tool $22.15 71547 Spark Tester $46.35 71548 Flywheel Disassembly Tool $31.45 71550 Limiter Cap Puller $89.25 71565 Electronic Tachometer $240.00...
  • Page 5: Saw Specifications

    2. SPECIFICATIONS 660GC SERVICE MANUAL SPECIFICATIONS Engine Type 2-stroke Single Cylinder Air Cooled Displacement 3.9 cu-in (64 cc) Horsepower 4.2 HP (3.1 kw) @ 9,500 RPM Torque 32 in-lbs (3.6 Nm) @ 6,000 RPM 11,500 +/- 500 rpm (max) Engine Speed 2,800-3,200 rpm (idle) 18.2 lbs (8.3 kg) without guidebar and Weight diamond chain Cut Depth Up to 10 inches (25.4 cm) 17 inches (44 cm) length Dimensions 10 inches (25.5 cm) height 11.6 inches (29.5 cm) width Air Filter Water Resistant Polyester Carburetor Walbro HDA225 Starter Dust and Water resistant Special water resistant electronic Ignition ignition Clutch Centrifugal three shoe, single spring Fuel Mix ratio 25:1 (4%) Fuel Capacity 0.26 gallons (1 Liter)
  • Page 6: Serial Number Location

    660GC SERVICE MANUAL 3. SERIAL # LOCATION 3 660GC serial number series. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 7: Spare Parts Diagrams (Torque Specs & Loctite ® Application)

