ICS 695GC/F4 Service Manual

695GC/F4

SERVICE MANUAL

695GC/F4 SERVICE MANUAL

TABLE OF CONTENTS

SECTION SECTION TITLE PAGE NUMBER

SERVICE MANUAL USE 3

1 TOOLS

4

2 SAW SPECIFICATIONS 5

3 SERIAL NUMBER LOCATION 6

4 SPARE PARTS DIAGRAM (TORQUE SPECIFICATIONS AND LOCTITE

®

APPLICATION) 7

5 AIR INTAKE 19

6 SPARK PLUG 20

7 SIDE COVER & TENSIONER 22

8 CLUTCH & RIM SPROCKET 24

9 STARTER SYSTEM 30

10 CARBURETOR REMOVAL 35

11 MUFFLER/W BAR STUD 39

12 MUFFLER/W BAR STUD 40

13 IGNITION MODULE 41

14 STOP SWITCH 42

15 WATER HOSE 44

16 CYLINDER & PISTON 45

17 BOTTOM GUARD/FRONT HANDLE 51

18 REAR HANDLE 53

19 FUEL TANK & COMPONENTS 57

20 CR ANKCASE 63

21 CARBURETOR TUNING 77

22 IDLE SPEED ADJUSTMENT 80

23 TROUBLESHOOTING DIAGRAMS 81

24 TROUBLESHOOTING: FUEL SYSTEM 83

25 TROUBLESHOOTING: CRANKCASE LEAKS 87

APPENDIX

1. SPARK PLUG REFERENCE GUIDE 89

2

SERVICE MANUAL USE

Service Manual Use

This manual contains all the technical information necessary for carrying out repairs on the 695GC/F4 saw. For safe, efficient work, it is of prime importance that the values indicated be adhered to. Routine periodic maintenance is covered in the operator’s manual included with each saw.

General Service Rules

• Always use the right tools for the job, otherwise components may be damaged.

• Use a plastic dead blow mallet to separate parts attached solidly to each other.

• Mark mating parts as a reassembly reference.

• Keep component parts together as a group. Assemble screws and nuts into appropriate subgroups.

695GC/F4 SERVICE MANUAL

• When reassembling, clean all parts carefully, lubricate moving parts and replace all oil seals, o-rings, gaskets, washers and self-locking nuts.

®

• For best results, use only original ICS

replacement parts.

General Recommendations

• Some procedures in this manual require the use of special tools. These are noted in the service manual.

• Detailed carburetor maintenance and overhaul information is available in Walbro’s Diaphragm Carburetor Service Manual. Walbro can be contacted at http:\\www.walbro.com or by calling 1.989.872.2131.

3

695GC/F4 SERVICE MANUAL

1

5

4

32

1. TOOLS

9876

14 15

18

1110

19

12

20

13

1716

Key # Part No. Description

1 71541 Pressure Gauge Bulb

2 71543 Cylinder Assembly Clamps & Piston Stop

3 71565 Electronic Tachometer

4 73425 Fuel Tank Pressure Cap

5 546191 Workshop Key Torx T27

6 546192 Test Spark Plug

7 546193 Air Gap Gauge

8 546194 Flywheel Puller

9 547277 Piston Stop

10 546196 Wrist Pin Punch

11 546197 Cylinder Seal, Exhaust

12 546198 Cylinder Seal, Inlet Port

13 546289 Puller, Sealing Ring

14 546291 Assembly Punch

15 546292 Universal Puller

16 546293 Grip Plate

17 546294 Bearing Puller

18 546295 Bearing Press

19 546307 Screwdriver, Idle

20 546659 Clutch Tool

not shown 70249 14T Bar Nose Sprocket Repair Kit (for 695GC)

not shown 530046 FORCE4™ Bar Nose Sprocket Repair Kit (for 695F4)

not shown 505882 2-Stroke Oil, 25:1 Mix, 5.2 oz. (158 ml) (6-pack)

not shown 505883 2-Stroke Oil, 25:1 Mix, 5.2 oz. (158 ml) (24-pack)

