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

8. CLUTCH & RIM SPROCKET

8.13 Remove the springs.

• Set into a vice to hold in place.

• Place a at head screwdriver or at tipped rod against the spring hook.

• Tap lightly at the end of the screwdriver or rod. This will cause the spring hook to detach.

• Push the spring out.

• Repeat with the remaining two springs.

695GC/F4 SERVICE MANUAL

8.14 Fit clutch shoes.

• Slide the spring into the narrower section of the clutch shoe rst.

NOTE: All spring hooks should point the same direction as the word “OFF”. See illustration at right for an example.

8.15 Fit springs.

• Turn the clutch so the word “OFF” is facing down.

• Push the spring hook into its hole by using a pointed tool.

29

695GC/F4 SERVICE MANUAL

9. STARTER

9. This section covers the removal of the starter cover, replacement of the starter rope and replacement of the recoil spring.

9.1 Loosen (4) starter cover screws.

9.2 Remove starter cover from saw.

9.3 Relieve spring tension in starter recoil.

• Pull 6 - 8 in (15 - 20 cm) of rope out.

• Line up rope with notch in pulley.

30

9. STARTER

9.4 Rotate pulley shaft counter clockwise, allowing pulley to unwind using rope as a brake.

695GC/F4 SERVICE MANUAL

9.5 Pulley removal from spring.

9.6 Remove the center screw and components.

Note the orientation of the parts.

refer to photo (9.7).

31

695GC/F4 SERVICE MANUAL

9.7 Note the orientation of the parts for re-installation.

9.8 A. Lift pulley from spring housing. NOTE: the spring catch and spring hook must be aligned during installation (arrows). B. Remove the two screws holding the spring housing. C. Use CAUTION when removing the spring to prevent the spring from unwinding. D. Inspect spring and lubricate with light oil. E. Align notch in spring housing with end of spring.

9. STARTER

9.9 Inspect rope (P/N 544023) and pulley (P/N 544127). Replace if necessary. Note the orientation of the knot.

32

9. STARTER

9.10 Assemble in reverse order.

695GC/F4 SERVICE MANUAL

9.11 Install the center screw and components. Note the orientation of the parts for re-installation. See 9.7 for orientation.

9.12 Tension pulley.

• Wind rope onto pulley clockwise, leaving 6-8 in (15 - 20 cm) of rope out.

• Ensure the pulley spring catch is installed on the spring hook.

33

695GC/F4 SERVICE MANUAL

9.13 Insert the rope into the pulley notch.

• Wind rope clockwise around pulley shaft 3 - 4 times. Then pull starter rope handle.

• Repeat as necessary to ensure proper spring tension.

• Ensure with starter rope fully extended the pulley can still be rotated an additional 1/2-turn before being stopped by the spring.

9. STARTER

9.14

• Rope must fully retract into starter cover.

9.15 Install starter cover.

• Pull starter rope to engage starter pawls and seat cover.

• Tighten side cover screws.

34

10. CARBURETOR REMOVAL

695GC/F4 SERVICE MANUAL

10. This section covers the removal & replacement of the carburetor & cylinder cover. Removal of air intake components and front handle is required. Refer to sections 5 & 15 if necessary.

10.1 Remove air lter cover and air lter. Refer to section 5.

Remove (2) screws (P/N 544065).

Lift cylinder cover off from the front of the cover.

®

Install in reverse order using Loctite

242

10.2 Carburetor Removal.

Remove choke lever (P/N 544117).

10.3 Lift up choke lever and rotate 90 degrees then pull out from carburetor.

Install in reverse order.

35

695GC/F4 SERVICE MANUAL

10.4 Remove (2) carburetor mounting screws (P/N 544115) using a Workshop Key Torx T27 (P/N 546191).

10. CARBURETOR REMOVAL

10.5 Remove bracket screw (P/N 544072).

Remove air intake manifold (P/N

544113).

Inspect for damage.

10.6 Remove fuel line, check valve tube and carburetor.

36

10. CARBURETOR REMOVAL

10.7 Remove throttle cable from carburetor.

695GC/F4 SERVICE MANUAL

10.8 Remove clutchside ange screw (P/N

544072) and screw (P/N 544065).