    4. SPARE PARTS DIAGRAM 660GC SERVICE MANUAL 4 This section covers torque, Loctite , and lubrication requirements of the individual ® c omponents. The key numbers used are not related to the key numbers in the 660GC Replacement Parts Price List. CYLINDER & PISTON ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. SPARK PLUG 27.5 73199 CYLINDER BOLT 10.7 73874 DECOMPRESSION VALVE 12.8 71642 CYLINDER BASE GASKET 505439 COMPLETE CYLINDER & PISTON ASSEMBLY 505428 WRIST PIN NEEDLE BEARING 505403 © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 8 660GC SERVICE MANUAL 4. SPARE PARTS DIAGRAM CRANKCASE ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. CRANKCASE PLUG 505407 TANK PLUG 512461 CRANKCASE 537665 CRANKCASE DOWEL PIN 73281 FUEL LINE GROMMET 505627 CRANKCASE GROMMET 505408 CRANKSHAFT BEARING 505375 BAR MOUNTING STUD 509555 TENSIONER 505393 BAR MOUNT PAD COVER PLATE 505467 SCREW, 5 X 50 mm 509709 WASHER 73897 CRANKCASE BOLT...
  • Page 9 660GC SERVICE MANUAL 4. SPARE PARTS DIAGRAM CLUTCH & CRANKCASE ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. CRANKSHAFT RETAINER SEAL 540139 CRANKCASE SEAL RETAINER 505423 WASHER 73285 BOLT 73940 CLUTCH SPACER 505421 CLUTCH BEARING 505378 8T RIM SPROCKET KIT 70949 CLUTCH CUP WITH SPLINED ADAPTOR 505422 CLUTCH SPACER INSIDE 505436 CLUTCH 33.3 505442 CLUTCH SPRING 505434 TORQUE LOCTITE ®...
  • Page 10 660GC SERVICE MANUAL 4. SPARE PARTS DIAGRAM MUFFLER ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. CYLINDER-TO-MUFFLER GASKET 505385 MUFFLER 537692 MUFFLER SCREW & WASHER 548518f LOWER MUFFLER SCREW 73866 © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 11 4. SPARE PARTS DIAGRAM 660GC SERVICE MANUAL CARBURETOR ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. SCREW 4.9 505469 WASHER 73897 OUTER INTAKE MANIFOLD 507427 OUTER INTAKE MANIFOLD FLANGE SCREW 73901 OUTER INTAKE MANIFOLD FLANGE 505384 COMPENSATOR TUBE 505382 CARBURETOR SPRING 73888 CARBURETOR, WALBRO 517742 PULSE TUBE 71751 CARBURETOR MOUNTING BRACKET 505411 SCREW 73866 ADJUSTMENT GUIDE 505391...
  • Page 12 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...
  • Page 13 4. SPARE PARTS DIAGRAM 660GC SERVICE MANUAL FLYWHEEL ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. FLYWHEEL SHROUD 548514 FLYWHEEL 548515 24.5 73891 WASHER 73911 WASHER 73912 STARTER PAWL ASSEMBLY 508852 © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 14 660GC SERVICE MANUAL 4. SPARE PARTS DIAGRAM IGNITION ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. IGNITION TOGGLE SWITCH NUT 73239 IGNITION TOGGLE PLATE ON/OFF 73238 IGNITION TOGGLE SWITCH 73237 TOGGLE SWITCH CONNECTING PLATE 71449 IGNITION TOGGLE CABLE 73919 SCREW 73914 WASHER 73285 WASHER 73890 SPARK PLUG BOOT W/SPRING 73241 SPARK PLUG SPRING 73917 IGNITION COIL WITH SPARK PLUG LEAD & PRIMARY 505426 © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 15 4. SPARE PARTS DIAGRAM 660GC SERVICE MANUAL STARTER ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. SCREW 73230 STARTER ROPE HANDLE 505514 STARTER ROPE 508854 STARTER ASSEMBLY 537666 STARTER CASE PLATE 71451 RECOIL HOUSING SCREW 505380 STARTER PULLEY WASHER 73905 STARTER ASSEMBLY CAP 508853 STARTER PULLEY SCREW 73907 STARTER ROPE PULLEY 508857 STARTER COIL SPRING & HOUSING 73909 © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 16 660GC SERVICE MANUAL 4. SPARE PARTS DIAGRAM AIR FILTER ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. AIR FILTER O-RING 73331 FILTER COVER SCREW 73992 AIR FILTER COVER ASSEMBLY (WITH 3 SCREWS) 537661 AIR FILTER FLANGE 71758 AIR FILTER CANISTER, POLYESTER 71752 PREFILTER PLASTIC, SECONDARY FILTER 73336 WASHER 73897 CYLINDER COVER SCREW 505429 FILTER SUPPORT SCREW 505437 FILTER SUPPORT 73338 CYLINDER COVER 537660 O-RING 71472 COMPENSATOR TUBE...
  • Page 17 660GC SERVICE MANUAL 4. SPARE PARTS DIAGRAM WATER DELIVERY SYSTEM TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. WATER HOSE GASKET 71469 FITTING 71467 RING NUT 71457 WATER HOSE O-RING 71468 WATER SHUT-OFF VALVE 71458 FITTING 71466 FITTING 71454 HOSE CLAMP 71465 WATER HOSE 509488 HOSE HANGER 71461 WATER HOSE COVER 71464 © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 18 660GC SERVICE MANUAL 4. SPARE PARTS DIAGRAM SIDE COVER ASSEMBLY TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. GUARD FLAP SCREW 71479 GUARD FLAP MOUNTING BRACKET, FRONT 505491 GUARD FLAP 505492 GUARD FLAP MOUNTING BRACKET, BACK 505490 GUARD FLAP NUT 505468 BOLT 73983 RUBBER BUMPER, COVER 73310 SIDE COVER GASKET 505417 MOUNTING NUT 509852 RUBBER WALLWALKER 505493 SCREW 73982 SIDE COVER NUT 27.5 73958...
  • Page 19 4. SPARE PARTS DIAGRAM 660GC SERVICE MANUAL CARBURETOR REPAIR KIT TORQUE LOCTITE ® DESCRIPTION PART NUMBER in‑lbs. CARBURETOR REPAIR KIT 548394 CARBURETOR WALBRO HDA-225 548393 © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 20: Air Intake

    660GC SERVICE MANUAL 5. AIR INTAKE This section covers the disassembly, inspection, and assembly of the air induction system. 5.1 Loosen the air filter cover screws and remove air filter cover. 5.2 Remove air filter from cover. A Inspect air filter. B Replace if necessary (P/N 71752). 5.3 Remove secondary filter from air filter mount. A Clean secondary filter with cleaning solution and a nylon brush. B Let dry and reinstall. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 21 660GC SERVICE MANUAL 5. AIR INTAKE 5.4 Inspect air filter cover gasket. A Replace if permanently depressed or hard due to slurry. 5.5 Inspect filter cannister gasket. A Clean. B Replace if necessary. 5.6 Secure air filter mount screws (3) using Loctite 242. ® © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 22: Spark Plug