4

2. SPECIFICATIONS

695GC/F4 SERVICE MANUAL

Specifications

Engine Type

Displacement

Horsepower

Torq ue

Engine Speed

Piston ring gap (Maximum)

Weight

Dimensions

Carburetor

Air Filtration

Starter

2-stroke, Air Cooled

5.7 cu-in (94 cc)

6.4 hp (4.8 kW) @ 9000 rpm

50.4 in-lbs (5.7 Nm) @ 7,200 rpm

9,300 +/- 150 rpm (max)

2,700 +/- 100 rpm (idle)

.04 in/1.0mm

21 lbs (9.5 kg) powerhead only

18 in (46 cm) length

14 in (36 cm) height

12 in (30 cm) width

Walbro RWJ-5A

Water resistant polyester

Dust and water resistant

Ignition

Spark plug type

Clutch

Fuel Mix Ratio

Fuel Capacity

Water Supply

Noise Level

Vibration Level

Special water resistant electronic ignition

NGK BPMR7A or Champion RCJ6Y

Electrode gap 0.020 in (0.5 mm)

Centrifugal, three shoe, three spring

25:1 (4%) gasoline-to-oil

0.26 gallon (1 liter)

Minimum 20 psi (1.5 bar)

112 dB(A) at 3 ft (1 m)

3.9 m/s2 (front handle)

4.1 m/s2 (rear handle)

5

695GC/F4 SERVICE MANUAL

3. This section shows the single location of the serial number.

3. SERIAL NUMBER LOCATION

6

4. SPARE PARTS DIAGRAM

4. This section covers spare parts.

8

695GC/F4 SERVICE MANUAL

1

2

3

4

3

5

6

7

KEY DESCRIPTION

1 STARTER COVER ASSEMBLY 544013 2 STARTER PULLEY KIT 544127 3 SCREW x 543974

4 RECOIL SPRING 544021 5 STARTER CORD 544023 6 STARTER HANDLE 544024 7 SCREW 7 - 9 60 - 78 544012 8 STARTER COVER SHIELD 544026

STARTER ASSEMBLY

TORQUE LOCTITE

Nm in‑lbs. 242

®

PART NUMBER

7

695GC/F4 SERVICE MANUAL

3

4

5

4. SPARE PARTS DIAGRAM

1

2

9

7

8

6

10

FLYWHEEL & IGNITION ASSEMBLY

11

12

KEY DESCRIPTION

1 STOP SWITCH SCREW x 544030 2 STOP SWITCH 544031 3 STOP SWITCH CABLE 544032

4 SPARK PLUG CAP 544033 5 SPARK PLUG 544034 6 PROTECTIVE SLEEVE 544035 7 IGNITION MODULE 544036 8 IGNITION MODULE SCREW 10 - 12 89 - 105 x 544038 9 FLYWHEEL 544053