37

695GC/F4 SERVICE MANUAL

10.9 Remove plate from inlet boot.

Remove the ange bracket and ange from the inlet boot.

Note orientation of plate “UP”.

10. CARBURETOR REMOVAL

Flange and bracket.

10.10 Loosen clamp.

Inspect and replace inlet boot if damaged (see section 16.2).

• Cylinder must be loosened in order to remove the inlet boot.

• Install in reverse order.

• Using Loctite® 242 for screws.

• Note orientation of plate “UP”.

38

11. MUFFLER

695GC/F4 SERVICE MANUAL

11. This section covers the removal, inspection and assembly of the mufer. Removal of

WallWalker

®

and cylinder cover is required. Refer to section 10 if necessary.

11.1 Mufer removal.

• Remove (2) cylinder/mufer screws (P/N 543942) with scrench.

• Remove (1) lower mufer mounting screw (P/N 543846) and mufer mounting washer (P/N 543847).

11.2 Inspect and replace if damaged.

• Mufer (P/N 543845).

• Mufer gasket (P/N 543938).

• Heat Deector (P/N 543844).

Reassemble in reverse order using

®

Loctite

242.

39

695GC/F4 SERVICE MANUAL

12. GUIDE BAR STUD

12. This section covers the removal, inspection and installation of the guide bar stud. Removal of WallWalker® and mufer is required. Refer to section 10 if necessary.

12.1 Bar stud removal (P/N 544129).

12.2 Using a 6 mm allen or hex head, remove (2) bolts holding bar stud.

12.3 Inspect bar stud (P/N 544129).

• Replace if damaged.

• Install in reverse order using Loctite®242.

40

13. IGNITION MODULE

695GC/F4 SERVICE MANUAL

13. This section covers the removal, inspection and installation of the ignition module. Removal of the starter is required. Refer to section 8 if necessary.

13.1

• Remove starter cover.

• Remove starter cover shield.

• Disconnect the stop switch cable.

• Inspect and replace if damaged (P/N 544032).

13.2

• Remove (2) ignition module screws (P/N 544038).

• Remove ignition module (P/N 544036).

• Inspect and replace if damaged.

13.3 Reassemble in reverse order.

Place air gap gauge (.010 in/0.3 mm) on the magnet side of the ywheel.

• Set ignition module in place.

• Install ignition module screws with blue

®

Loctite

242.

• Holding gauge, rotate ywheel magnets around to coil.

• Torque ignition coil screws to 89-105 in/lbs (10 - 12 Nm).

• Remove gauge, rotate ywheel and check for clearance.

• Connect stop switch cable.

41

695GC/F4 SERVICE MANUAL

14.1 Remove stop switch (P/N 544031).

Disconnect cable wire.

14. STOP SWITCH

14.2 Remove screw (P/N 544030).

42

14. STOP SWITCH

14.3 Pry the switch to the left using the scrench.

695GC/F4 SERVICE MANUAL

14.4 Pull the right side out rst.

• Replace switch if damaged.

• Install in reverse order.

• Switch will snap back into place.

• Use Loctite®242 only on screw.

43

695GC/F4 SERVICE MANUAL

15. This section covers water hose and water tank cap.

15.1 Inspect hose (P/N 543999), water pipe (P/N 543915) and water valve (P/N

543996).

Replace if damaged.

15. WATER HOSE

15.2 Release clip from water inlet pipe. Pull hose upward.

Inspect hose and water inlet pipe, replace if damaged.

44

16. CYLINDER & PISTON

695GC/F4 SERVICE MANUAL

16. This section covers the removal, inspection and assembly of the cylinder, piston and related components. Refer to section 5 & 10 if necessary

16.1 Remove outer shock absorber screw (set aside for reassembly) (P/N 543981).

Loosen (4) cylinder screws(P/N 543942).

16.2 Remove cylinder from piston.

Remove shock absorber screw (see section 16.1).