    660GC SERVICE MANUAL 6. SPARK PLUG This section covers the removal, inspection, and installation of the spark plug. 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. A If dirty, clean with a wire brush as shown. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 23 660GC SERVICE MANUAL 6. SPARK PLUG 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. 6.6 Assemble in the reverse order. A Make sure the plug boot is seated completely. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 24: Clutch & Rim Sprocket

    660GC SERVICE MANUAL 7. CLUTCH & RIM SPROCKET 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. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 25 7. CLUTCH & RIM SPROCKET 660GC 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. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 26 660GC SERVICE MANUAL 7. CLUTCH & RIM SPROCKET 7.7 Assemble clutch. Insert top edge of clutch shoe over spring as shown. 7.8 Snap clutch shoe into place. 7.9 Inspect the rim sprocket for wear. A Replace if the rim sprocket teeth are worn to points, as shown on right. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 27 660GC SERVICE MANUAL 7. CLUTCH & RIM SPROCKET 7.10 Clean and assemble. A Clean all parts in solvent. B Grease needle bearing (ICS P/N ® 505378) with a waterproof grease C Assemble clutch spacer washer, bearing, clutch cup with rim sprocket, and inside clutch spacer washer. 7.11 Install clutch. A Torque to 295 in-lbs (33.3 Nm) Left hand threads © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 28: Starter System

    660GC SERVICE MANUAL 8. STARTER This section covers the removal of the starter cover, replacement of the starter rope, and replacement of the recoil spring. 8.1 Remove starter cover screws (4). 8.2 Remove starter cover assembly from saw. 8.3 Remove starter cord shield screws. 8.4 Relieve spring tension. A Pull 4-6” (10-15 cm) of rope out. Line rope up with notch on pulley. C To release pulley, slowly rotate pulley counterclockwise until spring pressure is released. Use thumb as a brake. 8.5 Remove rubber screw seal. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 29 8. STARTER 660GC SERVICE MANUAL 8.6 Remove starter pulley. A Remove pulley screw. 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. Carefully remove coil spring and housing to prevent spring from unwinding. 8.8 Lubricate with lightweight oil. 8.9 Replace parts carefully. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 30 660GC SERVICE MANUAL 8. STARTER 8.10 Inspect pulley spring catch. A Clean with cleaning solution. B Replace if worn or broken. 8.11 Install starter rope and tie knot. 8.12 Knot tying instructions: A Make a loop at the end of the pulley rope with the end of the rope crossing on top of the tail. B Bring the end of the rope through the loop, creating a single loose knot. C Pull the end of the rope down and in front of the tail. D Send the end through the loop a second time, creating a double knot; cinch tight. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 31 660GC SERVICE MANUAL 8. STARTER 8.13 Install pulley. A Wind rope onto pulley clockwise leaving 4-6”(10 - 25 cm) out. B Make sure that the pulley spring catch is in the spring hook. 8.14 Install center screw. A Use Loctite 242. ® Torque to 26 in-lbs. (2.9 Nm). 8.15 Wind the recoil spring. A Line rope up with notch on pulley. B Rotate the pulley with the rope clockwise 5 times. C Untangle rope and release. 8.16 Assemble starter cord shield. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 32 660GC SERVICE MANUAL 8. STARTER 8.17 Remove starter pawl screws, pawls, spring, and plain washer. NOTE: Piston stop tool may be required to remove the starter pawl screws. 8.18 Inspect and clean pawl components. A Inspect the components. Replace if necessary. Clean the components with a brush and solvent. 8.19 Assemble components. A Make sure the spring is in the correct position. B Use Loctite 242 on the pawl screws. ® Torque to 60 in-lbs. (6.8 Nm). 8.20 Install starter cover. A Pull out cord 4-6” (10 - 15 cm). Slowly release while placing cover to allow pawls to engage. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 33 660GC SERVICE MANUAL 8. STARTER 8.21 Install starter cover screws (4). A Use Loctite 242. ® Torque to 60 in-lbs. (6.8 Nm). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 34: Wallwalker