10 STARTER PAWL KIT (INCL. TWO OF EACH ITEM) 544125 11 FLYWHEEL WASHER 544058 12 FLYWHEEL NUT 25 - 30 216 - 264 544059

TORQUE LOCTITE

Nm in‑lbs. 242

®

PART NUMBER

8

4. SPARE PARTS DIAGRAM

695GC/F4 SERVICE MANUAL

14

1

2

3

4

5

6

10

8

15

7

11

12

13

9

16

CLUTCH ASSEMBLY & WALLWALKER

KEY DESCRIPTION

1

RETAINING RING 543905

2

SPLIT RETAINER 543906

3

SPACER 543907

4

695F4 FORCE4™ SPROCKET 525496

4

695GC RIM SPROCKET 70949

5

CLUTCH CUP 543909

6

NEEDLE BEARING 543910

7

BAR BRACKET SCREW x 543911

8

CRANK CASE BOLT x 543912

9

WALLWALKER

10

WALLWALKER

11

WATER PIPE 543915

12

WATER PIPE SCREW x 546548

13

BAR BRACKETS 543916

14

CLUTCH ASSEMBLY 547856

15

CLUTCH SPRING 543928

16

SHIELD 544137

®

SCREW 543920

TORQUE LOCTITE

Nm in‑lbs. 242

®

PART NUMBER

544130

9

695GC/F4 SERVICE MANUAL

2

4. SPARE PARTS DIAGRAM

1

3

5

4

5

6

SIDE COVER & TENSIONER ASSEMBLY

KEY DESCRIPTION

1 SIDE COVER ASSEMBLY 543899

2 SIDE COVER NUT 27 - 34 240 - 300 543900

3 SIDE COVER NUT CIRCLIP 543901

4 TENSIONER COVER PLATE SCREW 543902

5 SCREW, SIDE COVER CAP x 543903

6 TENSIONER 543904

TORQUE LOCTITE

Nm in‑lbs. 242

®

PART NUMBER

10

4. SPARE PARTS DIAGRAM

3

5

4

695GC/F4 SERVICE MANUAL

1

2

1

8

11

1

7

6

9

1

9

13

10

13

6

7

4

12

14

CYLINDER & EXHAUST ASSEMBLIES

KEY DESCRIPTION

TORQUE LOCTITE

Nm in‑lbs. 242

1 CYLINDER/MUFFLER SCREW 15 - 18 132 - 156 x 543942

2 PISTON/CYLINDER KIT 545873

3 HEAT DEFLECTOR 543844

4 MUFFLER GASKET 543938

5 MUFFLER 543845

6 LOWER MUFFLER MOUNTING SCREW x 543846

7 MUFFLER MOUNTING WASHER 543847

8 DECOMPRESSION VALVE 543848

9 CYLINDER BASE GASKET 543937

10 NEEDLE BEARING 543949

11 MUFFLER MOUNT KIT 543950

12 GASKET KIT 543936

13 SEALING RING 543931

14 CRANKCASE GASKET 543933

®

PART NUMBER

4

11

695GC/F4 SERVICE MANUAL

2

3

4. SPARE PARTS DIAGRAM

12

4

1

5

4

7

6

11

8

3

9

5

3

6

3

10

CRANKCASE ASSEMBLY

®

PART NUMBER

KEY DESCRIPTION

1

CRANKCASE ASSEMBLY 543929

2

CRANKCASE SCREW 12 - 14 106 - 124 x 543930

3

SEALING RING 543931

4

GUIDE PIN 543932

5

CRANKCASE GASKET 543933

6

MAIN BEARING 543934

7

RUBBER BUSHING 543935

8

GASKET KIT 543936

9

CYLINDER BASE GASKET 543937

10

MUFFLER GASKET 543938

11

BAR STUD KIT x 544129

12

BAR BRACKET NUT 543941

TORQUE LOCTITE

Nm in‑lbs. 242

12

4. SPARE PARTS DIAGRAM

2

695GC/F4 SERVICE MANUAL

1

3

4

3

CRANKSHAFT ASSEMBLY