Remove inlet boot and clamp. Set aside shock absorber, boot & clamp for reassembly later (see section 10.9).

CLAMP

BOOT

45

695GC/F4 SERVICE MANUAL

16.3 Remove wrist pin clip from each side of piston.

16. CYLINDER & PISTON

16.4 Remove wrist pin using the wrist pin punch (P/N 543196).

Remove piston and cylinder base gasket.

16.5 Clean crankcase.

46

16. CYLINDER & PISTON

16.6 Inspect cylinder and piston (P/N 543843) replace if damaged.

695GC/F4 SERVICE MANUAL

16.7 Install piston rings. Install lower piston ring rst.

16.8 Note the ring locator pins.

47

695GC/F4 SERVICE MANUAL

16.9 Note ring orientation. *If rings are installed upside down or incorrectly, ring will not seat properly and piston damage will occur.

16. CYLINDER & PISTON

16.10 Lubricate crankcase gasket mating surface with ICS® 2-stroke oil.

Install cylinder base gasket.

16.11

®

Lubricate needle roller with ICS

2-stroke

oil. Insert into the connecting rod.

48

16. CYLINDER & PISTON

16.12 Lubricate wrist pin with ICS

®

2-stroke oil

and partially install in the piston.

695GC/F4 SERVICE MANUAL

16.13

Install wrist pin clip into opposite side of the piston.

Make sure wrist pin clip is in the proper orientation.

See 16.15

16.14 Align the piston in correct orientation. Arrow on top of the piston points towards the mufer/exhaust port.

49

695GC/F4 SERVICE MANUAL

16.15 Install piston. A.) Align wrist pin with wrist pin needle bearing. B.) Complete wrist pin installation. C.) Install second wrist pin clip (note the orientation of the pin clips). D.) Coat piston with ICS® 2-stroke oil.

16.16 Install the inlet boot clamp, ange bracket, ange and shock absorber screw before cylinder installation. A.) Lubricate the cylinder bore with ICS® 2-stroke oil. B.) Compress the rings with compression tool (P/N 71543). C.) Slide cylinder onto piston, pushing ring tool down. D.) Remove ring compressor. E.) Slide cylinder onto piston and into the crankcase. F.) Align cylinder bolt holes with crankcase. Align cylinder screw with holes on gasket & crankcase.

16. CYLINDER & PISTON

A

B

C

16.17 Install (4) cylinder screws using Loctite

®

242. Torque to 132-156 in-lbs

(15 - 18 Nm).

50

17. BOTTOM GUARD/FRONT HANDLE

695GC/F4 SERVICE MANUAL

17. This section covers the removal, inspection and installation of the bottom guard and front handle.

17.1 Remove (2) screws (P/N 544012) and guard ap backing plate (P/N 544011).

Inspect guard ap for damage (P/N

544010) replace if damaged.

Reassemble in reverse order using

®

Loctite

242.

17.2 Remove (2) screws from lower front handle (P/N 544009).

51

695GC/F4 SERVICE MANUAL

17.3 Remove (3) screws on the side of the handle (P/N 544009).

17. BOTTOM GUARD/FRONT HANDLE

17.4 Lift up crankcase and remove handle, inspect and replace if damaged.

Install in reverse order

Use Loctite®242 on all screws except shock absorber screw.

52

18. REAR HANDLE

695GC/F4 SERVICE MANUAL

18. This section covers the removal, inspection and installation of the rear handle.

18.1 Remove screw from rear handle (P/N

543974).

18.2 Remove rear handle cover (P/N 543816).

53

695GC/F4 SERVICE MANUAL

18.3 Remove throttle lock out (P/N 543815) by squeezing, pulling up and out.

18. REAR HANDLE

18.4 Remove throttle trigger (P/N 543976) by pushing the (2) parallel pins (P/N

543813) from the rear handle housing.

18.5 Pull the throttle trigger and spring (P/N

543977) down from the rear handle.

54

18. REAR HANDLE

18.6 Remove throttle cable (P/N 543975) See section 10 to remove cable from carburetor.

695GC/F4 SERVICE MANUAL

18.7 Remove cable lever (P/N 543814) using needle nose pliers pulling up.

55

695GC/F4 SERVICE MANUAL

18.8 Remove throttle cable from cable lever using an awl or small punch.

18. REAR HANDLE

18.9 Remove throttle cable through the front of the handle.

18.10 Inspect all throttle component parts.

• Replace if damaged.

• Reassemble in reverse order.

56

19. FUEL TANK & COMPONENTS

695GC/F4 SERVICE MANUAL

19. This section covers the removal, inspection, and assembly of the shock absorbers, fuel tank and components

19.1 Remove fuel cap (P/N 543979).

• Inspect fuel cap and O-ring.

• Replace if damaged.

19.2 Remove fuel lter (P/N 543971).

Use a small hook to remove lter from gas tank.

19.3 Remove fuel lter.

• Pull up on hose clamp (P/N 543970).

• Pull down on fuel lter.

57

695GC/F4 SERVICE MANUAL

19.4 Inspect fuel lter and line.

• Replace if damaged or dirty.

• Reassemble in reverse order.

19. FUEL TANK

19.5 Before separating the fuel tank from crankcase, remove the front handle (see section 17) and throttle cable (see section 10). Remove the (2) shock absorber screws from the clutch side of the saw.

19.6 Remove the (2) shock absorber screws from the ywheel side of the saw.

58

19. FUEL TANK

19.7 Separate fuel tank from crankcase by pulling up on the crankcase while holding the fuel tank.

695GC/F4 SERVICE MANUAL

19.8 Inspect Tank Vent Assembly.

Location of the tank vent on a disassembled saw.

19.9 Location of the tank vent on an assembled saw.

59

695GC/F4 SERVICE MANUAL

19.10 Inspect the tank vent and replace if damaged. Refer to troubleshooting (section 25) if necessary.

19. FUEL TANK

19.11 Inspect fuel tank for damage.

Replace if damaged.

60

19. FUEL TANK

19.12 Shock Absorbers Using the Workshop Key Torx T27 (P/N

546191), remove shock absorbers.

A.)Front shock absorber (P/N 543983). B.) Clutch side shock absorber (P/N

543982). C.)Flywheel side shock absorber (P/N

543984). Inspect and replace if damaged.

Install in reverse order using Loctite® 242 (except Tank Vent).

695GC/F4 SERVICE MANUAL

B

A

C

19.13 Purge bulb circuit.

Refer to troubleshooting (section 24) if necessary.

19.14 Disconnect the purge bulb tube, return line (P/N 543995) and disconnect check valve tube (P/N 543994).

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695GC/F4 SERVICE MANUAL

19.15 Remove purge bulb (P/N 543973) lightly depress tab to disengage purge bulb.

19. FUEL TANK

19.16 Inspect all components.

Replace if damaged. Check valve (P/N

543969) ows one way, ensure that it is installed correctly. Fuel ows towards the purge bulb.

Refer to troubleshooting (section 24) if necessary.

19.17 Reassemble in reverse order. Check valve tube must be inserted back into channel and connected to fuel line with clip. (P/N 543818).

62

20. CRANKCASE

695GC/F4 SERVICE MANUAL

20. This section covers the disassembly, inspection and assembly of the crankcase seals and bearings.

20.1 Crankcase seal puller and punch.

20.2 Crankcase seals.

20.3 Seal removal.

A.) Insert T-handle puller over the shaft. B.) Apply downward pressure to the T-handle and turn the barrel clockwise with a wrench to thread into the seal.

63

695GC/F4 SERVICE MANUAL

20.4 Turn the T-handle until it presses against the shaft and pulls the seal from the crankcase.

20. CRANKCASE

20.5 Lift off the seal and inspect the shaft for damage.

20.6 Lubricate the shaft with High Pressure Grease.

64

20. CRANKCASE

20.7 Install the new seal. Use caution as seal slides over the threads.

695GC/F4 SERVICE MANUAL

20.8 Use the punch and soft mallet to tap seal into place.

20.9 Repeat procedure for the ywheel side.

65

695GC/F4 SERVICE MANUAL

20.10 Using soapy water on both sides, perform a crankcase leak down test using pressure gauge and vacuum gauge.

20. CRANKCASE

20.11 Use pressure gauge to perform a leak down test. Pressure should hold at 7 psi (0.5 bar).

20.12 Crankcase separation.

The universal puller and grip plate are required to separate the crankcase.

66

20. CRANKCASE

20.13 Remove the shaft seals from both sides of the crankcase.

See seal removal.

695GC/F4 SERVICE MANUAL

20.14 Install grip plate on the clutch side of the crankcase.

20.15 Attach universal puller and press out the crank shaft.

67

695GC/F4 SERVICE MANUAL

20.16 Using the same process, press out the other half from the ywheel side.

20. CRANKCASE

20.17 Separated crankcase halves with bearings installed.

20.18 If the bearing(s) remain on the shaft upon separation, the bearing removal tool must be used.

68

20. CRANKCASE

20.19 Install the bearing clamp and tighten nuts.

695GC/F4 SERVICE MANUAL

20.20 Install the bearing puller and press the bearing off the shaft.

20.21 Crankcase bearing tools. These tools are required to remove the bearing from the crankcase.

69

695GC/F4 SERVICE MANUAL

20.22 Heat crankcase halves to 150°F (65.5°) C. Use the shaft sleeve and soft mallet

to tap out both bearings.

20. CRANKCASE

20.23 Bearing installation. Bearing press tools.

20.24 Place the bearing on the bearing support plate. Holding the bearing support plate under the crankcase half.

70

20. CRANKCASE

20.25 Place the screw with nut and washers through the crankcase support plate and thread into the bearing support plate.

695GC/F4 SERVICE MANUAL

20.26 Hold the screw in place and turn the nut until the bearing stops against the crankcase.

Repeat the process for the other half of the crankcase.

20.27 Bearing Tools.

Shaft Sleeve. Shaft Mandrels.

71

695GC/F4 SERVICE MANUAL

20.28 Bearing press kit.

20. CRANKCASE

20.29 Crankshaft install. Secure clutch side crankcase face down, so the connecting rod is not pinched against the crankcase.

20.30 Slide the clutch side shaft through the bearing.

72

20. CRANKCASE

20.31 Slide the shaft sleeve over the shaft, against the crankcase. Thread the M12 mandrel with the nut and washer until it bottoms (Note - REVERSE THREAD on the clutch side).

695GC/F4 SERVICE MANUAL

20.32 Hold mandrel in place, turn nut clockwise until the shaft reaches the top at the bearing. Ensure the connecting rod is not pinched against the case.

20.33 Install the (2) crankcase guide pins.

73

695GC/F4 SERVICE MANUAL

20.34 Lubricate the crankcase halves with ICS® 2-stroke oil and install the crankcase gasket.

20. CRANKCASE

20.35 Lubricate and assemble the ywheel side of the crankcase using the same method, with the M8 standard thread mandral. Ensure the connecting rod does not become pinched between the crankcase halves.

74

20. CRANKCASE

20.36 Loctite

®

242 and pret the (8) screws and align the guide pins before bringing the crankcase together.

695GC/F4 SERVICE MANUAL

20.37 Tighten the screws to 106 - 124 in-lbs./ 12 - 14 Nm using an “x” pattern.

75

695GC/F4 SERVICE MANUAL

20.38 Cut the excess gasket over the cylinder port and carburetor area. Tap both sides of the shaft with a soft mallet and ensure free movement of shaft and connecting rod.

20. CRANKCASE

20.39 Install shaft seals (refer to section 20.7).

76

21. CARBURETOR TUNING

21. This section covers the carburetor tuning.

21.1 Carburetor tuning. A.) Throttle screw. B.). Low speed jet. C.). High speed jet. D.). Model number.

695GC/F4 SERVICE MANUAL

A

D

21.2 Tools required: Tuning screwdriver. Flat screwdriver. Tachometer.

B

C

21.3 Carburetor adjustment. Tachometer is required for proper tuning of the saw.

77

695GC/F4 SERVICE MANUAL

21.4 Throttle screw. Basic setting: T = 3 turns from closed.

Used to adjust chain speed at idle.

