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SERVICE MANUAL
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1. SERVICE MANUAL 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL SECTION SECTION TITLE PAGE NUMBER SERVICE MANUAL USE 2 SAW SPECIFICATIONS La SERIAL NUMBER LOCATION 4 SPARE PARTS DIAGRAMS recs 6 WeWm 77000 8 o SPARK PLUG 7 CLUTCH 8 RIM SPROCKET WALLWALKER CYLINDER COVER MUFFLER w ewowco LL NEM NEN FRONT HANDLE FUEL TANK 088 CRANKCASE 8 BAR STUDS amp BAR PAD 88 CHAIN TENSIONER 8 CARBURETOR TUNING IDLE SPEED ADJUSTMENT TROUBLESHOOTING DIAGRAMS UROUMESHODTNGORGRARS 25 TROUBLESHOOTING FUEL SYSTEMTEARS U 35 TROUBLESHOOTING GRANKERSE REFERENCE GUIDE 8 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REVO6012011 1 SERVICE MANUAL USE 660GC SERVICE MANUAL Service Manual Use This manual contains all the technical information necessary for carrying out repairs on the 660GC saw For safe efficient work it is of prime importance that the values indicated be adhered to Routine periodic maintenance is covered in the operator s manual included with each saw General Shop Rules Always use the right tools for the job otherwise components may be damaged Use a plastic dead blow mallet to separate parts attached solidly to each oth
2. 4 BOLT 73940 5 CLUTCH SPACER 505421 6 CLUTCH BEARING 505378 T 8T RIM SPROCKET KIT 70949 8 CLUTCH CUP WITH SPLINED ADAPTOR 505422 9 CLUTCH SPACER INSIDE 505436 10 CLUTCH OON 295 505442 11 CLUTCH SPRING 505434 1 CRANKSHAFT SEAL 505381 2 CRANKSHAFT BEARING 505375 3 CRANKSHAFT ASSEMBLY 505397 4 WRIST PIN NEEDLE BEARING 505403 5 CRANKSHAFT BUSHING X 509487 8 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM MUFFLER ASSEMBLY TORQUE LOCTITE Nm in lbs 242 PART NUMBER DESCRIPTION 505385 1 CYLINDER TO MUFFLER GASKET 2 MUFFLER 537692 3 MUFFLER SCREW amp WASHER 8 8 78 548518f 4 LOWER MUFFLER SCREW 5 8 52 73866 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 9 4 SPARE PARTS DIAGRAM 660GC SERVICE MANUAL CARBURETOR ASSEMBLY KEY DESCRIPTION TORQUE PART NUMBER Nm in Ibs 242 1 SCREW 4 9 43 505469 2 WASHER 73897 3 OUTER INTAKE MANIFOLD 507427 4 OUTER INTAKE MANIFOLD FLANGE SCREW 73901 5 OUTER INTAKE MANIFOLD FLANGE 505384 6 COMPENSATOR TUBE 505382 7 CARBURETOR SPRING 73888 8 CARBURETOR WALBRO 517742 9 PULSE TUBE 71751 10 CARBURETOR MOUNTING BRACKET 505411 11 SCREW 4 0 35 X 73866 12 ADJUSTMENT GUIDE 505391 13 INTAKE MANIFOL
3. 191 Remove outer crankshaft seal housing screws 3 and wave washers 19 2 Remove crankcase bolts 5 60 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 19 CRANKCASE 19 3 Heat the flywheel side crankcase with heat gun for 5 minutes approximately 150 F 65 5 19 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 19 5 Remove the flywheel side crankcase seal with 1 2 13 mm socket i E LH 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 61 19 CRANKCASE 660GC SERVICE MANUAL 19 6 Disassembly of crankcase Heat the clutch side crankcase with heat gun to 150 F 65 5 197 Remove crankshaft from the clutch side crankcase tap crankshaft with a plastic mallet A Suspend above work surface Tap with plastic mallet 19 8 Remove the bearing from the E flywheel side of crankshaft 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 62 660GC SERVICE MANUAL 19 CRANKCASE 19 9 Remove the bearing seal and bushing from the clutch side of crankshaft 19 10 Assembly of crankcase Clea
4. 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 A Install bottom ring first Installing bottom ring over the top ring may cause the ring to break 660GC SERVICE MANUAL 46 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 13 14 Ring orientation NOTE Make sure both piston ring end gaps are correctly oriented over their locating pins in the piston ring grooves 13 15 Install one 1 wrist pin retaining clip 13 16 Make sure wrist pin retaining clip is in the proper orientation Improper installation may result in serious engine damage Never attempt to reuse wrist pin retaining clips or substitute wrist pins from another model or brand Install two new retaining clips with their open ends facing either to the six o clock toward the crankcase or twelve o clock toward the cylinder head position Each retaining clip should produce an audible click as it seats in its groove in the piston 13 CYLINDER amp PISTON 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 47 13 CYLINDER amp PISTON 1317 Lube and partially install wrist pin 13 18 Align piston in correct orientation A Make sure arrow points to exhaust port 13
5. been isolated to the carburetor Refer to the Walbro Diaphragm Carburetor Service Manual The fuel tank breather stabilizes the pressure in the fuel tank preventing both excessive pressure which could flood the engine and negative pressure which could starve the engine of fuel Fuel tank breather is located inside the air filter compartment Testing the fuel tank breather Attach the pressure gauge and bulb to the fuel tank breather Pressurize the tube to 7psi 0 5 bar The pressure should reduce to nearly 0 psi 0 bar over about 3 seconds 660GC SERVICE MANUAL 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 25 FUEL SYSTEM LEAKS 25 6 Ifthe pressure does not reduce to 0 psi disassemble or replace the breather A Disassemble by snapping off cap B Clean parts with solvent or fuel 2 25 7 Assemble in reverse order A Make sure duck bill opens easily B Make sure that the spring taper is oriented in the correct direction C Assemble by snapping cap in place 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 79 26 CRANKCASE LEAKS 660GC SERVICE MANUAL 26 This section covers testing the crankcase for leaks A leak in the crankcase can cause the engine not to run 26 1 Install the intake seal flange Plug cylinder pulse tu