    660GC SERVICE MANUAL 9. WALLWALKER This section covers the removal, inspection, and assembly of the rubber padded WallWalker and ® guard flap. 9.1 Inspect bumpers. A Replace if worn. 9.2 Remove side cover assembly. 9.3 Remove cover plate. 9.4 Remove crankcase screws (2) and wave washers. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 35 660GC SERVICE MANUAL 9. WALLWALKER 9.5 Remove and inspect guard flap. A Replace the flap if it is torn or damaged in any way. 9.6 Remove guard flap screws and washers. 9.7 Reassemble in the reverse order. A Install crankcase screws and wave washers. B Use Loctite 242. ® Torque to 70 in-lbs. (7.9 Nm). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 36: Cylinder Cover

    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.
  • Page 37 660GC SERVICE MANUAL 10. CYLINDER COVER 10.7 Remove stop switch leads. 10.8 Inspect cylinder cover for damage. A Replace if necessary. 10.9 Check filter cover gasket. A Replace if necessary. 10.10 Check cylinder cover water seal. A Replace if necessary. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 38 660GC SERVICE MANUAL 10. CYLINDER COVER 10.11 Assemble in reverse order. A Reassemble stop switch leads. 10.12 Make sure carburetor screw boot is in place. 10.13 Install cylinder cover. A Pull spark plug lead into slot in cylinder cover. B 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. Approximately 3/4” of tube B (1) should protrude from B (2) cylinder cover. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 39 660GC SERVICE MANUAL 10. CYLINDER COVER C Push the cylinder cover down on the crankcase, guide intake manifold into cylinder cover. D Align throttle linkage with cylinder cover and crankcase. E Install the cylinder cover screws. Use Loctite 242. Torque to ® 35 in-lbs. (4.0 Nm). 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 (see section 10.5). Install air filter mount screws (3) using Loctite 242. ® Torque to 43 in-lbs. (4.9 Nm). 10.15 Install air filters and cover. A Install pre-filter. Install clean air filter. Install air filter flange and tighten. D Install air filter cover and tighten. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 40: Muffler

    660GC SERVICE MANUAL 11. MUFFLER 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. 11.1 Remove muffler support screws. 11.2 Remove muffler screws located inside the muffler. 11.3 Remove muffler and heat shield gasket. • Replace any damaged components. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 41 660GC SERVICE MANUAL 11. MUFFLER 11.4 Install muffler. • Insert muffler screws (2) into muffler. • Hold muffler screws in place with heat shield gasket. • Thread muffler screws into cylinder with Loctite 242. Torque to 78 in-lbs. (8.8 Nm). ® 11.5 Install bottom (2) muffler support screws with Loctite 242. ® • Torque top screws to 78 in-lbs. (8.8 Nm). • Torque bottom screws to 52 in-lbs. (5.8 Nm). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 42: Carburetor

    660GC SERVICE MANUAL 12. CARBURETOR NOTE: All saws are equipped with This section covers the removal and installation of the carburetor model # HDA-225. 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 22. 12.1 Remove throttle linkage. A Push trigger end out of rear handle. B Pivot linkage around. C Remove carburetor end of linkage from throttle rod tab on carburetor. 12.2 Remove fuel line from carburetor and support bracker. 12.3 Remove carburetor support bracket. A Remove carburetor support screw (1) with #4 Torx or straight blade screwdriver. Remove carburetor body screws (2). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 43 660GC SERVICE MANUAL 12. CARBURETOR 12.4 Remove carburetor. A Remove pulse tube. B Remove carburetor jet cover. Remove carburetor from choke linkage. 12.5 Assemble in the reverse order. A Torque carburetor body screws to 43 in-lbs. (4.9 Nm). Torque supporter screw with Loctite 242 to 43 in-lbs. (4.9 Nm). ® © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 44: Cylinder & Piston