21. CARBURETOR TUNING

21.5 Carburetor basic setting: H= 1 1/2 turns from closed. L= 1 5/8 turns from closed.

Insert the tuning screw driver into the crankcase slot. Note the H screw is on the right as seen in the picture.

L

H

78

21. CARBURETOR TUNING

21.6 Turn both the H and the L needle screws clockwise until they stop.

695GC/F4 SERVICE MANUAL

21.7 Turn the screws counter clockwise to the carburetor basic settings.

Carburetor basic setting: H= 1 1/2 turns from closed. L= 1 5/8 turns from closed.

79

695GC/F4 SERVICE MANUAL

22.1 Verify the RPM’s using the tachometer.

Start and warm up the saw.

NOTE: This is a “no load” tuning procedure. The side cover must be securely fastened with a bar and chain.

Water MUST be used, failure to follow this procedure may result in personal injury and or damage to the saw.

22.2 Using the tachometer, check the saw RPM’s at idle.

• Idle speed = 2700 RPM’s +/- 150.

22. IDLE SPEED ADJUSTMENT

• Make minor adjustments using the throttle screw.

Using the tachometer, check the saw RPM’s at full throttle.

• Full throttle target = 9300 RPM’s +/-

150.

• Make minor adjustments using the throttle screw.

Do not hold the saw at maximum RPM for more than 5 seconds.

If the full throttle RPM falls below this range, turn the H needle clockwise 1/16 of a turn at a time, checking the RPM’s at each interval. NOTE: pulse the throttle to stablize the system.

Once the carburetor is adjusted, install the chain to the proper tension and continue normal operations.

80

23. DIAGRAMS

TROUBLESHOOTING

695GC/F4 SERVICE MANUAL

23. This section provides several flowcharts to aid diagnosing common problems.

CHECK POSSIBLE CAUSE REPAIR

• Clean or replace the air filter.

The engine runs rough at

all speeds.

YES

• Dirty or clogged air filter.

• Water has been ingested.

• Loose or dirty spark plug.

• Inspect air intake system for water.

• Inspect fuel system for water.

• Tighten, clean, or replace spark plug.

A dirty air filter is the #1 reason for engine problems.

The engine is overheating.

Poor acceleration.

Uneven idle or engine

may “run away”.

YES

• Operator is overworking the saw.

• Carburetor mixture is too

YES

• Dirty or clogged air filter.

• Clogged fuel filter.

• Incorrect carburetor tune.

• Plugged fuel tank breather.

YES

lean.

• Incorrect fuel/oil ratio.

• Flywheel fins are clogged.

• Air deflector is missing.

• Cylinder fins are clogged.

• Air leak at intake boot, cylinder gasket, or crankcase gasket.

• Faulty carburetor diaphragm.

• 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.

• Clean or replace the air filter.

• Replace fuel filter.

• See Carburetor Tuning section.

• Repair or replace fuel tank breather.

• Inspect air intake boot.

• Pressure test crankcase.

• Replace carburetor.

Diamond chain moves

at idle.

Excessive vibration.

YES

• Idle speed too high.

• Broken clutch spring.

• Damaged shock absorber.

• Damaged or broken flywheel fins.

• Bent crankshaft.

• Adjust idle speed.

• Replace clutch spring.

• Replace shock absorbers.

• Replace flywheel.

• Replace crankshaft.

81

695GC/F4 SERVICE MANUAL

CHECK POSSIBLE CAUSE REPAIR

TROUBLESHOOTING

Saw Will Not Start

23. DIAGRAMS

Does the engine crank?

YES

Is there spark?

YES

Is the spark plug firing

properly?