6. clean or replace spark plug A A dirty air filter is the 1 reason for engine problems Operator is overworking the saw Carburetor mixture is too l ar See Saw Specifications section The engine is overheating Incorrect fuel oil ratio e Clean flywheel fins with wire brush dogged See Starter Cover section Air deflector is missing Cylinder fins are clogged See Operator s Manual See Carburetor Tuning section Clean or replace the air filter Replace fuel filter Blogged er ner See Carburetor Tuning section Poor acceleration YES Incorrect carburetor tune Rep irorreblace fuel tank Plugged tank breather 2 Blocked pulse tube Replace pul s Dirty or clogged air filter Airleak at intake boot 3 cylinder gasket or Inspect air intake boot Ad a YES crankcase gasket Pressure test crankcase y Faulty carburetor Replace carburetor diaphragm Diamond chain YES Idle speed too high e Adjust idle speed moves at idle Broken clutch spring Replace clutch spring Damaged shock absorber Replace shock absorbers Damaged or broken Excessive vibration Replace flywheel flywheel fins Bent crankshaft Replace crankshaft 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 75 24 DIAGRAMS 660GC SERVICE
7. the removal and installation of the carburetor Removal of the air intake components and cylinder cover is required Please refer to sections 5 and 10 or 11 if necessary Carburetor tuning is covered in section 22 Remove throttle linkage Push trigger end out of rear handle Pivot linkage around Remove carburetor end of linkage from throttle rod tab on carburetor Remove fuel line from carburetor and support bracker Remove carburetor support bracket Remove carburetor support screw 1 with 4 Torx or straight blade screwdriver Remove carburetor body screws 2 12 CARBURETOR NOTE All saws are equipped with carburetor model HDA 225 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 41 12 CARBURETOR 660GC SERVICE MANUAL 12 4 Remove carburetor A Remove pulse tube B Remove carburetor jet cover C Remove carburetor from choke linkage 12 5 Assemble in the reverse order Torque carburetor body screws to 43 in lbs 4 9 Nm Torque supporter screw with Loctite 242 to 43 in Ibs 4 9 Nm 42 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 13 CYLINDER amp PISTON 13 This section covers the NOTE When replacing the 660GC cylinder disassembly inspection and and piston it is necessary to tune the assembly of the cylinder piston car
8. used are not related to the key numbers in the 660GC Replacement Parts Price List CYLINDER amp PISTON ASSEMBLY TORQUE LOCTITE Nm in Ibs SPARK PLUG 27 5 73199 CYLINDER BOLT 10 7 X 73874 DECOMPRESSION VALVE 12 8 71642 CYLINDER BASE GASKET 505439 COMPLETE CYLINDER amp PISTON ASSEMBLY 505428 WRIST PIN NEEDLE BEARING 505403 6 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM CRANKCASE ASSEMBLY CRANKCASE PLUG 505407 TANK PLUG 512461 CRANKCASE 537665 CRANKCASE DOWEL PIN 73281 FUEL LINE GROMMET 505627 CRANKCASE GROMMET 505408 CRANKSHAFT BEARING 505375 BAR MOUNTING STUD 509555 9 TENSIONER 505393 10 BAR MOUNT PAD COVER PLATE 505467 11 SCREW 5 50 mm 4 9 43 X 509709 12 WASHER 73897 13 CRANKCASE BOLT 7 9 69 X 73930 14 CRANKCASE GASKET 505440 15 CHOKE LEVER BUSHING 73955 16 CHOKE LEVER 505409 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 7 4 SPARE PARTS DIAGRAM 660GC SERVICE MANUAL CLUTCH amp CRANKCASE ASSEMBLY 2 6 3 5 6 8 1 4 C 10 Dre i 5 v 8 7 Gh UR 9 11 BESCHIBTION TORQUE LOCTITE Nm in Ibs 242 1 CRANKSHAFT RETAINER SEAL 540139 2 CRANKCASE SEAL RETAINER 505423 3 WASHER 73285
9. 1 WASHER 73912 STARTER PAWL ASSEMBLY 6 8 60 508852 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 12 660GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM IGNITION ASSEMBLY UB DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in lbs 242 KEY 1 IGNITION TOGGLE SVVITCH NUT 73239 2 IGNITION TOGGLE PLATE ON OFF 73238 3 IGNITION TOGGLE SVVITCH 73237 4 TOGGLE SWITCH CONNECTING PLATE 71449 5 IGNITION TOGGLE CABLE 73919 6 SCREW DIO 26 X 73914 7 WASHER 73285 8 WASHER 73890 9 SPARK PLUG BOOT W SPRING 73241 10 SPARK PLUG SPRING 73917 11 IGNITION COIL WITH SPARK PLUG LEAD amp PRIMARY 505426 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 1 3 4 SPARE PARTS DIAGRAM 660GC SERVICE MANUAL STARTER ASSEMBLY DESCRIPTION TORQUE FORNITE PART NUMBER Nm in lbs 242 KEY 1 SCREW 73230 2 STARTER ROPE HANDLE 505514 3 STARTER ROPE 508854 4 STARTER ASSEMBLY 537666 5 STARTER CASE PLATE 71451 6 RECOIL HOUSING SCREW 505380 7 STARTER PULLEY WASHER 73905 8 STARTER ASSEMBLY CAP 508853 9 STARTER PULLEY SCREW 2 9 26 X 73907 10 STARTER ROPE PULLEY 508857 11 STARTER COIL SPRING amp HOUSING 73909 14 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV060