    660GC SERVICE MANUAL 13. CYLINDER & PISTON This section covers the NOTE When replacing the 660GC cylinder disassembly, inspection and and piston it is necessary to tune the assembly of the cylinder, piston carburetor prior to returning the saw to and related components. service (see section 22). Removal of several component groups is required. Refer to sections 5, 6, 10, and 12 if necessary. 13.1 Remove carburetor base screws (3). A Remove carburetor base bracket from rear manifold. B Remove carburetor base bracket from pulse tube. 13.2 Remove pulse tube and protective spring from cylinder base. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 45 660GC 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 (2 on front and 2 on back) 13.6 Remove cylinder. A Remove cylinder gasket and clean case. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 46 660GC SERVICE MANUAL 13. CYLINDER & PISTON 13.7 Remove wrist pin retaining clips (2). 13.8 Press wrist pin out with an 8 mm deep socket. 13.9 Remove piston and inspect. Replace if damaged. 13.10 Remove wrist pin bearing. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 47 660GC SERVICE MANUAL 13. CYLINDER & PISTON 13.11 Assemble cylinder gasket. A Oil gasket with ICS 2-stroke ® engine oil. 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. A Install bottom ring first. Installing bottom ring over the top ring may cause the ring to break. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 48 660GC SERVICE MANUAL 13. CYLINDER & PISTON 13.14 Ring orientation. NOTE: Make sure both piston ring end gaps are correctly oriented over their locating pins in the piston ring grooves. 13.15 Install one (1) 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. 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. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 49 660GC SERVICE MANUAL 13. CYLINDER & PISTON 13.17 Lube and partially install wrist pin. 13.18 Align piston in correct orientation. A Make sure arrow points to EXHAUST exhaust port. INTAKE 13.19 Install piston. A Oil piston with ICS 2-stroke oil. ® B Align wrist pin with wrist pin bearing. 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). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 50 660GC SERVICE MANUAL 13. CYLINDER & PISTON 13.20 Install cylinder. A Lubricate cylinder bore with 2-stroke oil. ® Compress rings with ring compression tool. Slide cylinder onto piston, pushing ring compression tool down. 13.21 Install cylinder. A 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 Use Loctite 242. ® Torque bolts to 95 in-lbs. (10.7 Nm). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 51 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.
  • Page 52 660GC SERVICE MANUAL 13. CYLINDER & PISTON 13.27 Install carburetor base. A 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 Loctite 242 on screws (3). ® B Make sure to include stop switch wire on front screw. Torque to 35 in-lbs. (4.0 Nm). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 53: Water Hose

    660GC SERVICE MANUAL 14. WATER HOSE This section covers water hose and side cover. 14.1 Inspect water hose and side cover. A Replace if damaged. 14.2 Assemble in reverse order. 14.3 Remove water hose connector from side cover. A Remove clamp and hose from fitting. B Unthread fitting from side cover. 14.4 Inspect side cover for damage. A Replace if necessary. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 54: Ignition Coil

    660GC SERVICE MANUAL 15. IGNITION COIL 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 ignition coil. A Look for: • Cracks • Missing insulation • Wear marks in wire Clean flywheel magnets and coil if rusty. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 55 660GC SERVICE MANUAL 15. IGNITION COIL 15.5 Install Ignition coil. A Place ignition coil shim (0.012”) on magnet counterweight side of flywheel. Set ignition coil in place. Install ignition coil screws, wave washers, and plain washers with Loctite 242. ® Holding shim, rotate flywheel magnet around to coil. E Torque ignition coil screws to 26 in-lbs. (2.93 Nm). F 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. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 56: Flywheel

    660GC SERVICE MANUAL 16. FLYWHEEL 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. 16.1 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 (4 mm) space between tool and flywheel. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 57 660GC SERVICE MANUAL 16. FLYWHEEL 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 cast woodruff key inside the flywheel. NOTE: Key is cast into flywheel. 16.8 Install flywheel, plain washer, wave washer, and flywheel nut. A Torque nut to 217 in-lbs. (24.5 Nm). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 58: Front Handle

    660GC SERVICE MANUAL 17. FRONT HANDLE This section covers the removal, inspection, and installation of the front handle. 17.1 Remove front handle screws (2) on right side. 17.2 Remove front handle screws (2) on bottom. 17.3 Install front handle. A Roll front handle into place. Install front handle screws (4). C Use Loctite 242. ® D Torque to 69 in-lbs. (7.8 Nm). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 59: Fuel Tank

    660GC SERVICE MANUAL 18. FUEL TANK This section covers the disassembly, inspection, and assembly of the vibration isolaters, fuel tank, and rear handle. 18.1 Remove vibration isolator screws (2) and wave washers on clutch side of saw. 18.2 Remove vibration isolator screws (2) and wave washers on flywheel side of saw. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 60 660GC SERVICE MANUAL 18. FUEL TANK 18.3 Separate crankcase and fuel tank. NOTE: Saws have a rubber water deflector connected to the front vibration isolator on the clutch side (circled). 18.4 Remove vibration isolators (4) from fuel tank if necessary. NOTE: Shock absorber tool (p/n #71546) must be used to remove vibrator isolators. 18.5 Assemble in reverse order. NOTE: During assembly be careful to avoid kinking the fuel line. Torque vibration isolators to 35 in-lbs. (4.0 Nm). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 61: Crankcase

    660GC SERVICE MANUAL 19. CRANKCASE This section covers the disassembly, inspection, and assembly of the crankcase seals and crankshaft bearings. 19.1 Remove outer crankshaft seal housing screws (3) and wave washers. 19.2 Remove crankcase bolts (5). © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 62 660GC SERVICE MANUAL 19. CRANKCASE 19.3 Heat the flywheel side crankcase with heat gun for 5 minutes, approximately 150° F (65.5° C). 19.4 Remove the flywheel side crankcase – tap crankshaft with plastic mallet. A Suspend above work surface. Tap with mallet. NOTE: A nut should always be placed on a threaded shaft when pounding or pressing on it. 19.5 Remove the flywheel side crankcase seal with 1/2” (13 mm) socket. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 63 660GC SERVICE MANUAL 19. CRANKCASE 19.6 Disassembly of crankcase. Heat the clutch side crankcase with heat gun to 150° F (65.5° C). 19.7 Remove crankshaft from the clutch-side crankcase tap crankshaft with a plastic mallet. A Suspend above work surface. Tap with plastic mallet. 19.8 Remove the bearing from the flywheel side of crankshaft. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 64 660GC SERVICE MANUAL 19. CRANKCASE 19.9 Remove the bearing, seal, and bushing from the clutch side of crankshaft. 19.10 Assembly of crankcase. A Clean mating crankcase faces. 19.11 Heat crankcase halves to 150° F (65.5° C). 19.12 Install bearing into crankcase halves. 19.13 Tap with bearing driver and mallet. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 65 660GC SERVICE MANUAL 19. CRANKCASE 19.14 Repeat with other half. 19.15 Install crankshaft into clutch side of case. 19.16 Place clutch side crankcase seal on crankshaft. A Tap lightly with bearing driver and mallet. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 66 660GC SERVICE MANUAL 19. CRANKCASE 19.17 Coat crankcase gasket with 2-stroke engine oil. ® 19.18 Align crankcase gasket on flywheel side crankcase pins. 19.19 Place crankcase halves together and align crankcase pins. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 67 660GC SERVICE MANUAL 19. CRANKCASE 19.20 Assemble crankcase halves – tap with bearing driver and mallet. 19.21 Install crankcase bolts (5). A Use Loctite 242. ® Torque to 70 in-lbs. (7.9 Nm). 19.22 Install flywheel side crankcase seal – tap with bearing driver and mallet. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 68 660GC SERVICE MANUAL 19. CRANKCASE 19.23 Assemble in reverse order A Install outer crankshaft seal housing with 3 bolts and use Loctite 242. ® 19.24 Trim crankcase gasket flush. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 69: Bar Studs & Bar Pad

    660GC SERVICE MANUAL 20. BAR STUDS & BAR PAD This section covers the removal and installation of the bar studs and bar pad. 20.1 On 660GC saws: NOTE: This requires the removal of the piston and cylinder, and to split the crankcase. (Refer to section 13 & 19 for detailed instructions) A Remove side cover. B Remove bar pad cover. C Split the crankcase. D Press out bar studs. E Assemble in reverse order. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 70: Chain Tensioner

    660GC SERVICE MANUAL 21. CHAIN TENSIONER This section covers the removal and installation of the chain tensioner. 21.1 Remove bar plate to expose the chain tensioner. 21.2 Unscrew tensioner to remove. A Remove tensioner pin. B Remove tensioner screw keeper. 21.3 Assemble in reverse order. NOTE: The tensioner is intended to perform as a fuse in high load or sudden impact situations. (p/n 505393) © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 71: Carburetor Tuning