KEY DESCRIPTION

1

CRANKSHAFT ASSEMBLY 543952

2

MAIN BEARING 543934

3

CRANKSHAFT SHIELD 543953

4

NEEDLE BEARING 543949

TORQUE LOCTITE

Nm in‑lbs. 242

®

2

PART NUMBER

13

695GC/F4 SERVICE MANUAL

4. SPARE PARTS DIAGRAM

1

COMPLETE ENGINE ASSEMBLY

KEY DESCRIPTION

1 CRANKCASE W/PISTON & CYL COMPLETE 544121

TORQUE LOCTITE

Nm in‑lbs. 242

®

PART NUMBER

14

4. SPARE PARTS DIAGRAM

695GC/F4 SERVICE MANUAL

16

15

9

6

4

U

7

5

3

13

14

11

4

17

12

8

10

2

1

CARBURETOR & INTAKE ASSEMBLIES

KEY DESCRIPTION

1

INLET BOOT CLAMP 544069

2

INLET BOOT 544070

3

FLANGE 544071

4

FLANGE CLUTCH SIDE SCREW x 544072

5

FLANGE BRACKET 544073

6

SCREW x 544065

7

SEPARATOR PLATE 544074

8

CARBURETOR (WALBRO RWJ-5A) 544075

9

THROTTLE CABLE LEVER 544111

10

ADJUSTMENT GUIDE 544116

11

MANIFOLD BRACKET 544112

12

AIR INTAKE MANIFOLD 544113

13

AIR FILTER BRACKET 544114

14

CARBURETOR MOUNTING SCREW x 544115

15

THROTTLE CABLE ASSEMBLY 543975

16

CHOKE LEVER 544117

17

CARBURETOR REPAIR KIT 544118

TORQUE LOCTITE

Nm in‑lbs. 242

®

PART NUMBER

15

695GC/F4 SERVICE MANUAL

4. SPARE PARTS DIAGRAM

2

3

6

8

1

4

5

6

8

7

8

CYLINDER & AIR FILTER ASSEMBLIES

KEY DESCRIPTION

1

FILTER COVER REAR SCREW 3.5 31 544060

2

FILTER COVER FRONT SCREW 2 20 544061

3

FILTER COVER 544062

4

AIR INTAKE INSERT 544063

5

AIR FILTER 544064

6

CYLINDER COVER SCREW x 544065

7

CYLINDER COVER ASSEMBLY 544066

8

CYLINDER COVER SEALS 544067

TORQUE LOCTITE

Nm in‑lbs. 242

®

PART NUMBER

16

4. SPARE PARTS DIAGRAM

695GC/F4 SERVICE MANUAL

2

4

3

22

23

24

17

KEY DESCRIPTION

1

FUEL TANK ASSEMBLY 543812

2

PARALLEL PIN 543813

3

CABLE LEVER 543814

4

THROTTLE LOCK OUT LEVER 543815

5

REAR HANDLE COVER 543816

6

CLIP 543818

7

FUEL LINE 543993

8

CHECK VALVE TUBE 543994

9

CHECK VALVE 543969

10

HOSE CLAMP 543970

11

FUEL FILTER 543971

12

TANK VENT ASSEMBLY 544990

13

TANK VENT FITTING 544122

14

REAR HANDLE GROUND SUPPORT 543972

15

PURGE BULB 543973

16

REAR HANDLE SCREW 543974

17

THROTTLE CABLE ASSEMBLY 543975

18

THROTTLE TRIGGER 543976

19

TRIGGER SPRING 543977

20

PURGE BULB TUBE 543995

21

GROMMET 543978

22

GAS TANK CAP ASSEMBLY 543979

23

SHOCK ABSORBER SCREW x 543981

24

SHOCK ABSORBER CLUTCH SIDE x 543982

25

SHOCK ABSORBER FRONT x 543983

26

SHOCK ABSORBER FLYWHEEL SIDE x 543984

6

7

10

11

(76mm)

9

13

8

12

(102mm)