10. 1 kw 9 500 RPM Torque Engine Speed 32 in Ibs 3 6 Nm 6 000 RPM 11 500 500 rpm max 2 800 3 200 rpm idle 18 2 lbs 8 3 kg without guidebar and Weight diamond chain Cut Depth Up to 10 inches 25 4 cm 17 inches 44 cm length Dimensions 10 inches 25 5 cm height 11 6 inches 29 5 cm width Air Filter Water Resistant Polyester Carburetor Walbro HDA225 Starter Dust and Water resistant Special water resistant electronic Ignition qa ignition Clutch Centrifugal three shoe single spring Fuel Mix ratio 25 1 4 Fuel Capacity 0 26 gallons 1 Liter Water Supply Minimum 20 psi 1 5 bar Water Flow Minimum 2 gpm 8 Noise Level 101 dB at 3 ft 1m Vibration Level 6 2 m s front handle 7 3 m s rear handle Engine Break in Period One tank without cutting cycling throttle Spark Plug Champion CJ7Y Bosch BWSTF or NGK BPMR7A Electrode gap 020 in 0 5 mm 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 3 SERIAL LOCATION 3 660GC serial number series 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 5 4 SPARE PARTS DIAGRAM 660GC SERVICE MANUAL 4 This section covers torque Loctite and lubrication requirements of the individual components The key numbers
11. 12011 660GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM AIR FILTER ASSEMBLY DESCRIPTION ROROUE PART NUMBER Nm in Ibs 242 1 AIRFILTER O RING 2 FILT R COVER SCREW 4 0 35 3 AIR FILTER COVER ASSEMBLY WITH 3 SCREWS 4 _ AIR FILTER FLANGE 5 _ AIR FILTER CANISTER POLYESTER 6 PREFILTER PLASTIC SECONDARY FILTER 7 WASHER 8 CYLINDER COVER SCREW 4 0 35 X FILTER SUPPORT SCREW 4 9 43 X S E esse 11 CYLINDER COVER 537660 12 O RING 71472 13 COMPENSATOR TUBE 505382 14 TUBE CLAMP 71760 15 FILTER COVER GASKET 71756 16 BREATHER GROMMET 71763 17 FILTER CANISTER GASKET 73335 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 15 4 SPARE PARTS DIAGRAM 660GC SERVICE MANUAL WATER DELIVERY SYSTEM DESCRIPTION TORQUE LOCTITE PART NUMBER Nm in Ibs 242 WATER HOSE GASKET 1 2 FITTING 3 RING NUT 4 WATER HOSE O RING 5 WATER SHUT OFF VALVE 71458 6 FITTING 71466 7 FITTING 71454 8 HOSE CLAMP 71465 9 WATER HOSE 509488 10 HOSE HANGER 71461 11 WATER HOSE COVER 71464 1 6 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM SIDE COVER ASSEMBLY 2 3 ej 6 2 SAN DESCRIPTION PAR
12. 19 Install piston A B D 48 Oil piston with ICS 2 stroke oil Align wrist pin with wrist pin bearing Complete wrist pin installation Install second wrist pin retaining clip dh Make sure wrist pin retaining clip is in the proper orientation see 13 16 660GC SERVICE MANUAL F 4 i d a 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 13 20 A B 13 21 13 22 Install cylinder Lubricate cylinder bore vvith ICS 2 stroke oil Compress rings with ring compression tool Slide cylinder onto piston pushing ring compression tool down Install cylinder Remove ring compression tool Slide cylinder down piston and into crankcase Align cylinder bolt holes with crankcase Install 4 cylinder screws and washers Use Loctite 242 Torque bolts to 95 in Ibs 10 7 Nm 13 CYLINDER amp PISTON 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 49 13 CYLINDER amp PISTON 660GC SERVICE MANUAL 13 23 Install rear manifold A Apply lightweight grease on the inside lip of the rear manifold B Push rear manifold onto cylinder intake C Align mold seams of intake boot with casting seams of the cylinder 13 24 Install rear manifold clamp A Torque to 11 in Ibs 1 Nm NOTE Insure that th
13. 242 C Torque to 43 in Ibs 4 9 Nm 10 15 Install air filters and cover A Install pre filter Install clean air filter Install air filter flange and tighten Install air filter cover and tighten 38 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 11 MUFFLER 11 This section covers the disassembly inspection and assembly of the muffler Removal of the bumpers and cylinder cover is necessary Refer to sections 9 and 10 if necessary 111 Remove muffler support screws 11 2 Remove muffler screws located inside the muffler 11 3 Remove muffler and heat shield gasket e Replace any damaged components 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 39 11 MUFFLER 11 4 Install muffler Insert muffler screws 2 into muffler Hold muffler screws in place with heat shield gasket Thread muffler screws into cylinder with Loctite 242 Torque to 78 in Ibs 8 8 Nm 11 5 Install bottom 2 muffler support screws with Loctite 242 Torque top screws to 78 in Ibs 8 8 Nm e Torque bottom screws to 52 in lbs 5 8 Nm 660GC SERVICE MANUAL 40 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 12 12 12 2 12 3 This section covers
14. D 505383 14 INTAKE MANIFOLD CLAMP 1 0 11 73867 1 0 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 4 SPARE PARTS DIAGRAM FUEL TANK amp HANDLE ASSEMBLY 13 od 2 3 5 LS 8 12 Ps 10 9 ti 1 d 8 8 18 14 15 Fo a 76 Nm in Ibs 242 EI AE ME ME ME JEN SCREW 1 0 9 73976 THROTTLE LEVER THROTTLE LINKAGE ASSEMBLY TRIGGER LOCKOUT LEVER SPRING TRIGGER LOCKOUT LEVER SHOCK ABSORBER SHOCK ABSORBER WITH SCREW REAR HANDLE SHOCK ABSORBER BUMPER SHOCK ABSORBER FUEL TANK TOP FUEL TANK 548391 FRONT HANDLE BOLT X 73983 FRONT HANDLE 548483 WASHER 73897 SCREW X 73982 NI N O A RUBBER WATER DEFLECTOR 505445 FUEL BREATHER COMPLETE 71748 FUEL BREATHER REMOTE 71761 FUEL FILTER CLIP 71588 TUBE CLAMP 71760 BREATHER TUBE ELBOW 71759 BREATHER TUBE BODY 71751 FUEL LINE 73375 24 73459 25 FUEL CAP O RING 73448 26 FUEL CAP ASSEMBLY WITH OUTER SEAL RIING 71739 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REVO6012011 1 1 4 SPARE PARTS DIAGRAM 660GC SERVICE MANUAL FLYWHEEL ASSEMBLY KEY DESCRIPTION TORQUE LOC TIE PART NUMBER Nm in lbs 242 FLYWHEEL SHROUD 548514 FLYWHEEL 548515 NUT 24 5 217 73891 WASHER 7391