    660GC SERVICE MANUAL 22. CARBURETOR TUNING 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 EPA Phase II emmissions standards. However, minor adjustments may be required in certain conditions, such as high elevation. A 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. Adjusting the carburetor for maximum rpm will cause engine damage). Always set the carburetor jets to factory settings when replacement or complete rebuild becomes necessary. NOTES: • These 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 © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 72 660GC SERVICE MANUAL 22. CARBURETOR TUNING 22.1 Basic Setting - RPM Settings for saws. H = 1 turn from closed NOTE: Saw tuned without bar and chain installed. L = 1 turn from closed Idle Speed = 3,000 ± 500 rpm Full Throttle = 12,500 ± 500 rpm Complete carburetor readjustment. 22.2 Remove limiter cap. A. Limiter caps can only be removed after the cylinder cover and screw boot have been removed. Observe orientation of the release slots on the adjustment screw limiter cap. See section 10 for cylinder cover removal. B. Insert the limiter cap puller into the center of the limiter cap. 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, 1/4 turn and pull straight out. Repeat for second limiter cap. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 73 22. CARBURETOR TUNING 660GC SERVICE MANUAL 22.3 Using a 5/64” straight blade screwdriver, gently turn the adjustment screws clockwise until completely closed. 22.4 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. 22.5 Start the saw and warm up the engine. 22.6 With a tachometer check the saw rpm, with bar and no chain: A Idle = 3,000 ± 500 rpm If the idle rpm does not fall into this range, adjust the T screw, clockwise to raise RPM, counterclockwise to lower RPM. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 74 660GC SERVICE MANUAL 22. CARBURETOR TUNING 22.7 With a tachometer check the saw full throttle rpm, with a bar and no chain: A Target = 12,500 ± 500 rpm 22.8 If the full throttle rpm falls below this range, turn the H screw in (clockwise) 1/16 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. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 75: Idle Speed Adjustment

    23. IDLE SPEED ADJUSTMENT 660GC SERVICE MANUAL This section covers idle speed adjustment. 23.1 If engine stops while idling: A Make sure the chain is properly tensioned. Turn T screw clockwise until chain begins to move. Back T screw out ½ turn. 23.2 If chain turns at idle: A Back T screw out until chain stops moving. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 76: Troubleshooting Diagrams

    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.
  • Page 77 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.
  • Page 78: Troubleshooting Fuel System Leaks

    660GC SERVICE MANUAL 25. FUEL SYSTEM LEAKS 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. 25.1 Remove and inspect the fuel filter. A Replace the fuel filter if there is any foreign material in the felt or the internal screen. 25.2 Test the main fuel pick-up tube for leaks. A Connect tube to the pressure gauge and to the fuel line. B Pressurize the tube to 7psi (0.5 bar). If the pressure does not maintain, separate the fuel line from the carburetor. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 79 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.
  • Page 80 660GC SERVICE MANUAL 25. FUEL SYSTEM LEAKS 25.6 If the pressure does not reduce to 0 psi, disassemble or replace the breather. A Disassemble by snapping off cap. B Clean parts with solvent or fuel. 25.7 Assemble in reverse order. A Make sure duck bill opens easily. B Make sure that the spring taper is oriented in the correct direction. C Assemble by snapping cap in place. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 81: Troubleshooting Crankcase Leaks

    26. CRANKCASE LEAKS 660GC SERVICE MANUAL This section covers testing the crankcase for leaks. A leak in the crankcase can cause the engine not to run. 26.1 Install the intake seal flange. A Plug cylinder pulse tube. 26.2 Install the exhaust seal flange. 26.3 Block one of the flange tubes with a rubber plug. 26.4 Install the pressure gauge and bulb. 26.5 Pressurize the crankcase to 7psi (0.5 bar). 26.6 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. © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 82: Appendix

    660GC SERVICE MANUAL APPENDIX 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 CHAMPION NGK RESISTOR BOSCH RESISTOR RESISTOR 73199 RCJ7Y BPMR7A WSR7F © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...
  • Page 83 660GC SERVICE MANUAL ICS, Blount Inc. 4909 SE International Way Portland, OR 97222 Tel 800.321.1240 Fax 503.653.4393 icsbestway.com © 2011 ICS | Blount, Inc. Specifications and pricing are subject to change without notice. P/N 550416 REV06012011...

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