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SERVICE MANUAL

1. Clean or replace the air filter Replace fuel filter See Carburetor Tuning section Repair or replace fuel tank breather Replace pulse tube e Dirty or clogged air filter e Clogged fuel filter e Incorrect carburetor tune e Plugged tank breather e Blocked pulse tube Poor acceleration e Air leak at intake boot cylinder gasket or Inspect air intake boot crankcase gasket Pressure test crankcase e Faulty carburetor Replace carburetor diaphragm Uneven idle or engine may run away Diamond chain moves YES e Damaged shock absorber Replace shock absorbers uds Replace ias e Bent crankshaft Replace crankshaft 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 81 25 DIAGRAMS 680GC SERVICE MANUAL Saw Will Not Start CHECK POSSIBLE CAUSE REPAIR e Clean rebuild or replace the recoil e Dirty or broken recoil caer a po Pe ae NO selber e Inspect for internal damage such e Internal damage as seized piston e The ignition switch is e Move switch to ON and re test OFF e Tighten connections or replace Is there spark NO e Faulty ignition ground ground wire e Faulty spark plug lead e Repair or replace spark plug lead e Faulty ignition coil e Replace ignition coil e Plug is soaked with fuel e Dry plug expel excess fuel from cylinder and crankcase ls the spark plug firing NO W s der he e
2. 23 This section covers carburetor tuning Included in this section are basic settings idle speed adjustment and complete adjustment peen set at the factory tor optimal performance and compliance to emissions standards However minor adjustments may be required in certain conditions such as high elevation NOTES e These saws are equipped with an electronic speed limiter as part of the ignition system This will prevent the saw from going above 12 000 RPM Attempting to set the carburetor mixture to increase the speed or power beyond this limit may seriously damage the engine e 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 525747 REV12Sep2012 TI 23 CARBURETOR TUNING 680GC SERVICE MANUAL 23 1 Basic Setting H 2 1 4 2 3 8 turns from closed L 1 1 4 to 1 3 8 turns from closed Complete carburetor readjustment 23 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 pul
3. 680GC SERVICE MANUAL 13 CYLINDER amp PISTON CYLINDER amp PISTON 13 This section covers the removal inspection and assembly of the cylinder piston and related components Removal of several component groups is required Refer to sections 5 6 10 and 12 if necessary NOTE When replacing the 680GC cylinder and piston it is necessary to tune the carburetor prior to returning the saw to service See section 23 13 1 Remove carburetor base screws A Remove carburetor base from rear manifold Push rear manifold through carburetor base while holding carburetor base B Remove carburetor base from pulse tube 19 2 Remove pulse tube and protective spring from cylinder base AN BEE ae OT L 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 49 13 CYLINDER amp PISTON 680GC SERVICE MANUAL 13 3 Remove rear manifold clamp 13 4 Remove rear manifold from cylinder A Inspect for holes and tears in the manifold replace if damaged 13 5 Remove cylinder screws 4 and wave washers 13 6 Remove cylinder A Remove cylinder gasket and clean crankcase mating surface 50 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 13 CYLINDER amp PISTON CYLINDER amp PISTON 13 7 Remove wrist pin retaining clips 2 13 8 Pr
4. When the carburetor is adjusted correctly set the limiter caps securely onto the needle screws with a straight blade screwdriver 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 19 24 IDLE SPEED ADJUSTMENT 680GC SERVICE MANUAL 24 This section covers idle speed adjustment 24 1 If engine stops while idling A Make sure the chain is properly tensioned B Turn T screw clockwise until chain begins to move C Back T screw out 1 2 turn 24 2 If chain turns at idle Back T screw out until chain stops moving 80 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 25 DIAGRAMS CHECK POSSIBLE CAUSE REPAIR Clean or replace the air filter e Dirty or clogged air filter Inspect air intake sysetm for water The engine runs rough at e Water has been ingested Inspect fuel system for water all speeds e Loose or dirty spark plug Tighten clean or replace spark plug e Operator is overworking the saw e Carburetor mixture is too lean e Incorrect fuel oil ratio e Flywheel fins are clogged e Air deflector is missing e 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
5. SERVICE MANUAL 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL TABLE OF CONTENTS SECTION SECTION TITLE PAGE NUMBER SERVICE MANUAL USE 2 1 TOOLS 3 Z SAVV SPECIFICATIONS 4 3 SERIAL NUMBER LOCATION 5 4 SPARE PARTS DIAGRAM TORQUE AND LOCTITE 6 5 AIR INTAKE 25 6 SPARK PLUG Zi T CLUTCH amp RIM SPROCKET 29 8 STARTER SYSTEM 33 9 WALLWALKER 38 10 CYLINDER COVER 40 11 MUFFLER 43 12 CARBURETOR 4 13 CYLINDER amp PISTON 49 14 WATER HOSE amp CAP 98 19 IGNITION COIL 60 16 FLYWHEEL 62 17 BOTTOM GUARD 64 18 FRONT HANDLE 65 19 FUEL TANK 66 20 CRANKCASE 67 21 BAR STUDS amp BAR PAD 13 22 CHAIN TENSIONER 76 23 CARBURETOR TUNING TT 24 IDLE SPEED ADJUSTMENT 80 25 TROUBLESHOOTING DIAGRAMS 81 26 TROUBLESHOOTING FUEL SYSTEM LEAKS 83 ZY TROUBLESHOOTING CRANKCASE LEAKS 85 APPENDIX 1 SPARK PLUG REFERENCE GUIDE 86 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 1 SERVICE MANUAL USE 680GC SERVICE MANUAL Service Manual Use This manual contains all the technical information necessary for carrying out repairs on the 680GC 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 e Always use the right tools for the job otherwis
6. x pres Termine xr 9 o ee xf x rs pin nor SS H 2 parernoseorne x x _ prue o WATER SHUTOFF VANE x x sa eme HT x ru as fuse oss o ose came x x os ar ROSE HANGER xx ra WATER Hose cover x x _ prue o WATER HOSE SCREW x x or ame ae o Femme TTT H H pres a 2 xx a WareRTankcap x x jo pres as Furtcaporne x x H o o a fus Sx x I mu prin o eme x tar ar pane xx ee za HOSE HANGERBUTTON x x Com 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 2 4 SPARE PARTS DIAGRAM 680GC SERVICE MANUAL SIDE COVER ASSEMBLY For saws with serial number starting 967 amp 977 14 wer DESCRIPTION oe pa PART NUMBER SIDE COVER INSERT TOP m es a 71534 ego COVER CAP ALLWALKER SIDE ARM ALLWALKER SIDE ARM SCREW SIDE COVER PLATE LOWER GUARD SIDE COVER INSERT BOTTOM REAR SIDE COVER INSERT TOP REAR RUBBER BUMPER COVER SIDE COVER ASSEMBLY COMPLETE 22 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM CARBURETOR REPAIR KIT For saws with serial number starting 967 amp 977 5 SE Ke DESCRIPTION pS etl PART NUMBER i CARBURETOR WALBRO WJ 122B im is a 528628 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 23 RG 6
7. 6 Pack Not Shown 505883 2 Stroke Oil 25 1 Mix 5 2 oz 158 ml 24 Pack 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 3 2 SPECIFICATIONS 680GC SERVICE MANUAL Specifications Engine Type 2 stroke Single Cylinder Air Cooled Displacement 4 7 cu in 76 5 cc Horsepower 5 hp 3 7 kW 9 500 rpm Torque 36 3 in lbs 4 1 Nm 6 500 rpm 11 500 500 rpm max 2 800 3 200 rpm idle 21 lbs 9 5 kg without guidebar and diamond chain 18 inches 46cm length 11 5 inches 29cm height 10 inches 25cm width Engine Speed Weight Dimensions Air Filter Water resistant polyester Carburetor Walbro WJ122B Starter Dust and water resistant a Special water resistant electronic Ignition ignition Clutch Centrifugal three shoe single spring Fuel ratio 25 1 4 gasoline to oil Fuel Capacity 0 23 gal 88 liter Water Supply Minimum 20 psi 1 5 bar Water Flow Minimum 2 gpm 8 Ipm Noise Level 101 dB at 3 ft 1m 7 2 mis front handle 8 5 m s rear handle One tank without cutting cycling throttle NGK BPMR8Y Electrode gap 020 in 0 5 mm Vibration Level Engine Break in Period Spark Plug 4 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 3 SERIAL LOCATION 3 This section shows the two locations of the serial number 2011 ICS B
8. REMOTE OO RER a BREATHERTUBEEXTENSION S S rare s poscam O Ooo or 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 1 F 4 SPARE PARTS DIAGRAM 680GC SERVICE MANUAL FUEL TANK AND HANDLE ASSEMBLY For saws with serial numbers starting 977 see page 17 for serial number starting 967 TORQUE KEY DESCRIPTION A A LOCTITE PART NUMBER in lbs 242 Nm 1 Emwee TTT See 2 MREARHANDLE KAF O I ames a FUELCAPORING 8 TRIGGER LOCKOUT LEVER 9 TRIGGER LOCKOUT LEVER SPRING 78 FUEL BREATHER REMOTE 1 8 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM AIR INTAKE ASSEMBLY For saws with serial numbers starting 967 see page 20 for serial number starting 977 x bn i a h e 7 oo L l e v E Lil D i 16 i we EA A ee S A A a eT ee 2 WIRFILTERCANISTER POLYESTER rmm a rrmercover O a a FILTER COVER SCREW SSES RER 5 FILTER SUPPORT AAA a e FILTER COVER GASKET LL HT ES Ee HEAD 71771 8 PREFILTER PLASTIC SECONDARY FILTER NN 73386 10 _ FILTER SUPPORT SCREW as 2 x rar FILTER CANISTER GASKET AAA ees iz formo ar a rose came el TI 1 TC mme 14 COMPENSATOR TUBE LE RTT C _ H pys e H H H H er 2011 ICS Blount Inc Specifications
9. 13 19 A Oil piston with ICS 2 stroke oil B Align wrist pin with wrist pin bearing C Complete wrist pin installation D Install second wrist pin retaining clip AA 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 525747 REV12Sep2012 94 680GC SERVICE MANUAL 13 CYLINDER amp PISTON CYLINDER amp PISTON 12 a We l 13 20 Install cylinder A Lubricate cylinder bore with ICS 2 stroke Sr A oil 5 gjase B Compress rings vvith ring compression tool C Slide cylinder onto piston pushing ring compression tool down 13 21 Install cylinder A Remove ring compression tool B 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 B Torque bolts to 95 in lbs 10 7 Nm 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 5 5 13 CYLINDER amp PISTON 680GC SERVICE MANUAL 13 23 Install rear manifold A Lubricate rear manifold with ICS 2 stroke oil B Push rear manifold onto cylinder intake C Align rear manifold seam with cylinder and crankcase seam 13 24 Install rear manifold clamp A Torque to 11 in lbs 1 2 Nm A Do not over tighten damage to rear manifold ma
10. Clean and re gap the plug to properly SEE N 0 020 inch 0 05 mm WEN e Replace with the correct plug the wrong type p pig see Spark Plug Reference Guide e Loose spark plug Insure cylinder e If below 125 psi excess e Tighten plug and re test compression is above NO vvear on the piston e Replace piston and cylinder 125 psi cylinder rings and or e Ensure correct fuel oil mixture ES improper fuel mixture 25 1 e Fuel is old varnished or e Empty tank and re fill with fresh D e Clogged fuel filter e Replace fuel filter Is the fuel reaching the e Damaged fuel line e Replace fuel line NO e Damaged pulse tube e Replace pulse tube e Plugged fuel tank e Repair or replace fuel tank breather breather e Carburetor is tuned e Refer to Carburetor Tuning incorrectly section e Plugged fuel tank e Repair or replace fuel tank breather breather Is too much fuel reaching the carburetor NO Is the flywheel key l YES Loose flywheel Replace key and reinstall flywheel 82 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 26 FUEL SYSTEM LEAKS 26 This section covers testing the fuel system for leaks Engine starvation can result from a leak or malfunction of any of the main components of the fuel system The five main components are the fuel tank fuel tank breather fuel filter delivery tubes and carbur
11. 2 680GC SERVICE MANUAL 18 FRONT HANDLE FRONT HANDLE 18 This section covers the removal inspection and installation of the front handle 18 1 Remove front handle screws on right side 18 2 Remove front handle screws on bottom 18 3 Install front handle A Roll front handle into place B 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 525747 REV12Sep2012 65 19 FUELTANK 680GC SERVICE MANUAL 19 This section covers the disassembly inspection and assembly of the vibration isolators fuel tank and rear handle 19 1 Remove vibration isolator screws and wave washers on clutch side of saw 19 2 Remove vibration isolator screws and wave washers on flywheel side of saw 66 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL ERIC 19 3 Separate crankcase and fuel tank NOTE Saws have a rubber water deflector connected to the 2 bottom vibration isolators on the clutch side circled 19 4 Remove vibration isolators from fuel tank 6 if necessary Shock absorber tool p n 71546 should be used for removal and installation 19 5 Assemble in reverse order NOTE During assembly be careful to avoid kinking the fuel line 2011 ICS Blount Inc Specifications
12. 25747 REV12Sep2012 VW A3 eme ETM alas 928653 930469 531107 15 4 SPARE PARTS DIAGRAM 680GC SERVICE MANUAL CRANKCASE ASSEMBLY For saws with serial numbers starting 977 see page 15 for serial number starting 967 Me Il ES re III Se SSES HH a II H LI mer II mm Y ss ra x E i a x 1 8 TORQUE TORQUE T LOCTITE ART NUMBER 242 X X 9 4 ne 1a rs o f oa TI Dm Les TI e IL me sn E 73955 1 6 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM FUEL TANK AND HANDLE ASSEMBLY For saws with serial numbers starting 967 see page 18 for serial number starting 977 11 AAA C 2 REARWANDLEMALF HH amos Cs bew OO oO J H H H e a jmrormeveve O O o O oa VS FUEL CAP ASSEMBLY WTH OUTER SEALRING TI son 6 Fuetcaporne as Co former ll o 1 a fTRIGGERLOcKOUTLeveR lo sem o TRIGGER LOCKOUTLEVERSPRNG IT e berg OO O ar Con bew OOO oO rr 12 Foie O O O JO OOO ao TIS ZT HTH T H H TC Dee nu BER ll rs 15 SHOCK ABSORBER REAR HANDLE II mg 16 BUMPER SHOCK ABSORBER FUEL TANK TOP LL AT FRONT HANDLE Bor e a x IT ee me Forma os me FOEL BREATHER COMPLETE H IT r ATER DEFLECTOR BOTTOM T f rme a prearmen TUBE sooy ll TC mm e pREATHERTUBEELBOW Ll rm 23 FUEL BREATHER
13. 7 8 Nm NOTE The 3 remaining crankcase bolts will be installed during the completion of the assembly 20 22 Install flywheel side crankcase seal tap with bearing driver and mallet 20 23 Trim crankcase gasket flush 74 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 21 BAR STUDS 8 BAR PAD BAR STUDS amp BAR PAD 21 This section covers the removal and installation of the bar studs and bar pad 21 1 Remove bar studs A Remove side cover B Install side cover nuts flange to flange and tighten together C Attempt to remove the inside nut which should pull out the bar stud D Repeat on the second bar stud 21 2 Remove bar pad A Remove sealing o ring 21 3 Assemble in reverse order 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 15 22 CHAIN TENSIONER CHAIN TENSIONER 680GC SERVICE MANUAL 22 This section covers the removal and installation of the chain tensioner 22 1 Remove bar plate to expose the chain tensioner 22 2 Unscrew tensioner to remove A Remove tensioner pin B Remove tensioner screw keeper 22 3 Assemble in reverse order 76 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 23 CARBURETOR TUNING
14. 80GC SERVICE MANUAL This page intentionally left blank 24 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 9 AIR INTAKE 5 This section covers the disassembly inspection and assembly air induction system 9 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 5 9 Clean filter with cleaning solution and a nylon brush A Clean filter with cleaning solution and water B Let dry and reinstall 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 25 5 AIRINTAKE 0 680GC SERVICE MANUAL 5 4 Inspect air filter cover gasket A Replace if permanently depressed or hard due to slurry 5 5 Inspect filter canister gasket A Clean B Replace if necessary 9 6 Check air filter mount screws and lightly secure them if they are loose 26 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 6 SPARKPLUG SPARK PLUG 6 This section covers the removal inspection and installation of the spark plug 6 1 Remove spark plug cap and spring spring is located inside of the cap 6 2 Loosen and remove the spark plug 6 3 Inspect spark plug for damage or corrosion Clean
15. A6 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 12 CARBURETOR CARBURETOR 12 This section covers the removal and insallation of the carburetor Removal of the air intake components and cylinder cover is required Please refer to section 5 10 or 11 if necessary Carburetor tuning is covered in section 23 NOTE All saws are equipped with carburetor model WJ 122B 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 choke lever split pin 12 3 Remove choke lever 12 4 Remove adjustment screw boot 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 AY 12 CARBURETOR CARBURETOR 680GC SERVICE MANUAL 12 5 Remove carburetor support screw 1 with 4 Torx or straight blade screwdriver 12 6 Remove carburetor body screws 2 12 7 Remove fuel line 12 8 Remove pulse tube 12 9 Remove carburetor compensator tube on top of carburetor 12 10 Assemble in the reverse order A Torque carburetor body screws to 43 in los 4 9 Nm B Torque supporter screw with blue Loctite to 43 in lbs 4 9 Nm 48 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012
16. ANUAL CLUTCH ASSEMBLY For saws with serial number starting 967 amp 977 TORQUE i KEY DESCRIPTION TORQUE _ LOCTITE PART NUMBER Nm Lines 242 1 JOUTER CRANKCASE SEAL CLUTCH SIDE a e A 73931 IO E EC A aj ST S ie O 2908 BEES AM ME IN A 73940 173285 533 14 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM CRANKCASE ASSEMBLY For saws with serial numbers starting 967 see page 16 for serial number starting 977 13 DESCRIPTION 1 FUELLINE GROMMET CRANKCASE 285 CRANKCASE ASSEMBLY RIGHT 8 LEFT MI RANKCASE DOWEL PIN RANKSHAFT BEARING HOKE LEVER SPLIT PIN RANKCASE GASKET RANKCASE BOLT ASHER HAIN GUARD AR MOUNT PAD SPACER OVER GUARD MOUNTING BOLT CREW AR MOUNTING STUD CREW AR MOUNT PAD COVER PLATE REMIUM TENSIONER KIT ENSIONER SCREW RETAINER HOKE LEVER RANKCASE GROMMET RIGHT SIDE HOKE LEVER BUSHING OJO d N 8 O w O CRANKCASE DOWEL CNL CRANKSHAFTBEARING CHOKE LEVER SPLIT NI CRANKCASE GASKET 1 WASHER SO GHAN GUARD Y BAR MOUNT PAD SPACER LI COVER GUARD MOUNTINGBOLT 78 BAR MOUNTING STUD ns BARMOUNTPADCOVERPLATE PREMIUMTENSIONERKIT J TENSIONER SCREW RETAINER 1 CHOKE LEVER o o CRANKCASE GROMMET RIGHT SIDE Ir CHOKE LEVER BUSHING LI 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 5
17. Slowly rotate pulley counter clockwise until spring pressure is released Use thumb as brake 8 5 Remove starter pulley screw and washer NOTE Hold starter cover firmly 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 33 8 STARTER 680GC SERVICE MANUAL 8 6 Remove starter pulley gt ort ZS 8 Inspect coil spring A Replace if spring hook is damaged Attemping to re bend the spring hook may cause the hook to break off B Carefully remove coil spring and housing to prevent spring from unwinding 8 8 Lubricate with lightweight oil 8 9 Replace parts carefully 34 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL B STARTER 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 Install pulley A Wind rope onto pulley clockwise leaving 4 6 10 15 cm out B Make sure that the pulley spring catch is in the spring hook 8 13 Install center screw spacer and washer A Use Loctite 242 B Torque to 26 in lbs 2 9 Nm 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 35 8 STARTER 680GC SERVICE MANUAL 8 14 Wind the recoil spring A Line rope up with no
18. all bottom 2 muffler support screws with Loctite 242 C Torque top screws to 78 in lbs 8 8 Nm D Torque bottom screws to 52 in lbs 5 8 Nm 44 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL M MUFFLER 11 This section covers the disassembly inspection and assembly of the muffler Removal of the WallWalker and cylinder cover is necessary Refer to sections 7 and 10 if necessary or saws with serial number starting 977 for saws with serial number starting 967 see pages 43 44 11 1 Remove muffler support screws 11 2 Remove muffler screws located inside the muffler 11 3 Remove muffler and heat shield gasket A Replace any damaged components P LI U ih 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 45 14 MUFFLER 680GC SERVICE MANUAL or saws with serial number starting 977 for saws with serial number starting 967 see pages 43 44 Install muffler 11 4 A Insert muffler screws 2 into muffler B Hold muffler screws in place with heat shield gasket C 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 A Torque top screws to 78 in lbs 8 8 Nm B Torque bottom screws to 52 in lbs 5 8 Nm
19. and pricing are subject to change without notice P N 525747 REV12Sep2012 1 9 4 SPARE PARTS DIAGRAM AIR INTAKE ASSEMBLY 680GC SERVICE MANUAL For saws with serial numbers starting 977 see page 19 for serial number starting 967 OKEY E ERETON TORQUE o E CYLINDER COVER ASSEMBLY AIR FILTER CANISTER POLYESTER AIR FILTER COVER FILTER COVER SCREW FILTER SUPPORT FILTER COVER GASKET SCREW CYLINDER COVER LONG SOCKET HEAD A e O A PLASTIC SECONDARY FILTER SS AIR FILTER FLANGE 10 JFILTER SUPPORT SCREW 11 FILTER CANISTER GASKET 12 O RING 13 TUBE CLAMP COMPENSATOR TUBE ie 15 BREATHER GROMMET 16 THROTTLE ASSEMBLY 17 O RING AIR FILTER ASHER 11771 Nm ks AR IL PE SS a E S SE IL mm as x a S mes LL mm IL mme IL Les 7 am mme IL mme IL mm LL me 20 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM WALL WALKER AND WATER DELIVERY SYSTEM il Gi p weg fak For savvs vvith serial a Se e SA i number starting 967 8 977 a A e a 16 e W E 9 ew a 9 16 WC Kei 13 S j T SERIAL NUMBER KEY DESCRIPTION STARTING pe PART NUMBER 967 977 Nm linibs 242 AA I ro ye a hawe cover I el el 71582 a fouaro Flap clamp Joti O oe 4 korevevashr x x aos 6 waster x x _ pren varo ruxp sekoer xx e WATER HOSE casket
20. and pricing are subject to change without notice P N 525747 REV12Sep2012 67 20 CRANKCASE CRANKCASE 680GC SERVICE MANUAL 20 This section covers the removal inspection and assembly of the crankcase seals and crankshaft bearings 20 1 Remove outer crankshaft seal housing screws and wave washers 20 2 Remove crankcase bolts 20 3 Heat the flywheel side crankcase with heat gun for 5 minutes approximately 150 F 65 5 C 68 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 20 CRANKCASE CRANKCASE 20 4 Remove the flywheel side crankcase tap crankshaft with plastic mallet A Suspend above work surface B Tap with mallet NOTE A nut should always be placed on a threaded shaft when pounding or pressing on it 20 5 Remove the flywheel side crankcase seal with 1 2 13 mm socket 20 6 Heat the clutch side crankcase with heat gun to 150 F 65 5 C 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 69 20 CRANKCASE CRANKCASE 680GC SERVICE MANUAL 20 7 Remove crankshaft from the clutch side crankcase tap crankshaft with a plastic mallet A Suspend above work surface B Tap with plastic mallet 20 8 Remove the bearing from the flywheel side of crankshaft 20 9 Remove the bearing seal and bushing from the clutc
21. ce P N 525747 REV12Sep2012 680GC SERVICE MANUAL 10 CYLINDER COVER CYLINDER COVER 10 7 Remove stop switch leads 10 8 Inspect cylinder cover for damage A Replace if necessary 10 9 Check cylinder cover water seal and filter cover gasket are in place and in good condition A Replace if necessary 10 10 Reassemble stop switch leads 10 11 Make sure carburetor screw boot is in place 10 12 Lubricate compensating tube and fuel tank breather tube with soapy water guide through cylinder cover install compensating tube first NOTE Be careful as to not pull tubes away from their point of connection Approximately 3 4 2 cm of tube should protrude from cylinder cover 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 41 10 CYLINDER COVER CYLINDER COVER 680GC SERVICE MANUAL 10 13 Install cylinder cover A Pull spark plug lead into slot in cylinder cover B Align throttle linkage with cylinder cover and crankcase C Push the cylinder cover down on the crankcase guide intake manifold into cylinder cover D Install the cylinder cover screws Use Loctite 242 Torque to 35 in lbs 4 0 Nm E Install fuel tank breather and clamp 10 14 Install air filter mount A Guide carburetor compensating tube through air filter mount Make sure manifold sits flat over lip on cylinder cover B Install air filter mount scr
22. e components may be damaged e Use a plastic dead blow mallet to separate parts attached solidly to each other e Mark mating parts as a reassembly reference e Keep component parts together as a group Assemble screws and nuts into appropriate Subgroups e When reassembling clean all parts carefully lubricate moving parts and replace all oil seals O rings gaskets washers and self locking nuts e For best results use only original ICS replacement parts General Recommendations e Some procedures in this manual require the use of special tools A complete tool kit for the 680GC is available from ICS e 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 2 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 1 TOOLS 680GC Service Tool Kit P N 71700 Key _ Part No Description Above 71700 Gas Saw Service Tool Kit includes all items shown above 4 71521 Scrench 13 19 mm 2 71541 Pressure Gauge Bulb 8 71542 CoilFlywheel Timing Shim 4 71543 Cylinder Assembly Clamps amp Piston Stop Manifold Assembly Tool 6 71546 Shock Absorber Tool e HIRR Flywheel Disassembly Tag EIS Jomiter Cap Puner Not Shown 71734 Joasket Set Not Shown 1505882 2 Stroke Oil 25 1 Mix 5 2 oz 158 ml
23. ess wrist pin out with an 8mm deep socket 1329 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 525747 REV12Sep2012 51 13 CYLINDER amp PISTON CYLINDER amp PISTON 680GC SERVICE MANUAL 13 11 Cylinder gasket A Oil gasket with ICS 2 stroke engine oil B Install and align holes and notch 13 12 Install wrist pin bearing in rod A Oil bearing with ICS 2 stroke engine oil 13 13 Install rings Install bottom ring first Installing the 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 525747 REV12Sep2012 52 680GC SERVICE MANUAL 13 CYLINDER amp PISTON CYLINDER amp PISTON 13 14 Ring orientation 13 15 Install 1 wrist pin retaining clip 13 16 Make sure wrist pin retaining clip is in the proper orientation A Improper installation may result in serious engine damage 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 53 13 CYLINDER amp PISTON 680GC SERVICE MANUAL 13 17 Partially install wrist pin A 13 18 L mg i e A EXHAUST Align piston in correct orientation SHIH Pe d 7 Le to ege Li a A b il Lee in D t E gengt E INTAKE
24. etor 26 1 I Remove and inspect the fuel filter A Replace the fuel filter if there is any foreign material in the felt or the internal screen 26 2 Test the main fuel pick up tube for leaks A Install the pressure gauge and bulb B Pressurize the tube to 7psi 0 5 bar C If the pressure does not maintain separate the fuel line from the carburetor D Plug one end of the main fuel pick up tube E Re pressureize 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 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 83 26 FUEL SYSTEM LEAKS 680GC SERVICE MANUAL 26 3 The fuel tank breather stabilizes the pressure in the fuel tank preventing both excessive pressure which could flood the engine and negative pressure which could starve the engine of fuel 26 4 Fuel tank breather is located inside the air filter compartment 26 5 Testing the fuel tank breather A Attached the pressure gauge and bulb to the main fuel pick up tube at the carburetor Pressurize the tube to 4 5 psi 0 3 bar B The pressure should reduce to nearly 0 psi 0 bar over about 3 seconds 26 6 If the pressure does not reduce to 0 psi disassemble or replace the brea
25. ews 3 using Loctite 242 C Torque to 43 in lbs 4 9 Nm 10 15 Install air filters and cover A Install pre filter B Install clean air filter C Install air filter flange and tighten D Install air filter cover and tighten 4 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 11 This section covers the disassembly inspection and assembly of the muffler Removal of the WallWalker and cylinder cover is necessary Refer to sections 7 and 10 if necessary For saws with serial number starting 967 for saws with serial number starting 977 see pages 45 46 11 1 Remove muffler support screws 11 2 Remove muffler screws and serrated washers located inside the muffler 11 3 Remove muffler and heat shield gasket A Replace any damaged components 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 43 1 MUFFLER 0 680GC SERVICE MANUAL per starting for saws with serial number starting 977 see pages 45 46 11 4 Install muffler A Insert muffler screws and serrated washer 2 into muffler B Hold muffler screws in place with heat shield gasket C Thread muffler screws into cylinder torque to 78 in lbs 8 8 Nm 11 5 Install muffler support A Install top 3 muffler support screws and serrated washer finger tight B Inst
26. h side of crankshaft 70 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 20 CRANKCASE CRANKCASE 20 10 Clean mating crankcase faces 20 11 Heat crankcase halves to 150 F 65 5 C 20 12 Install bearing into crankcase halves 20 13 Tap with bearing driver and mallet 20 14 Repeat with other half 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 TA 20 CRANKCASE CRANKCASE 680GC SERVICE MANUAL 20 15 Install crankshaft into clutch side of case 20 16 Place clutch side crankcase seal on crankshaft A Tap lightly with bearing driver and mallet 20 17 Coat crankcase gasket with ICS 2 stroke engine oil 12 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 20 CRANKCASE CRANKCASE 20 18 Align crankcase gasket on flywheel side crankcase pins 20 19 Place crankcase halves together and align crankcase pins 20 20 Assemble crankcase halves tap with bearing driver and mallet 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 73 20 CRANKCASE CRANKCASE 680GC SERVICE MANUAL 20 21 Install main crankcase bolts A Use Loctite 242 B Torque to 69 in lbs
27. icing are subject to change without notice P N 525747 REV12Sep2012 4 SPARE PARTS DIAGRAM MUFFLER ASSEMBLY 680GC SERVICE MANUAL For saws with serial numbers starting 967 see page 12 for serial number starting 977 TORQUE DESCRIPTION SSe E PART NUMBER CYLINDER TO MUFFLER GASKET aa S ERRATED WASHER MUFFLER ASSEMBLY MUFFLER MOUNTING SCREW SECH 1 1 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM MUFFLER ASSEMBLY For saws with serial numbers starting 977 see page 11 for serial number starting 967 TORQUE KEY DESCRIPTION EISES Mm in lbs 242 kytiNDERTO MUFFLER Gasket sera DIS a EI Losas 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 1 2 680GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM CRANKSHAFT ASSEMBLY For saws with serial number starting 967 amp 977 e 8 Ga DESCRIPTION E pd PART NUMBER CRANKSHAFT SEAL FLYVVHEEL SIDE Dn rb 242 73877 3 KRANKSHAFT FLYWHEELWOODRUFFKEY O ree a IGRANKSHAFTAssems tv T TTS 5 _ WRISTPINNEEDLEBEARNG free 6 CRANKSHAFT SEAL CLUTCH SIDE e 7 GRANKSHAFT Bushne C re 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 1 3 4 SPARE PARTS DIAGRAM 680GC SERVICE M
28. le in reverse order 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 59 15 IGNITION COIL 680GC SERVICE MANUAL 15 This section covers the removal inspection and installation of the ignition coil Removal of the starter is required Refer to section 8 if necessary 15 1 Remove starter flywheel shroud by unhooking wires 15 2 Remove ignition coil screws wave washers and plain washers 15 3 Remove ignition coil 15 4 Inspect A Look for cracks missing insulation B Clean flywheel magnets and coil if rusty 60 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 15 IGNITION COIL 19 0 Install ignition coil A Place ignition coil shim 0 012 B Set ignition coil in place C Install ignition coil screws wave washers and plain washers with Loctite 242 D Holding shim rotate flywheel magnet around to coil E Torque ignition coil screws to 26 in lbs 3 Nm F Remove shim rotate flywheel to check clearance 15 6 Install flywheel shroud 15 7 Route 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 525747 REV12Sep2012 61 16 FLYWHEEL 680GC SERVICE MANUAL 16 This section cove
29. ler shaft D Unscrew the puller screw 1 4 turn and pull straight out Repeat for second limiter Cap 23 3 Using a 5 64 straight blade screwdriver gently turn the adjustment screws clockwise until completely closed 23 4 Set the adjustment screws at the basic setting see section 23 1 The side cover must be held tightly in place with the side cover nuts using a bar and no chain Failure to follow this procedure may result in personal injury and or damage to the saw RPM settings for saws NOTE Saw tuned without chain installed Idle Speed 3 000 200 rpm Full Throttle 11 500 500 rpm 78 O 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 23 CARBURETOR TUNING CARBURETOR TUNING 23 5 Start the saw and warm up the engine 23 6 With a tachometer check the saw rpm with a j ADG L bar and no chain Idle 3 000 200 rpm If the idle rom does not fall into this range adjust the T screw clockwise to raise rpm counterclockwise to lower rpm 29 1 With a tachometer check the saw full throttle rom with no bar and chain Target 11 500 500 rom 23 8 If the full throttle falls below this range turn the H screw in clockwise 1 16th of a turn at a time A Pulse the throttle to help stablize the system dh Do not hold the savv at max rpm for more than 5 seconds or cylinder damage could occur 23 9
30. llWalker Assemble in reverse order 38 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 9 WALLWALKER WALLWALKER 9 4 Remove guard flap screws and washers 9 5 Remove and inspect guard flap A Replace the flap if it is torn or damaged in any way 9 6 Reassemble in the reverse order A Install guard flap screws and washers B Use blue Loctite 242 C Torque to 43 in lbs 4 8 Nm L d 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 39 10 CYLINDER COVER CYLINDER COVER 680GC SERVICE MANUAL 10 This section covers the disassembly and assembly of the cylinder cover Removal of the air intake components and front handle is necessary Refer to sections 1 and 14 if needed 10 1 Remove the air filter mount screws 10 2 Remove the cylinder cover screws 3 10 3 Remove spark plug lead from cylinder cover 10 4 Remove fuel tank breather cap and clamp 10 5 Partially remove intake manifold from cylinder cover 10 6 Remove cylinder cover A 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 40 2011 ICS Blount Inc Specifications and pricing are subject to change without noti
31. lount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 5 4 SPARE PARTS DIAGRAM 680GC SERVICE MANUAL 4 This section covers torque Loctite and lubrication requirements of the individual components STARTER ASSEMBLY For saws with serial number starting 967 amp 977 KEY DESCRIPTION 1 SCREW STARTER ROPE HANDLE STARTER ROPE STARTER COIL SPRING amp HOUSING STARTER CASE PLATE CREW STARTER PULLEY WASHER STARTER PULLEY SCREW STARTER COVER ASSEMBLY STARTER ASSEMBLY WASHER SPRING HOUSING WASHER 43 STARTER ASSEMBLY CAP o2 WEG KE O5 E 7 STARTER ROPE PULLEY A MEE ot CH 2 3 4 5 T 1 1 1 0 1 2 3 6 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM FLYWHEEL amp STARTER PAWL ASSEMBLY For saws with serial numbers starting 967 see page 8 for serial number starting 977 K DESCRIPTION E E PART NUMBER Tee Sms Le Ten ram TI Soe 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 T 4 SPARE PARTS DIAGRAM 680GC SERVICE MANUAL FLYWHEEL amp STARTER PAWL ASSEMBLY For saws with serial numbers starting 977 see page 7 for serial number starting 967 DESCRIPTION BORE SE PART NUMBER KEY K We Jindbs RSR
32. powes RER ss 2 TESTS TS NE 20 sms a STARTERPAWLASSEMeLY sos 8 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM CYLINDER AND INTAKE ASSEMBLY For saws with serial numbers starting 967 see page 10 for serial number starting 977 Nm 242 1 INTAKE MANIFOLD CLAMPS N T 3 WRISTPINNEEDLEBEARING 4 COMPLETE PISTONCYLINDERASSEMBDY 5 CYLINDER BASE GASKETASSEMBLY 6 bareu T x 18 CARBURETOR PULSE TUBE SE e CARBURETOR Waow LI BECH wm 243 95 35 113 O a JINTAKE MANIFOLO FLANGE Ll 22 INTAKE maniFoco OJ U 28 CARBURETORSPRING OS 24 b s TJ e Fouss T C bew Oo ar Emma O J 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 9 4 SPARE PARTS DIAGRAM CYLINDER AND INTAKE ASSEMBLY 14 680GC SERVICE MANUAL For saws with serial numbers starting 977 see page 9 for serial number starting 967 1 3 5 6 9 10 12 13 LI CN Es A Y i z i PRS pi r EA E TORQUE R DESCRIPTION TORRE pi PART NUMBER SCREW 4 WASHER 15 CYLINDER BOLT COMPLETE PISTON CYLINDER ASSEMBLY GASKET BASE RIST PIN NEEDLE BEARING 10 42 DES H ow rr ms Ta Te SSES Sex es IS S Lee e SSES TI es 39 35 243 99 2011 ICS Blount Inc Specifications and pr
33. rs the removal inspection and installation of the flywheel Removal of the starter and spark plug is requried 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 1 2 turns leaving approximately 1 8 inch 5 mm space between tool and flywheel 62 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC 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 woodruff key 16 8 Install flywheel plain washer wave washer and flywheel nut A Torque nut to 260 in lbs 29 3 Nm 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 63 17 BOTTOM GUARD BOTTOM GUARD 680GC SERVICE MANUAL 17 This section covers the removal inspection and installation of the bottom guard A Remove bottom guard screws and split washers B Inspect bottom guard C Replace if damaged D Assemble in reverse order 64 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep201
34. s 30 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 7 CLUTCH A RIM SPROCKET CLUTCH amp RIM SPROCKET 1 1 Assemble clutch shoes as shown 78 Finish installation of clutch shoe as shown 7 9 Inspect the rim sprocket for wear A Replace if the rim sprocket teeth are worn to points as shown on right 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 31 7 CLUTCH amp RIM SPROCKET CLUTCH amp RIM SPROCKET 680GC SERVICE MANUAL 7 10 Clean and Assemble A Clean all parts in solvent B Grease clutch cup bearing with a waterproof grease C Assemble clutch spacer washer bearing clutch cup with rim sprocket and inside clutch spacer washer 7 11 Install clutch Torque to 295 in lbs 33 3 Nm Left hand threads 32 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 8 STARTER _ STARTER 8 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 B Line rope up with notch on pulley C
35. t to change without notice P N 525747 REV12Sep2012
36. tch on pulley B Rotate the pulley with the rope clockwise 5 times C Untangle rope and release 8 15 Assemble starter cord shield um 8 16 Remove starter pawl screws pawls spring and plain washer NOTE Piston stop tool may be required to remove the starter pawl screws 8 17 Inspect and clean pawl components A Inspect the components Replace if necessary B Clean the components with a brush and solvent 36 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL B STARTER STARTER 8 18 Assemble components A Make sure the spring is in the correct position B Use Loctite 242 on the pawl screws C Torque to 60 in lbs 6 8 Nm 8 19 Install starter cover A Pull out cord 4 6 10 15cm B Slowly release while placing cover to allow pawls to engage 8 20 Install starter cover screws A Use Loctite 242 B Torque to 60 in lbs 6 8 Nm 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 37 9 WALLWALKER 680GC SERVICE MANUAL 9 This section covers the removal inspection and assembly of the WallWalker and guard flap 9 1 Inspect WallWalker tip A lf the tip is worn as shown replace J2 Remove bar mount pad 9 3 Remove crankcase screws and wave washers Remove WallWalker from saw Install new Wa
37. ther A Clean the parts with solvent or fuel B Assemble in reverse order C Make sure that the spring taper is oriented in the correct direction Narrow end towards the end of the cap SS m an 84 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 27 CRANKCASE LEAKS 27 This section covers testing the crankcase for leaks A leak in the crankcase can cause the engine not to run 27 1 Install the intake seal flange A Plug cylinder pulse tube 21 2 Install the exhaust seal flange 218 Block one of the flange tubes vvith a rubber plug 27 4 Install the pressure gauge and bulb 21 5 Pressurize the crankcase to 7psi 0 5 bar 27 6 If the pressure does not remain the same use soapy water to find the leak NOTE Itis 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 525747 REV12Sep2012 85 APPENDIX 680GC SERVICE MANUAL Spark Plug Reference Guide 914770 RCYJ4 BPMR8Y 86 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL ICS Blount Europe S A Rue Emile Francqui 5 1435 Mont Saint Guibert Belgium Tel 32 10 301 251 Fax 32 10 301 259 icsbestway com 87 2011 ICS Blount Inc Specifications and pricing are subjec
38. with a wire brush 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 21 6 SPARKPLUG SPARK PLUG 680GC SERVICE MANUAL 6 4 Gap if necessary to 0 02 0 5mm NOTE If the spark plug must be replaced refer to the spark plug reference guide at the end of this manual to select the correct replacement plug 6 5 Assemble in the reverse order Make sure the plug boot is seated completely 28 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 7 CLUTCH amp RIM SPROCKET gt CLUTCH amp RIM SPROCKET 7 This section covers clutch removal rim sprocket removal inspection and assembly Refer to sections 5 and 6 if needed 1 1 Insert piston stop tool into spark plug hole 1 2 Pull starter handle until piston stops against tool 1 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 need to be performed 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 29 7 CLUTCH amp RIM SPROCKET CLUTCH amp RIM SPROCKET 680GC SERVICE MANUAL 7 4 Remove all drive components 19 Inspect the clutch shoes for vvear A Replace if the shoe has less than 0 04 1 mm of material as shown 7 6 Inspect spring for crack
39. y cause engine damage 13 25 Install the pulse tube onto cylinder barb 13 26 Install protective spring onto pulse tube ehh 56 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 13 CYLINDER 8 PISTON CYLINDER amp PISTON 13 27 Install carburetor base A Slip pulse tube into and through carburetor base B Slip rear manifold into and through carburetor base C Make sure rear manifold lip is flat 13 28 Install carburetor base screws A Use Loctite 242 on 3 screws without ground wire B Make sure to include stop switch wire installed on left rear screw C Torque to 35 in lbs 4 Nm 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 57 14 WATERHOSE 4 WATER HOSE 680GC SERVICE MANUAL 14 This section covers water hose and water tank cap 14 1 Loosen hose clamp screw 14 2 Remove water connection from hose 14 3 Remove hose from hose hanger 14 4 Remove water hose connector 14 5 Unscrew water tank cap from saw 7 8 wrench 58 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 525747 REV12Sep2012 680GC SERVICE MANUAL 14 WATERHOSE WATER HOSE 14 6 Release water tank cap from water tank tube A Depress orange fitting as shown to release water tank tube 14 7 Assemb

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