25

5

8

15

16

20

26

23

FUEL TANK ASSEMBLY

TORQUE LOCTITE

Nm in‑lbs. 242

1

14

18

2 19

21

23

®

PART NUMBER

17

695GC/F4 SERVICE MANUAL

2

4. SPARE PARTS DIAGRAM

6

8

1

5

12

4

3

13

9

10

9

10

11

7

KEY DESCRIPTION

1

WATER HOSE VALVE ASSEMBLY 543996

2

HOSE HANGER 547969

3

WATER HOSE WITH PROTECTIVE COVERING 543999

4

CLAMP, WATER HOSE TUBE SIDE 544000

5

CLAMP, WATER HOSE VALVE SIDE 544001

6

FRONT HANDLE 544002

7

SHOCK ABSORBER, FRONT HANDLE 544003

8

SCREW, SHOCK ABSORBERS x 543981

9

CLIP, FRONT HANDLE 544008

10

SCREW, FRONT HANDLE x 544009

11

GUARD FLAP 544010

12

BACKING PLATE, GUARD FLAP 544011

13

SCREW, GUARD FLAP x 544012

WATER DELIVERY SYSTEM

TORQUE LOCTITE

Nm in‑lbs. 242

®

PART NUMBER

18

5. AIR INTAKE

695GC/F4 SERVICE MANUAL

5. This section covers the removal, inspection, and assembly of the air intake.

5.1 Loosen the air lter cover screws and remove the air lter cover.

5.2 Loosen air lter screw.

• Inspect air lter for dirt or damage.

• Replace with P/N 544064.

19

695GC/F4 SERVICE MANUAL

6. SPARK PLUG

6. This section covers the removal, inspection and installation of the spark plug.

6.1 Remove the spark plug cap.

6.2 Remove the spark plug.

6.3 Inspect spark plug.

• If it’s dirty, clean with a wire brush.

• Replace spark plug if fouled or erroded. USE NGK BRMR7A or Champion RCJ6Y.

20

6. SPARK PLUG

6.4 Gap if necessary to 0.20” (0.5mm).

6.5 Assemble in reverse order ensuring that the spark plug is properly engaged in threads and fully seated.

695GC/F4 SERVICE MANUAL

21

695GC/F4 SERVICE MANUAL

7.SIDE COVER & TENSIONER

7. This section covers side cover removal, side cover nut removal, inspection and assembly.

7.1 Loosen side cover nut.

• Remove side cover.

• Remove tensioner plate screws and tensioner plate.

7.2 Remove tensioner assembly.

Note the orientation of the tensioner assembly.

7.3 Inspect tensioner and replace if needed.

• Clean tensioner threads and liberally apply grease to threads prior to assembly.

22

7.SIDE COVER & TENSIONER

7.4 Inspect side cover, nut and circlip. Replace if damaged.

Circlip can be removed with a large athead screwdriver.

7.5 Assemble in reverse order.

695GC/F4 SERVICE MANUAL

23

695GC/F4 SERVICE MANUAL

8. CLUTCH & RIM SPROCKET

8. This section covers clutch removal, rim sprocket removal, inspection and assembly. Refer to sections 5 and 6 if necessary.

Rim sprocket removal procedure.

8.1 Using at head screwdriver, remove retaining ring.

* Use caution when removing retaining ring to prevent damage to the split retainer or crankshaft.

24

8. CLUTCH & RIM SPROCKET

8.2 Remove the split retainer and spacer.

695GC/F4 SERVICE MANUAL

8.3 Inspect rim sprocket and replace if necessary (P/N 70949).

• Replace if the rim sprocket teeth are worn to points as shown on right.

8.4 Rim sprocket assembly.

• Assemble in reverse order.

25

695GC/F4 SERVICE MANUAL

8.5 Remove clutch cup and needle bearing.

• Apply grease to needle bearing prior to reinstalling.

8. CLUTCH & RIM SPROCKET

8.6 Clutch removal.

• Remove clutch cup & rim sprocket rst.

8.7 Insert piston stop tool into spark plug hole.

26

8. CLUTCH & RIM SPROCKET

8.8 Remove clutch with clutch tool (P/N 546659).

• Rotate clockwise to remove clutch (clutch is left-handed thread).

8.9 Clutch is marked with arrow (off) for direction of removal.

695GC/F4 SERVICE MANUAL

8.10 Inspect clutch shoes (P/N 543927) for excessive wear or damage.

27

695GC/F4 SERVICE MANUAL

8.12 Height of clutch shoes should not be less than 1 mm.

8. CLUTCH & RIM SPROCKET

8.12 Inspect and clean springs if necessary.

28

ICS 695GC/F4 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual