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Service Manual - 695GC/F4

1. 9 11 Install the center screw and components Note the orientation of the parts for re installation See 9 7 for orientation 9 12 Tension pulley e Wind rope onto pulley clockwise leaving 6 8 in 15 20 cm of rope out e Ensure the pulley spring catch is E Y installed on the spring hook 33 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 9 13 Insert the rope into the pulley notch e Wind rope clockwise around pulley shaft 3 4 times Then pull starter rope handle Repeat as necessary to ensure proper spring tension Ensure with starter rope fully extended the pulley can still be rotated an additional 1 2 turn before being stopped by the spring 9 14 e Rope must fully retract into starter cover Ww d t SN 4 N IN 9 15 Install starter cover Pull starter rope to engage starter pawls and seat cover e Tighten side cover screws 34 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 10 This section covers the removal amp replacement of the carburetor amp cylinder cover Removal of air intake components and front handle is required Refer to sections 5 amp 15 if necessary 10 1 Remove air filter cover and air filter Refer to section 5 Remove 2 screws P N 544065 Lift cylinder cover off from the front of the cover Install in rever
2. 20 26 Hold the screw in place and turn the nut until the bearing stops against the crankcase Repeat the process for the other half of the crankcase 20 2 Bearing Tools Shaft Sleeve Shaft Mandrels 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 71 D 20 28 Bearing press kit gt 8 20 29 Crankshaft install Secure clutch side crankcase face down so the connecting rod is not pinched against the crankcase 20 30 Slide the clutch side shaft through the bearing 72 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 20 31 Slide the shaft sleeve over the shaft against the crankcase Thread the M12 mandrel with the nut and washer until it bottoms Note REVERSE THREAD on the clutch side 20 32 Hold mandrel in place turn nut clockwise until the shaft reaches the top at the bearing Ensure the connecting rod is not pinched against the case 20 33 Install the 2 crankcase guide pins T3 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 20 34 Lubricate the crankcase halves with ICS9 2 stroke oil and install the crankcase gasket 20 35 Lubricate and assemble the flywheel side of the crankcase using the same method with the M8 standard thread mandral Ensure the connecting rod does not be
3. CONCRETE STONE MASONRY UNSTOPPABLE SERVICE MANUAL 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 SECTION SECTION TITLE PAGE NUMBER SERVICE MANUAL USE 3 1 TOOLS 4 2 SAW SPECIFICATIONS 5 3 SERIAL NUMBER LOCATION 6 4 SPARE PARTS DIAGRAM TORQUE SPECIFICATIONS AND LOCTITE APPLICATION T 5 AIR INTAKE 19 6 SPARK PLUG 20 7 SIDE COVER amp TENSIONER 22 8 CLUTCH amp RIM SPROCKET 24 9 STARTER SYSTEM 30 10 CARBURETOR REMOVAL 30 11 MUFFLER W BAR STUD 39 T2 MUFFLER W BAR STUD 40 13 IGNITION MODULE 41 14 STOP SWITCH 42 15 WATER HOSE 44 16 CYLINDER amp PISTON 45 17 BOTTOM GUARD FRONT HANDLE 51 18 REAR HANDLE 53 19 FUEL TANK amp COMPONENTS 57 20 CRANKCASE 63 21 CARBURETOR TUNING TI 22 IDLE SPEED ADJUSTMENT 80 23 TROUBLESHOOTING DIAGRAMS 81 24 TROUBLESHOOTING FUEL SYSTEM 83 25 TROUBLESHOOTING CRANKCASE LEAKS 8 APPENDIX 1 SPARK PLUG REFERENCE GUIDE 89 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL Service Manual Use This manual contains all the technical information necessary for carrying out repairs on the 695GC F4 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 Service Rules Always use the right tools for the job otherwise components m
4. PO IES IE AAA opo ox p Lo po o s II A 16 sueo 5487 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 eee a CJ O a SIDE COVER amp TENSIONER ASSEMBLY TORQUE KEY DESCRIPTION TORQUE LOCT TE PART NUMBER in lbs 242 Nm a oecoverassemsy VI Is 3 SIDE Cover Nara pso sooj 543900 3 SIDE COVER NUT CIRCLIP see 4 ENSIONERCOVERPLATESCREW T 5499 5 CREW SIDE COVER CAP ox mwa e henson Seen 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL jus E EZ EZ d aa E ech 8 er ss LOCTITE DESCRIPTION a Ex PART NUMBER Nm in lbs 242 NN 2 3 15 18 192 156 x 543902 3 psrowcvwwpRKT l sees 3 HEAT DEFLECTOR LC ma 4 mueren Basi Se 5 pure I Lem e ower MUFFLER MOUNTING serevi II Is Sms 7 MUFKLERMOUNTNGWaSHER ll IL mwa s pecowmessocvave ma 9 jvuwpRBAsEGAskET Ll Jo Lemmer 1 WensEmNG CS MUFFLERMOUNTKIT O O J emer m parer FAS FE o 1 Jean rne LO Lee 4 CRANKCASE GASKET 1L 99s 2012 ICS Blount Inc Spec
5. NO If below 125 psi excess Replace piston and cylinder compression wear on the piston Ensure correct fuel oil mixture cylinder rings and or 25 1 ves improper fuel mixutre Fuelis old varnished or e Empty tank and re fill with fresh P S ine tue esn NO fuel of the correct mixture 25 1 Clogged fuel filter Replace fuel filter Is the fuel reaching the NO Damaged fuel line Replace fuel line carburetor Plugged fuel tank Repair or replace fuel tank breather breather Refer to Carburetor Tuning section Repair or replace fuel tank breather Is the flywheel key 82 Is too much fuel Carburetor is tuned reaching the incorrectly carburetor Plugged fuel tank breather 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 TROUBLESHOOTING 695GC F4 SERVICE MANUAL 24 This section covers testing the fuel system 24 1 Engine starvation can result from a leak or malfunction of any of the main components of the fuel system 24 2 The main components are the fuel tank fuel tank breather fuel filter purge bulb delivery tubes and carburetor 24 3 Remove and inspect the fuel filter Replace the fuel filter if the filter is excessively dirty or there is foreign material stuck to it 83 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 24 4 Test the main fuel pick up for leaks Instal
6. RWJ 5A 9 THROTTLE CABLE LEVER ADJUSTMENT GUIDE 11 MANIFOLD BRACKET AIR INTAKE MANIFOLD AIR FILTER BRACKET 14 CARBURETOR MOUNTING SCREW 15 THROTTLE CABLE ASSEMBLY 16 CHOKE LEVER 17 CARBURETOR REPAIR KIT 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 TORQUE i DESCRIPTION IORA al PART NUMBER Nm T FILTER COVER REAR SCREW 3s IL Se 54 5 FILTER COVER Come ss 5mo 6 YUNDERCOVERSCREN x 5405 7 CYLINDER COVER ASSEMBLY 5400 NENNEN 8 CYLINDER COVER SEALS 544067 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL e ve Q FUEL TANK ASSEMBLY VT vet ranassemB Or 2 PARALLELPIN o 3 CABLE LEVER LL mm 4 mmorneiocourEvR Sms 5 Rear HANDLE COVER O e pue II TC Sms ER 543993 8 Jen valve TUBE 54994 9 CHECK VALVE LL ss 0 Hosecawe mm rue er SSS 2 mwvevrasEMRY TC mme n fankvenrernne O O J O sa 4 REARHANDEEGROUNDSUPPORT am 15 PURGE BULB L E am 16 REHANDESCREN a 7 THROTTLECABLEASSEMBLY S
7. at each interval NOTE pulse the throttle to stablize the system Once the carburetor is adjusted install the chain to the proper tension and continue normal operations 80 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 TROUBLESHOOTING 695GC F4 SERVICE MANUAL 23 This section provides several flowcharts to aid diagnosing common problems CHECK POSSIBLE CAUSE REPAIR Clean or replace the air filter Sic shal runs renajvat Dirty or clogged air filter Inspect air intake system for water 9 9 e Water has been ingested Inspect fuel system for water all speeds Loose or dirty spark plug Tighten clean or replace spark plug Operator is overworking the Saw Carburetor mixture is too lean Incorrect fuel oil ratio Flywheel fins are clogged Air deflector is missing Cylinder fins are clogged See Operator s Manual See Carburetor Tuning section See Saw Specifications section Clean flywheel fins with wire brush See Starter Cover section Clean cylinder fins The engine is overheating Clean or replace the air filter Dirty or clogged air filter Replace fuel filter ves Clogged fuel filter p l Poor acceleration See Carburetor Tuning section Repair or replace fuel tank breather Incorrect carburetor tune Plugged fuel tank breather e Air leak at intake boot cylinder e Inspect air intake boot gasket or crankcas
8. order 23 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 8 This section covers clutch removal rim sprocket removal inspection and assembly Refer to sections 5 and 6 if necessary Rim sprocket removal procedure 8 1 Using flat head screwdriver remove retaining ring Use caution when removing retaining ring to prevent damage to the split retainer or crankshaft 24 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 8 2 Remove the split retainer and spacer 8 3 Inspect rim sprocket and replace if necessary P N 70949 Replace if the rim sprocket teeth are worn to points as shown on right 8 4 Rim sprocket assembly e Assemble in reverse order 25 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 8 5 Remove clutch cup and needle bearing e Apply grease to needle bearing prior to reinstalling 8 6 Clutch removal e Remove clutch cup amp rim sprocket first 8 7 Insert piston stop tool into spark plug hole 8 CLUTCH amp RIM SPROCKET 1 26 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 8 8 Remove clutch with clutch tool P N 546659 e Rotate clockwise to remove clutch clutch
9. rs 18 THROTTLE TRIGGER II sese 19 TRIGGER SPRING L C m 20 VPurGE Bue TUBE 54995 21 krommer a 77 pasmwkcaeassEMgy O O o am 25 ISHOCK ABSORBER scREN x ss 24 ISHOCK ABSORBER CLUTCH SIDE II O mme 25 SHOCK ABSORBER FRONT Lo x See 36 BHockassomsERFUmwHEELSDE Jo Is mme 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 WATER DELIVERY SYSTEM ad 1 water HOSE VALVE AssemBry IT bnw 2 OSE HANGER ss ATER HOSE WITH PROTECTIVE COVERING 43999 4 puwewarERHosETUESDE Fan 5 rame VIATER HOSE VALVE sive oo 6 FRONT HANDLE B4002 7 ISHOCKABSORBER FRONTHANDLE a 8 EcmewsHOckaORBERS o x Fa 9 CLIP FRONT HANDLE 44008 16 screw FRONT HANDLE O bw Ww bung O bw 12 BACKING PLATE GUARD FLAP TI 544011 13 SCREW GUARD FLAP ox 44012 18 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 5 This section covers the removal inspection and assembly of the air intake 5 1 Loosen the air filter cover screws and remove the air filter cover 695GC icebestway com 5 2 Loosen air filter screw e Inspect air filter for dirt or damage e Replace with P N 544064 2012 ICS Blount Inc Specifications s
10. 1 Loosen 4 starter cover screws 9 2 Remove starter cover from saw 9 3 Relieve spring tension in starter recoil e Pull 6 8 in 15 20 cm of rope out e Line up rope with notch in pulley 30 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 9 4 Rotate pulley shaft counter clockwise allowing pulley to unwind using rope as a brake S kW KZ ho hs W Ki 9 5 Pulley removal from spring 9 6 Remove the center screw and components Note the orientation of the parts refer to photo 9 7 31 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 9 7 Note the orientation of the parts for re installation 9 8 A Lift pulley from spring housing NOTE the spring catch and spring hook must be aligned during installation arrows B Remove the two screws holding the spring housing C Use CAUTION when removing the spring to prevent the spring from unwinding D Inspect spring and lubricate with light oil E Align notch in spring housing with end of spring 9 9 Inspect rope P N 544023 and pulley P N 544127 Replace if necessary Note the orientation of the knot 32 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 9 10 Assemble in reverse order Vii UF H
11. D Remove ring compressor E Slide cylinder onto piston and into the crankcase F Align cylinder bolt holes with crankcase Align cylinder screw with holes on gasket amp crankcase 16 17 Install 4 cylinder screws using Loctite 242 Torque to 132 156 in lbs 15 18 Nm 50 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 17 This section covers the removal inspection and installation of the bottom guard and front handle 17 1 Remove 2 screws P N 544012 and guard flap backing plate P N 544011 Inspect guard flap for damage P N 544010 replace if damaged Reassemble in reverse order using Loctite 242 17 2 Remove 2 screws from lower front handle P N 544009 51 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 17 3 Remove 3 screws on the side of the handle P N 544009 17 4 Lift up crankcase and remove handle inspect and replace if damaged Install in reverse order Use Loctite 242 on all screws except shock absorber screw 92 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 18 This section covers the removal inspection and installation of the rear handle 18 1 Remove screw from rear handle P N 543974 18 2 Remove rear handle cov
12. UAL 11 This section covers the removal inspection and assembly of the muffler Removal of WallWalker and cylinder cover is required Refer to section 10 if necessary 11 1 Muffler removal e Remove 2 cylinder muffler screws P N 543942 with scrench e Remove 1 lower muffler mounting screw P N 543846 and muffler mounting washer P N 543847 112 Inspect and replace if damaged e Muffler P N 543845 Muffler gasket P N 543938 Heat Deflector P N 543844 Reassemble in reverse order using Loctite 242 39 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 12 This section covers the removal inspection and installation of the guide bar stud Removal of WallWalker and muffler is required Refer to section 10 if necessary 12 1 Bar stud removal P N 544129 12 2 Using a 6 mm allen or hex head remove 2 bolts holding bar stud 12 3 Inspect bar stud P N 544129 Replace if damaged e Install in reverse order using Loctite 242 40 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 13 IGNITION MODULE 695GC F4 SERVICE MANUAL 13 This section covers the removal inspection and installation of the ignition module Removal of the starter is required Refer to section 8 if necessary 13 1 e Remove starter cover e Remove starter cover shield e Disconnect the stop switc
13. ay 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 These are noted in the service manual 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 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 1 TOOLS Key Part No Description 1 171541 Pressure Gauge Bulb 2 71543 Cylinder Assembly Clamps amp Piston Stop Electronic Tachometer 4 73425 Fuel Tank Pressure Cap 5 1546191 Workshop Key Torx T27 6 546192 Test Spark Plug Air Gap Gauge 8 en weelPuler 9 bz pistonStop SSI 10 bone WisPmPuch 11 46197 Cylinder Seal Exhaust 12 546198 _ Cylinder Seal Inlet Port o 44 bes JsembyPunh O 15 546292 Universal Puller 16 j546293 Grip Plate 17 546294 Bearing Puller 18 1546295 Bearin
14. ch side of the crankcase 20 15 Attach universal puller and press out the crank shaft 67 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 20 16 Using the same process press out the other half from the flywheel side 20 17 Separated crankcase halves with bearings installed 20 18 If the bearing s remain on the shaft upon separation the bearing removal tool must be used 68 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 20 19 Install the bearing clamp and tighten nuts 20 20 Install the bearing puller and press the bearing off the shaft 20 21 Crankcase bearing tools These tools are required to remove the bearing from the crankcase 69 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 20 22 Heat crankcase halves to 150 F 65 5 C Use the shaft sleeve and soft mallet to tap out both bearings 20 23 Bearing installation Bearing press tools 20 24 Place the bearing on the bearing support plate Holding the bearing support plate under the crankcase half 70 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 20 25 Place the screw with nut and washers through the crankcase support plate and thread into the bearing support plate
15. come pinched between the crankcase halves 74 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 20 36 Loctite 242 and prefit the 8 screws and align the guide pins before bringing the crankcase together 20 37 Tighten the screws to 106 124 in Ibs 12 14 Nm using an x pattern 75 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 20 38 Cut the excess gasket over the cylinder port and carburetor area Tap both sides of the shaft with a soft mallet and ensure free movement of shaft and connecting rod 20 39 Install shaft seals refer to section 20 7 76 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 21 CARBURETOR TUNING 695GC F4 SERVICE MANUAL 21 This section covers the carburetor tuning 21 1 Carburetor tuning A Throttle screw B Low speed jet C High speed jet D Model number 21 2 Tools required Tuning screwdriver Flat screwdriver Tachometer 21 3 Carburetor adjustment Tachometer is required for proper tuning of the saw 77 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 21 4 Throttle screw Basic setting T 3 turns from closed Used to adjust chain speed at idle 21 5 Carburetor basic setting H 1 1 2
16. e Replace if damaged See fuel tank section 24 11 Inspect fuel purge lines and one way purge valve for leaks or damage The arrow is the purge flow direction Replace if damaged See fuel tank section 86 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 TROUBLESHOOTING 695GC F4 SERVICE MANUAL 25 1 This section covers testing the the crankcase for leaks A leak in the crankcase can cause the engine to run too lean causing engine damage or not run at all A Exhaust Seal Flange B Intake Seal Flange 25 2 With the carburetor and muffler removed block the intake and exhaust ports with the seal flanges See Cylinder Cover and Muffler sections NOTE Remove intake plate from intake boot prior to installing intake seal flange 25 9 Securely plug or tape over the clutch needle roller lubrication port on the crankshaft Clutch cup and needle roller must be removed See Clutch Cup and Rim oprocket Section section 8 87 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 25 4 Install the exhaust seal flange Use the muffler mounting screws to install the flange Be sure the spark plug is secure and the decompression valve is pulled out 25 5 Install the intake seal flange Use M4 x 20 screws w washers not supplied to secure the seal flange Install the pressure gauge and pressur
17. e Workshop Key Torx T27 P N 546191 remove shock absorbers A Front shock absorber P N 543983 B Clutch side shock absorber P N 543982 C Flywheel side shock absorber P N 543984 Inspect and replace if damaged Install in reverse order using Loctite 242 except Tank Vent 19 13 Purge bulb circuit Refer to troubleshooting section 24 if necessary 19 14 Disconnect the purge bulb tube return line P N 543995 and disconnect check valve tube P N 543994 61 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 19 15 Remove purge bulb P N 543973 lightly depress tab to disengage purge bulb 19 16 Inspect all components Replace if damaged Check valve P N 043969 flows one way ensure that it is installed correctly Fuel flows towards the purge bulb Refer to troubleshooting section 24 if necessary 19 17 Reassemble in reverse order Check valve tube must be inserted back into channel and connected to fuel line with clip P N 543818 62 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 20 This section covers the disassembly inspection and assembly of the crankcase seals and bearings 20 1 Crankcase seal puller and punch 20 2 Crankcase seals 20 3 Seal removal A Insert T handle puller over the shaft B Apply downwa
18. e clip from water inlet pipe Pull hose upward Inspect hose and water inlet pipe replace if damaged 44 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 16 This section covers the removal inspection and assembly of the cylinder piston and related components Refer to section 5 amp 10 if necessary 16 1 Remove outer shock absorber screw set aside for reassembly P N 543981 Loosen 4 cylinder screws P N 543942 16 2 Remove cylinder from piston Remove shock absorber screw see sec tion 16 1 Remove inlet boot and clamp Set aside shock absorber boot amp clamp for reassembly later see section 10 9 45 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 16 3 Remove wrist pin clip from each side of piston 16 4 Remove wrist pin using the wrist pin punch P N 543196 Remove piston and cylinder base gasket 16 5 Clean crankcase 46 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 16 6 Inspect cylinder and piston P N 543843 replace if damaged 16 7 Install piston rings Install lower piston ring first 16 8 Note the ring locator pins 47 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 16 9 Note ring orientat
19. e gasket e Pressure test crankcase e Faulty carburetor diaphragm e Replace carburetor Uneven idle or engine may run away Diamond chain moves Yes Idle speed too high Adjust idle speed at idle Broken clutch spring Replace clutch spring Replace shock absorbers e Damaged shock absorber e Replace flywheel l e Damaged or broken flywheel fins H y l Bent crankshaft Replace crankshaft 81 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL TROUBLESHOOTING 23 DIAGRAMS Saw Will Not Start CHECK POSSIBLE CAUSE REPAIR Clean rebuild or replace the recoil Dirty or broken recoil starter Does the engine crank NO ab deme Inspect for internal damage such as seized piston d Release switch from STOP and The ignition switch is in re test STOP position Tighten connections or replace Is there spark NO Faulty ignition ground ground wire Faulty spark plug lead Repair or replace spark plug lead VES Faulty ignition coil Replace ignition coil Plug is soaked with fuel Dry plug expel excess fuel from cylinder and crankcase Is the spark plug firing NO Messe shave gj Clean and re gap the plug to properly n 0 020 inch 0 05 mm Plug is internally faulty or the wrona tvpe Replace with the correct plug Yes See Spark Plug Reference Guide Loose spark plug Tighten plug and re test Check cylinder
20. er P N 543816 53 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 18 3 Remove throttle lock out P N 543815 by squeezing pulling up and out 18 4 Remove throttle trigger P N 543976 by pushing the 2 parallel pins P N 543813 from the rear handle housing 18 5 Pull the throttle trigger and spring P N 543977 down from the rear handle 54 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 18 6 Remove throttle cable P N 543975 See section 10 to remove cable from carburetor 18 7 Remove cable lever P N 543814 using needle nose pliers pulling up 55 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 18 8 Remove throttle cable from cable lever using an awl or small punch 18 9 Remove throttle cable through the front of the handle 18 10 Inspect all throttle component parts e Replace if damaged e Reassemble in reverse order 56 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 19 This section covers the removal inspection and assembly of the shock absorbers fuel tank and components 19 1 Remove fuel cap P N 543979 e Inspect fuel cap and O ring Replace if damaged 19 2 Remove fuel filter P N 543971 Use a small h
21. g Press 19 1546307 Screwdriver Idle 20 p46659 Clutch Tool os not shown 505882 2 Stroke Oil 25 1 Mix 5 2 oz 158 ml 6 pack not shown 505883 2 Stroke Oil 25 1 Mix 5 2 oz 158 ml 24 pack 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL opecifications Engine Type 2 stroke Air Cooled Displacement 5 7 cu in 94 cc Horsepower 6 4 hp 4 8 kW 9000 rpm Torque 50 4 in Ibs 5 7 Nm 7 200 rpm Engine Speed 9 300 150 rpm max 2 700 100 rpm idle Piston ring gap Maximum 04 in 1 0mm Weight 21 Ibs 9 5 kg powerhead only Dimensions 18 in 46 cm length 14 in 36 cm height 12 in 30 cm width Carburetor Walbro RWJ 5A Air Filtration Water resistant polyester otarter Dust and water resistant Ignition Special water resistant electronic ignition opark plug type NGK BPMR7A or Champion RCJ6Y Electrode gap 0 020 in 0 5 mm Clutch Centrifugal three shoe three spring Fuel Mix Ratio 25 1 496 gasoline to oil Fuel Capacity 0 26 gallon 1 liter Water Supply Minimum 20 psi 1 5 bar Noise Level 112 dB A at 3 ft 1 m Vibration Level 3 9 m s front handle 4 1 m s rear handle 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 3 This section shows the single location of the serial number K 97 16854363 2002188 0087 01 2012 ICS Blount Inc Specifica
22. h cable e Inspect and replace if damaged P N 544032 13 2 e Remove 2 ignition module screws P N 544038 e Remove ignition module P N 544036 e Inspect and replace if damaged 13 3 Reassemble in reverse order Place air gap gauge 010 in 0 3 mm on the magnet side of the flywheel Set ignition module in place Install ignition module screws with blue Loctite 242 Holding gauge rotate flywheel magnets around to coil Torque ignition coil screws to 89 105 in Ibs 10 12 Nm Remove gauge rotate flywheel and check for clearance Connect stop switch cable 41 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 14 1 Remove stop switch P N 544031 Disconnect cable wire 14 2 Remove screw P N 544030 42 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 14 3 Pry the switch to the left using the scrench 14 4 Pull the right side out first e Replace switch if damaged Install in reverse order e Switch will snap back into place e Use Loctite 242 only on screw 43 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 15 This section covers water hose and water tank cap 15 1 Inspect hose P N 543999 water pipe P N 543915 and water valve P N 543996 Replace if damaged 15 2 Releas
23. ifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 4 SPARE PARTS DIAGRAM CRANKCASE ASSEMBLY 1 CRANKCASE ASSEMBLY VI T aw 2 CRANKCASE SCREW 1 14 106 124 x 5495 3 SEALING RING A e FA FETO IEA 5 CRANKCASE GASKET RSR 6 Janin serine ll 7 RUBBER BUSHING p 5 faser ll o pvumpEREmEGASKET ll 1 Moreras n baang f x ar eracker ur O 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL CRANKSHAFT ASSEMBLY LOCTITE o T a 2 jawsEmmNG ll TC a a ICRANKSHAFT sete Sia 4 NEEDLE BEARING 1 EE 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 COMPLETE ENGINE ASSEMBLY TORQUE KEY DESCRIPTION Ora PART NUMBER CRANKCASE VVIPISTON 8 CYL COMPLETE 52 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL CARBURETOR amp INTAKE ASSEMBLIES TORQUE i KEY DESCRIPTION TORQUE ai PART NUMBER in ibs 242 Nm NLET BOOT CLAMP TT T T s069 2 INLET BOOT 3 FLANGE 4 FLANGE CLUTCH SIDE SCREW 5 FLANGE BRACKET 6 SCREW o O 8 CARBURETOR WALBRO
24. ion If rings are installed upside down or incorrectly ring will not seat properly and piston damage will occur 16 10 Lubricate crankcase gasket mating surface with ICS 2 stroke oil Install cylinder base gasket 16 11 Lubricate needle roller with ICS9 2 stroke oil Insert into the connecting rod j E E z hk ik U 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 48 695GC F4 SERVICE MANUAL 16 12 Lubricate wrist pin with ICS 2 stroke oil and partially install in the piston 16 13 Install wrist pin clip into opposite side of the piston Make sure wrist pin clip is in the proper orientation See 16 15 16 14 Align the piston in correct orientation Arrow on top of the piston points towards the muffler exhaust port 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 49 16 15 Install piston A Align wrist pin with wrist pin needle bearing B Complete wrist pin installation C Install second wrist pin clip note the orientation of the pin clips D Coat piston with ICS 2 stroke oil 16 16 Install the inlet boot clamp flange bracket flange and shock absorber screw before cylinder installation A Lubricate the cylinder bore with ICS 2 stroke oil B Compress the rings with compression tool P N 71543 C Slide cylinder onto piston pushing ring tool down
25. is left handed thread 8 9 Clutch is marked with arrow off for direction of removal 8 10 Inspect clutch shoes P N 543927 for excessive wear or damage 21 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 8 12 Height of clutch shoes should not be less than 1 mm 8 12 Inspect and clean springs if necessary 28 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 8 CLUTCH amp RIM SPROCKET 8 13 Remove the springs e Set into a vice to hold in place Place a flat head screwdriver or flat tipped rod against the spring hook Tap lightly at the end of the screwdriver orrod This will cause the spring hook to detach Push the spring out Repeat with the remaining two springs 8 14 Fit clutch shoes e Slide the spring into the narrower section of the clutch shoe first NOTE All spring hooks should point the same direction as the word OFF See illustration at right for an example 8 15 Fit springs e Turn the clutch so the word OFF is facing down Push the spring hook into its hole by using a pointed tool 695GC F4 SERVICE MANUAL 29 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 9 This section covers the removal of the starter cover replacement of the starter rope and replacement of the recoil spring 9
26. ize the crankcase to 7 psi 0 5 bar If the pressure does not hold use soapy water to find the leak Note it is recommended to pressure test the engine after a piston and cylinder rebuild and or crank seal replacements 88 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL This appendix covers the removal inspection and installation of the spark plug for the 695GC amp 695F4 Remove the spark plug lead Clean area around the spark plug to prevent debris from entering the cylinder Remove the spark plug Inspect the spark plug If dirty clean with a wire brush as shown 89 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 Gap if necessary to 0 02 0 5 mm 695GC Champion RCJ 6Y or NGK BPMR7A 695F4 Champion RCJ 6Y or NGK BPMR7A Assemble in the reverse order Make sure the plug boot is seated completely 90 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695 SERVICE MANUAL ICS Blount Inc 4909 SE International Way Portland OR 97222 Tel 800 321 1240 Fax 603 653 4393 icsbestway com 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529
27. l the pressure gauge and bulb to the filter end of the fuel line Pressurize the tube to 7psi 0 5 bar If the pressure does not maintain separate the fuel line from the carburetor 24 5 Plug one end of the fuel pick up tube Pressurize the tube to 7 psi 0 5 bar If the pressure holds the leak has been isolated to the carburetor Refer to the Walbro Carburetor Service Manual http wem walbro com distributors servicemanuals 24 6 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 84 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 TROUBLESHOOTING 695GC F4 SERVICE MANUAL 24 7 The fuel breather is located above the fuel cap on top of the fuel tank 24 8 Testing the fuel tank breather Attach the pressure gauge to the fuel tank plug Plug the fuel line at the carburetor end Pressurize the tube to 4 5 psi 0 3 bar The pressure should reduce to nearly 0 psi 0 bar over a period of 3 seconds 85 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL TROUBLESHOOTING 24 FUEL SYSTEM 24 9 If the pressure does not release disassemble or replace the breather 24 10 Inspect the fuel purge circuit Inspect the purge bulb for leaks or damag
28. ook to remove filter from gas tank 19 3 Remove fuel filter e Pull up on hose clamp P N 543970 e Pull down on fuel filter 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 57 19 4 Inspect fuel filter and line Replace if damaged or dirty e Reassemble in reverse order 19 5 Before separating the fuel tank from crankcase remove the front handle see section 17 and throttle cable see section 10 Remove the 2 shock absorber screws from the clutch side of the saw 19 6 Remove the 2 shock absorber screws from the flywheel side of the saw 58 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 19 7 Separate fuel tank from crankcase by pulling up on the crankcase while holding the fuel tank 19 8 Inspect Tank Vent Assembly Location of the tank vent on a disassembled saw 19 9 Location of the tank vent on an assembled saw 59 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 19 10 Inspect the tank vent and replace if damaged Refer to troubleshooting section 25 if necessary 19 11 Inspect fuel tank for damage Replace if damaged 60 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 19 12 Shock Absorbers Using th
29. rd pressure to the T handle and turn the barrel clockwise with a wrench to thread into the seal 63 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 20 4 Turn the T handle until it presses against the shaft and pulls the seal from the crankcase 20 5 Lift off the seal and inspect the shaft for damage 20 6 Lubricate the shaft with High Pressure Grease 64 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 20 CRANKCASE 695GC F4 SERVICE MANUAL 20 7 Install the new seal Use caution as seal slides over the threads 20 8 Use the punch and soft mallet to tap seal into place 20 9 Repeat procedure for the flywheel side 65 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 20 10 Using soapy water on both sides per form a crankcase leak down test using pressure gauge and vacuum gauge 20 11 Use pressure gauge to perform a leak down test Pressure should hold at 7 psi 0 5 bar 20 12 Crankcase separation The universal puller and grip plate are required to separate the crankcase 66 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 20 13 Remove the shaft seals from both sides of the crankcase See seal removal 20 14 Install grip plate on the clut
30. se order using Loctite 242 10 2 Carburetor Removal Remove choke lever P N 544117 10 3 Lift up choke lever and rotate 90 degrees then pull out from carburetor Install in reverse order 35 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 10 4 Remove 2 carburetor mounting screws P N 544115 using a Workshop Key Torx T27 P N 546191 10 5 Remove bracket screw P N 544072 Remove air intake manifold P N 544113 Inspect for damage 10 6 Remove fuel line check valve tube and carburetor 36 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 10 7 Remove throttle cable from carburetor 10 8 Remove clutchside flange screw P N 544072 and screw P N 544065 37 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 10 9 Remove plate from inlet boot Remove the flange bracket and flange from the inlet boot Note orientation of plate UP 10 10 Loosen clamp Inspect and replace inlet boot if damaged see section 16 2 e Cylinder must be loosened in order to remove the inlet boot e Install in reverse order Using Loctite 242 for screws Note orientation of plate UP 38 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MAN
31. tions subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 4 This section covers spare parts wi N N xX N e 5s STARTER ASSEMBLY TORQUE i DESCRIPTION BEREE pi PART NUMBER Weg Y Nm in bs 1 STARTERCOVERASSEMBLY Ir Pe ernie A 3 SCREW l j 4 JRECOLSPRNG 5 STARTERCORD Peri 8 STARTERCOVERSHIELD II 544024 544012 544026 LX m O X P p 5403 pM as IA 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 9 DH Dru lt gt E INN Legs I Dy gt SQ T9 ES E EU ES Be Th SIR ei S K SS gt e SO eer MN 7 WS 14 Em S T oN CD ee Ke G e a M 10 P 3 STOPSWITCHCABLE 6 PROTECTIVESLEEVE 8 IGNITION MODULE SCREW 10 12 9 FLYWHEEL 25 30 216 264 EY SE PART NUMBER 9 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL CLUTCH ASSEMBLY amp WALLWALKER LOCTITE DESCRIPTION sale me PART NUMBER Nm in lbs 242 RETAINING RING Od 2 2 6 NEEDLE BEARING 543910 BAR BRACKET SCREW 543911 NEN NENNEN IS ll Bisi Mem eee ll BEE A BEE zs 8 CRANKCASEBOLT jj o x ae K NO IO
32. turns from closed L 1 5 8 turns from closed Insert the tuning screw driver into the crankcase slot Note the H screw is on the right as seen in the picture 78 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 21 6 Turn both the H and the L needle screws clockwise until they stop 21 7 Turn the screws counter clockwise to the carburetor basic settings Carburetor basic setting H 1 1 2 turns from closed L 1 5 8 turns from closed 79 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 22 1 Verify the RPM s using the tachometer Start and warm up the saw NOTE This is a no load tuning 695GC procedure The side cover must be gt icsbestway com securely fastened with a bar and chain Water MUST be used failure to follow this procedure may result in personal injury and or damage to the saw 22 2 Using the tachometer check the saw RPM s at idle e Idle speed 2700 RPM s 150 Make minor adjustments using the throttle screw Using the tachometer check the saw RPM s at full throttle Full throttle target 9300 RPM s 150 Make minor adjustments using the throttle screw Do not hold the saw at maximum RPM for more than 5 seconds If the full throttle RPM falls below this range turn the H needle clockwise 1 16 of a turn at a time checking the RPM s
33. ubject to change without notice REV11272012 P N 546529 6 This section covers the removal inspection and installation of the spark plug 6 1 Remove the spark plug cap 6 2 Remove the spark plug 6 3 Inspect spark plug e f it s dirty clean with a wire brush Replace spark plug if fouled or erroded USE NGK BRMR 7A or Champion RCJ6Y 20 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 6 4 Gap if necessary to 0 20 0 5mm 6 5 Assemble in reverse order ensuring that the spark plug is properly engaged in threads and fully seated 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 21 T This section covers side cover removal side cover nut removal inspection and assembly 7 1 Loosen side cover nut e Remove side cover e Remove tensioner plate screws and tensioner plate 1 2 Remove tensioner assembly Note the orientation of the tensioner assembly 1 3 Inspect tensioner and replace if needed e Clean tensioner threads and liberally apply grease to threads prior to assembly 22 2012 ICS Blount Inc Specifications subject to change without notice REV11272012 P N 546529 695GC F4 SERVICE MANUAL 7 4 Inspect side cover nut and circlip Replace if damaged Circlip can be removed with a large flathead screwdriver 1 5 r Assemble in reverse

Service Manual - 695GC/F4

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