15. MANUAL Saw Will Not Start CHECK POSSIBLE CAUSE REPAIR Clean rebuild or replace the recoil starter Inspect for internal damage such as seized piston Dirty or broken recoil Does the engine crank NO starter Internal damage The ignition switch is Move switch to ON and re test OFF Tighten connections or replace NO Faulty ignition ground ground vvire Faulty spark plug lead Repair or replace spark plug lead 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 Be s sin Clean and re gap the plug to 2 4 properly Plug is internally faulty or lug the wrong type plug see Spark Plug Reference Guide Loose spark plug Insure cylinder If below 125 psi excess Tighten plug and re test compression is above NO wear on the piston Replace piston and cylinder 125 psi cylinder rings and or Ensure correct fuel oil mixuture VES improper fuel mixture 25 1 Is the fuel fresh NO Fuel is old varnished or Empty tank and re fill with fresh Is the fuel mixed 25 1 contaminated fuel of the correct mixture 25 1 Clogged fuel filter Replace fuel filter Damaged fuel line Replace fuel line Is the fuel reaching the bo NO Damaged pulse tube Replace pulse tube Plugged fuel tank Repair or replace fuel tank breather breather Carbu
16. T NUMBER GUARD FLAP SCREW GUARD FLAP MOUNTING BRACKET FRONT 505491 GUARD FLAP 505492 NUT GUARD FLAP MOUNTING BRACKET BACK 505490 GUARD FLAP NUT 505468 73983 RUBBER BUMPER COVER SIDE COVER GASKET MOUNTING NUT RUBBER VVALLVVALKER SCREW SIDE COVER NUT FITTING X 71454 i SIDE COVER PLATE 505419 17 SCREW 71487 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 17 4 SPARE PARTS DIAGRAM 660GC SERVICE MANUAL CARBURETOR REPAIR KIT KEY DESCRIPTION TORQUE FOC TITE PART NUMBER Nm in Ibs 242 CARBURETOR REPAIR KIT __ a Sa 548394 CARBURETOR WALBRO HDA 225 t 548393 1 8 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 5 AIR INTAKE 5 This section covers the disassembly inspection and assembly of the air induction system 5 1 Loosen the air filter cover screws and remove air filter cover 5 2 Remove air filter from cover A Inspect air filter B Replace if necessary P N 71752 5 3 Remove secondary filter from air filter mount A Clean secondary filter with cleaning solution and a nylon brush B Let dry and reinstall 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 1 9 5 AIR INTAKE 660GC SERVICE MANUAL 5 4 Inspect
17. air filter cover gasket Replace if permanently depressed or hard due to slurry 5 5 Inspect filter cannister gasket A Clean B Replace if necessary 5 6 Secure air filter mount screws 3 using Loctite 242 20 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 6 1 6 2 6 3 6 4 This section covers the removal inspection and installation of the spark plug Remove the spark boot taking care not to pry or damage the wire Clean area around the spark plug to prevent debris from entering the cylinder Remove the spark plug Inspect the spark plug for proper size gap and condition If dirty clean with a wire brush as shown 6 SPARK PLUG 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 21 6 SPARK PLUG 660GC SERVICE MANUAL 6 5 if necessary to 0 02 0 5 mm NOTE If the spark plug must be replaced refer to the Spark Plug Reference Guide on page 81 to select the correct replacement plug 6 6 Assemble in the reverse order A Make sure the plug boot is seated completely 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 22 660GC SERVICE MANUAL 7 CLUTCH amp RIM SPROCKET 7 This section covers clutch removal rim sprocket removal inspection and a
18. arter pawl screws pavvls spring and plain washer NOTE Piston stop tool may be required to remove the starter pawl screws 8 18 Inspect and clean pawl components A Inspect the components Replace if necessary Clean the components with a brush and solvent 8 19 Assemble components Make sure the spring is in the correct position B Use Loctite 242 on the pawl screws C Torque to 60 in Ibs 6 8 Nm 8 20 Install starter cover A Pull out cord 4 6 10 15 cm B Slowly release while placing cover to allow pawls to engage 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 31 8 STARTER 660GC SERVICE MANUAL 8 21 Install starter cover screws 4 A Use Loctite 242 B Torque to 60 in Ibs 6 8 Nm 32 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 9 WALLWALKER 9 This section covers the removal inspection and assembly of the rubber padded WallWalker and guard flap 9 1 Inspect bumpers Replace if worn 9 2 Remove side cover assembly 9 3 Remove cover plate 9 4 Remove crankcase screws 2 and wave washers 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 33 9 WALLWALKER 660GC SERVICE MANUAL 9 5 Remove and inspect guard flap Replace the flap
19. be 26 2 Install the exhaust seal flange 26 3 Block one of the flange tubes with a rubber plug 26 4 Install the pressure gauge and bulb 26 5 Pressurize the crankcase to 7psi 0 5 bar 26 6 If the pressure does not remain the same use soapy water to find the leak NOTE It is recommended that this test be performed after an engine rebuild 80 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL APPENDIX 1 The Spark Plug Reference Guide is to be used as a guide only When trying a plug from a different manufacturer perform a plug check to be sure that the plug will work SPARK PLUG REFERENCE GUIDE ICS RESISTOR CHAMPION RESISTOR BOSCH RESISTOR RESISTOR 73199 RCJ7Y BPMR7A WSRTF 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 81 660GC SERVICE MANUAL ICS Blount Inc 4909 SE International Way Portland OR 97222 Tel 800 321 1240 Fax 503 653 4393 icsbestway com 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011
20. bs 7 8 Nm 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 17 FRONT HANDLE 57 18 FUEL TANK 660GC SERVICE MANUAL 18 This section covers the disassembly inspection and assembly of the vibration isolaters fuel tank and rear handle 18 1 Remove vibration isolator screws 2 and wave washers on clutch side of saw 18 2 Remove vibration isolator screws 2 and wave washers on flywheel side of saw gt r N En 1 2 i j E im 58 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 18 3 Separate crankcase and fuel tank NOTE Saws have a rubber water deflector connected to the front vibration isolator on the clutch side circled 18 4 Remove vibration isolators 4 from fuel tank if necessary NOTE Shock absorber tool p n 71546 must be used to remove vibrator isolators 18 5 Assemble in reverse order NOTE During assembly be careful to avoid kinking the fuel line Torque vibration isolators to 35 in lbs 4 0 Nm 18 FUEL TANK 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 59 19 CRANKCASE 660GC SERVICE MANUAL 19 This section covers the disassembly inspection and assembly of the crankcase seals and crankshaft bearings
21. bserve orientation of the release slots on the adjustment screw limiter cap See section 10 for cylinder cover removal B Insert the limiter cap puller into the center of the limiter cap C Firmly hold the tool shaft while screwing in the puller screw until the screw head is against the puller shaft D Unscrew the puller screw 1 4 turn and pull straight out Repeat for second limiter 22 CARBURETOR TUNING RPM Settings for saws NOTE Saw tuned without bar and chain installed Idle Speed 3 000 500 rpm Full Throttle 12 500 500 rpm 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 71 22 CARBURETOR TUNING 660GC SERVICE MANUAL 22 3 Using 5 64 straight blade screwdriver gently turn the adjustment screws clockwise until completely closed 22 4 Set the adjustment screws at the Basic Setting H 1 turns from closed L 1 turns from closed dh The side cover must be held tightly in place with the side cover nuts using a bar and no chain Failure to do so may result in personal injury 22 5 Start the saw and warm up the engine 22 6 With a tachometer check the saw rpm with bar and no chain A Idle 3 000 500 rpm B If the idle rpm does not fall into this range adjust the T screw clockwise to raise RPM counterclockwise to lower RPM 72 2011 ICS Blount Inc Specifications and pricing are subject to chan
22. buretor prior to returning the saw to and related components service see section 22 Removal of several component groups is required Refer to sections 5 6 10 and 12 if necessary 131 Remove carburetor base screws 3 A Remove carburetor base bracket from rear manifold B Remove carburetor base bracket from pulse tube 13 2 Remove pulse tube and protective spring from cylinder base a EA a D i 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 43 13 CYLINDER amp PISTON 660GC SERVICE MANUAL 13 3 Remove rear manifold clamp 13 4 Remove rear manifold from cylinder A Inspect for holes and tears 13 5 Remove cylinder screws 4 and wave washers 2 on front and 2 on back 13 6 Remove cylinder A Remove cylinder gasket and clean case 44 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 13 CYLINDER amp PISTON 13 7 Remove wrist pin retaining clips 2 13 8 Press wrist pin out with an 8 mm deep socket 13 9 Remove piston and inspect Replace if damaged 13 10 Remove wrist pin bearing 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 45 13 CYLINDER amp PISTON 1311 Assemble cylinder gasket A Oil gasket with ICS 2 stroke engine oil
23. clutch cup with rim sprocket and inside clutch spacer washer 711 Install clutch A Torque to 295 in Ibs 33 3 Nm A Left hand threads 26 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 8 1 8 2 8 3 8 5 This section covers the removal of the starter cover replacement of the starter rope and replacement of the recoil spring Remove starter cover screws 4 Remove starter cover assembly from saw Remove starter cord shield screws Relieve spring tension Pull 4 6 10 15 cm of rope out Line rope up with notch on pulley To release pulley slowly rotate pulley counterclockwise until spring pressure is released Use thumb as a brake Remove rubber screw seal 8 STARTER a Le ERE SS m mmm Y T1 E j 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 27 8 STARTER 660GC SERVICE MANUAL 8 6 Remove starter pulley Remove pulley screw 8 7 Inspect coil spring Replace if spring hook is damaged Attempting 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 28 2011 ICS Blount Inc Specifications and pr
24. ction are basic settings idle speed adjustment and complete adjustment The carburetor on a new saw is set at the factory for optimal performance and compliance to EPA Phase emmissions standards However minor adjustments may be required in certain conditions such as high elevation A replacement carburetor is not set correctly from the factory Use the tuning instructions in this manual to adjust carburetor to factory recommended settings DO NOT adjust the carburetor for maximum rpm Adjusting the carburetor for maximum rpm will cause engine damage Always set the carburetor jets to factory settings when replacement or complete rebuild becomes necessary NOTES 70 These saws are equipped with an electronic speed limiter as part of the ignition system This will prevent the saw from going above 12 500 rpm Attempting to set the carburetor mixture to increase the speed or power beyond this limit may seriously damage the engine Always check the air filter pre filter fuel filter and spark plug before making carburetor tunings and clean or replace if necessary 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 221 Basic Setting H 1 turn from closed L 1 turn from closed Complete carburetor readjustment 22 2 Remove limiter cap A Limiter caps can only be removed after the cylinder cover and screw boot have been removed O
25. e intake boot is properly installed DO NOT OVER TIGHTEN INTAKE BOOT CLAMP If over tightened intake boot can tear resulting in an air leak which will cause engine damage 13 25 Install the pulse tube onto cylinder barb 13 26 Install protective spring onto pulse tube 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 50 660GC SERVICE MANUAL 13 27 Install carburetor base Slip pulse tube into carburetor base Slip rear manifold into carburetor base C Make sure rear manifold lip is flat 13 28 Install carburetor base screws A Use Loctite 242 on screws 3 B Make sure to include stop switch wire on front screw C Torque to 35 in Ibs 4 0 Nm vii d Eo oO o ye i 1 5 w i 13 CYLINDER amp PISTON 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 51 14 WATER HOSE 660GC SERVICE MANUAL 14 This section covers water hose and side cover 141 Inspect water hose and side cover A Replace if damaged 14 2 Assemble in reverse order 14 3 Remove water hose connector from side cover A Remove clamp and hose from fitting B Unthread fitting from side cover 14 4 Inspect side cover for damage A Replace if necessary 52 2011 ICS Blount Inc Specifications and pricing are subject to change
26. emoval inspection and installation of the flywheel Removal of spark plug and the starter is required Refer to sections 6 and 8 if necessary 16 1 Insert piston stop 16 2 Remove flywheel nut wave washer and plain washer 16 3 Screw on flywheel removal tool finger tight Unscrew tool 1 turns leaving approximately 1 8 inch 4 mm space between tool and flywheel 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 16 FLYWHEEL 660GC SERVICE MANUAL 16 4 Using pliers hold saw up by magnet counterweight 16 5 Strike flywheel removal tool with a ball peen hammer The flywheel should release from crankshaft 16 6 Inspect and clean flywheel Replace if any of the fins are broken 16 7 Inspect cast woodruff key inside the flywheel NOTE Key is cast into flywheel 16 8 Install flywheel plain washer wave washer and flywheel nut A Torque nut to 217 in Ibs 24 5 Nm 56 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 17 17 This section covers the removal inspection and installation of the front handle Remove front handle screws 2 on right side 17 2 Remove front handle screws 2 17 3 on bottom Install front handle Roll front handle into place Install front handle screws 4 Use Loctite 242 Torque to 69 in l
27. eplace if necessary 10 10 Check cylinder cover water seal Replace if necessary 36 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 10 CYLINDER COVER 1011 Assemble in reverse order A Reassemble stop switch leads 10 12 Make sure carburetor screw boot is in place 10 13 Install cylinder cover A Pull spark plug lead into slot in cylinder cover B Lubricate compensating tube 1 and b fuel tank breather tube 2 with soapy water guide through cylinder cover A AN Install compensating tube first 2 4 NOTE Be careful to not pull tubes away i from their point of connection a Approximately 3 4 of tube 4 should protrude from c cylinder cover E ea 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 37 10 CYLINDER COVER 660GC SERVICE MANUAL C Push the cylinder cover down on the crankcase guide intake manifold into cylinder cover D Align throttle linkage with cylinder cover and crankcase E Install the cylinder cover screws Use Loctite 242 Torque to 35 in Ibs 4 0 Nm 10 14 Install air filter mount A Guide carburetor compensating tube through air filter mount Make sure manifold sits flat over lip on cylinder cover see section 10 5 B Install air filter mount screws 3 using Loctite
28. er Mark mating parts as a reassembly reference Keep component parts together as a group Assemble screws and nuts into appropriate subgroups When reassembling clean all parts carefully lubricate moving parts and replace all oil seals o rings gaskets washers and self locking nuts For best results use only original ICS replacement parts General Recommendations Some procedures in this manual require the use of special tools A complete tool kit for ICS saws is available from ICS Detailed carburetor maintenance and overhaul information is available in Walbro s Diaphragm Carburetor Service Manual Walbro can be contacted at http www walbro com or by calling 1 989 872 2131 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 1 TOOLS Key Part No Description MSRP puo Assembly Camps E Psion Sap E b M62 Bearing Driver Toei ss 6 156 JShock Absorber Tool 5245 8 1548 Flywheel Disassembly Tool 53145 9 1560 Limiter Cap Puller 58925 Not Shown 505882 2 Stroke Oil 25 1 Mix 5 2 oz 158 ml 6 Pack 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 3 2 SPECIFICATIONS 660GC SERVICE MANUAL SPECIFICATIONS Engine Type Displacement 2 stroke Single Cylinder Air Cooled 3 9 cu in 64 cc Horsepower 4 2 HP 3
29. ge without notice P N 550416 REV06012011 660GC SERVICE MANUAL 22 CARBURETOR TUNING 227 With a tachometer check the saw full throttle rpm with a bar and no chain Target 12 500 500 rpm 22 8 If the full throttle rpm falls below this range turn the H screw in clockwise 1 16 of a turn at a time A Pulse the throttle to help stabilize the system dh Do not hold the saw at max rpm for more than 5 seconds or cylinder damage could occur 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 73 23 IDLE SPEED ADJUSTMENT 23 This section covers idle speed adjustment 231 If engine stops while idling A Make sure the chain is properly tensioned B Turn T screw clockwise until chain begins to move Back T screw out turn 23 2 If chain turns at idle A BackT screw out until chain stops moving 74 660GC SERVICE MANUAL T e SO HL 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 24 DIAGRAMS 24 This section provides several flowcharts to aid diagnosing common problems CHECK POSSIBLE CAUSE REPAIR Clean or replace the air filter The endine Ming rough at Dirty or clogged air filter Inspect air intake system for water 9 9 Water has been ingested Inspect fuel system for water all speeds Loose or dirty spark plug Tighten
30. icing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 8 STARTER 8 10 Inspect pulley spring catch Clean with cleaning solution B Replace if worn or broken 8 11 Install starter rope and tie knot 8 12 Knot tying instructions Make a loop at the end of the pulley rope with the end of the rope crossing on top of the tail Bring the end of the rope through the loop creating a single loose knot C Pull the end of the rope down and in front of the tail D Send the end through the loop a second time creating a double knot cinch tight 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 29 8 STARTER 660GC SERVICE MANUAL 8 13 Install pulley A Wind rope onto pulley clockwise leaving 4 6 10 25 cm out B Make sure that the pulley spring catch is in the spring hook 8 14 Install center screw A Use Loctite 242 B Torque to 26 in Ibs 2 9 Nm TI aM 8 15 Wind the recoil spring A Line rope up with notch on pulley B Rotate the pulley with the rope clockwise 5 times C Untangle rope and release 8 16 Assemble starter cord shield WU mm ATT I IT 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 30 660GC SERVICE MANUAL 8 STARTER 8 17 Remove st
31. if it is torn or damaged in any way 9 6 Remove guard flap screws and washers 9 7 Reassemble in the reverse order A Install crankcase screws and wave washers B Use Loctite 242 Torque to 70 in lbs 7 9 Nm 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 34 660GC SERVICE MANUAL 10 10 1 This section covers the disassembly and assembly of the cylinder cover Removal of the air intake components and front handle is necessary Refer to sections 5 and 17 if needed Remove the air filter mount screws NOTE May require heat to 10 2 10 3 10 4 10 5 10 6 remove SCrews Remove the cylinder cover screws 3 Remove spark plug boot from cylinder cover taking care not to pry or damage the wire Remove fuel tank breather cap and clamp Partially remove intake manifold from cylinder cover Remove cylinder cover Pull up on front Push intake manifold through hole Make sure throttle linkage is disengaged from cylinder cover Guide fuel breather tube and compensator tube through cylinder cover 10 CYLINDER COVER 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 35 10 CYLINDER COVER 660GC SERVICE MANUAL 10 7 Remove stop switch leads 10 8 Inspect cylinder cover for damage Replace if necessary 10 9 Check filter cover gasket R
32. n mating crankcase faces 1911 Heat crankcase halves to 150 65 5 1912 Install bearing into crankcase halves 19 13 Tap with bearing driver and mallet 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 63 19 CRANKCASE 660GC SERVICE MANUAL 19 14 Repeat with other half 1915 Install crankshaft into clutch side of case 1916 Place clutch side crankcase seal on crankshaft lightly with bearing driver and mallet 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 64 660GC SERVICE MANUAL 19 CRANKCASE 19 17 Coat crankcase gasket with ICS 2 stroke engine oil 19 18 Align crankcase gasket on flywheel side crankcase pins 19 19 Place crankcase halves together and align crankcase pins 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 65 19 CRANKCASE 660GC SERVICE MANUAL 19 20 Assemble crankcase halves tap with bearing driver and mallet 19 21 Install crankcase bolts 5 A Use Loctite 242 B Torque to 70 in Ibs 7 9 Nm 19 22 Install flywheel side crankcase seal tap with bearing driver and mallet 66 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 19 CRANKCASE 19 23 As
33. retor is tuned Referto Carburetor Tuning Is too much fuel reaching incorrectly section the carburetor Plugged fuel tank Repair or replace fuel tank breather breather z 2 i YES Loose flywheel Replace key and reinstall flywheel 76 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 25 25 1 25 2 This section covers testing the fuel system for leaks Engine starvation can result from a leak or malfunction of any of the main components of the fuel system The five main components are the fuel tank fuel tank breather fuel filter delivery tubes and carburetor Remove and inspect the fuel filter Replace the fuel filter if there is any foreign material in the felt or the internal screen Test the main fuel pick up tube for leaks Connect tube to the pressure gauge and to the fuel line Pressurize the tube to 7psi 0 5 bar If the pressure does not maintain separate the fuel line from the carburetor 25 FUEL SYSTEM LEAKS 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 77 25 FUEL SYSTEM LEAKS 25 3 25 4 25 5 78 Plug one end of the main fuel pick up tube Re pressurize the tube to 7psi 0 5 bar Replace the tube if pressure is not maintained If the main fuel pick up tube does maintain pressure then the leak has
34. semble in reverse order A Install outer crankshaft seal housing with 3 bolts and use Loctite 242 19 24 Trim crankcase gasket flush 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 67 20 BAR STUDS amp BAR PAD 660GC SERVICE MANUAL 20 This section covers the removal and installation of the bar studs and bar pad 201 On 660 saws NOTE This requires the removal of the piston and cylinder and to split the crankcase Refer to section 13 amp 19 for detailed instructions A Remove side cover B Remove bar pad cover C Split the crankcase Press out bar studs E Assemble in reverse order 68 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 21 CHAIN TENSIONER 21 This section covers the removal and installation of the chain tensioner 211 Remove bar plate to expose the chain tensioner 21 2 Unscrew tensioner to remove A Remove tensioner pin B Remove tensioner screw keeper 21 33 Assemble in reverse order NOTE The tensioner is intended to perform as a fuse in high load or sudden impact situations p n 505393 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 22 CARBURETOR TUNING 660GC SERVICE MANUAL 22 This section covers carburetor tuning Included in this se
35. ssembly Refer to sections 5 and 6 if needed Insert piston stop tool into spark plug hole 7 2 Pull starter handle until piston stops against tool 7 3 Remove clutch A Left hand threads rotate clockwise to loosen NOTE If an impact wrench is available steps 7 1 and 7 2 do not have to be performed 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 23 7 CLUTCH amp RIM SPROCKET 660GC SERVICE MANUAL 7 4 Remove all drive components 75 Inspect the clutch shoes for wear Replace if the shoe has less than 0 04 1 mm of material as shown 7 6 Inspect spring for cracks 24 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL TI Assemble clutch A Insert top edge of clutch shoe over spring as shown 7 8 Snap clutch shoe into place 7 9 Inspect the rim sprocket for wear Replace if the rim sprocket teeth are worn to points as shown on right 7 CLUTCH amp RIM SPROCKET 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 25 7 CLUTCH amp RIM SPROCKET 660GC SERVICE MANUAL 7 10 Clean and assemble A Clean all parts in solvent EN ivi Grease needle bearing ICS9 P N 505378 with a waterproof grease v C Assemble clutch spacer washer E d e bearing
36. without notice P N 550416 REV06012011 660GC SERVICE MANUAL 15 15 1 15 2 15 3 15 4 This section covers the removal inspection and installation of the ignition coil Removal of the starter is required Refer to section 8 if necessary Remove starter flywheel shroud by unhooking wires Remove ignition coil screws wave washers and plain washers Remove ignition coil Inspect ignition coil Look for e Cracks e Missing insulation e Wear marks in wire Clean flywheel magnets and coil if rusty 15 IGNITION COIL 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 53 15 IGNITION COIL 660GC SERVICE MANUAL 15 5 Install Ignition coil A Place ignition coil shim 0 012 on magnet counterweight side of flywheel Set ignition coil in place C Install ignition coil screws wave washers and plain washers with Loctite 242 Holding shim rotate flywheel magnet around to coil E Torque ignition coil screws to 26 in Ibs 2 93 Nm F Remove shim rotate flywheel to check clearance 15 6 Install flywheel shroud 15 7 Route yellow ignition stop switch wire through crankcase into carburetor chamber 15 8 Complete ignition wire routing 54 2011 ICS Blount Inc Specifications and pricing are subject to change without notice P N 550416 REV06012011 660GC SERVICE MANUAL 16 FLYWHEEL 16 This section covers the r
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