YES

Check cylinder

compression

YES

NO

• Dirty or broken recoil starter

• Internal damage

• The ignition switch is in “STOP” position

• Faulty ignition ground

• Faulty spark plug lead

• Faulty ignition coil

• Plug is soaked with fuel

• The plug is fouled or gapped improperly

• Plug is internally faulty or the wrong type

• Loose spark plug

• If below 125 psi – excess wear on the piston, cylinder, rings and/or improper fuel mixutre

• Clean, rebuild or replace the recoil starter

• Inspect for internal damage such as seized piston

• Release switch from “STOP” and re-test

• Tighten connections or replace ground wire

• Repair or replace spark plug lead

• Replace ignition coil

• Dry plug, expel excess fuel from cylinder and crankcase

• Clean and re-gap the plug to

0.020 inch (0.05 mm)

• Replace with the correct plug – See Spark Plug Reference Guide

• Tighten plug and re-test

• Replace piston and cylinder

• Ensure correct fuel/oil mixture (25:1)

Is the fuel fresh?

YES

Is the fuel reaching the

carburetor?

YES

Is too much fuel

reaching the

carburetor?

NO

Is the flywheel key

sheared?

NO

YES

• Fuel is old, varnished, or contaminated

• Clogged fuel filter

• Damaged fuel line

• Plugged fuel tank breather

• Carburetor is tuned incorrectly

• Plugged fuel tank breather

• Loose flywheel • Replace flywheel

• Empty tank and re-fill with fresh fuel of the correct mixture (25:1)

• Replace fuel filter

• Replace fuel line

• Repair or replace fuel tank breather

• Refer to Carburetor Tuning section

• Repair or replace fuel tank breather

82

24. FUEL SYSTEM

TROUBLESHOOTING

24. This section covers testing the fuel system.

24.1 Engine starvation can result from a leak or malfunction of any of the main components of the fuel system.

695GC/F4 SERVICE MANUAL

24.2 The main components are the fuel tank, fuel tank breather, fuel lter, purge bulb, delivery tubes and carburetor.

24.3 Remove and inspect the fuel lter.

Replace the fuel lter if the lter is excessively dirty or there is foreign material stuck to it.

83

695GC/F4 SERVICE MANUAL

24.4 Test the main fuel pick-up for leaks.

Install the pressure gauge and bulb to the lter end of the fuel line.

Pressurize the tube to 7psi (0.5 bar)

If the pressure does not maintain, separate the fuel line from the carburetor

TROUBLESHOOTING

24. FUEL SYSTEM

24.5 Plug one end of the fuel pick-up tube.

Pressurize the tube to 7 psi (0.5 bar).

If the pressure holds, the leak has been isolated to the carburetor. Refer to the Walbro Carburetor Service Manual.

http://wem.walbro.com/distributors/servicemanuals

24.6 The fuel tank breather stabilizes the pressure in the fuel tank preventing both excessive pressure, which could ood the engine and negative pressure which could starve the engine of fuel.

84

24. FUEL SYSTEM

24.7 The fuel breather is located above the fuel cap on top of the fuel tank.

TROUBLESHOOTING

695GC/F4 SERVICE MANUAL

24.8 Testing the fuel tank breather.

Attach the pressure gauge to the fuel tank plug. Plug the fuel line at the carburetor end. Pressurize the tube to

4.5 psi (0.3 bar).

The pressure should reduce to nearly 0 psi (0 bar) over a period of 3 seconds.

85

695GC/F4 SERVICE MANUAL

24.9 If the pressure does not release, disassemble or replace the breather.

TROUBLESHOOTING

24. FUEL SYSTEM

24.10 Inspect the fuel purge circuit.

Inspect the purge bulb for leaks or damage. Replace if damaged. See fuel tank section.

24.11 Inspect fuel purge lines and one way purge valve for leaks or damage. The arrow is the purge ow direction.

Replace if damaged. See fuel tank section.

86

25. CRANKCASE LEAKS

TROUBLESHOOTING

25.1

This section covers testing the the crankcase for leaks. A leak in the crankcase can cause the engine to run too lean, causing engine damage, or not run at all.

A.) Exhaust Seal Flange. B.) Intake Seal Flange.

25.2 With the carburetor and mufer removed, block the intake and exhaust ports with the seal anges.

695GC/F4 SERVICE MANUAL

A B

See Cylinder Cover and Mufer sections. NOTE: Remove intake plate from intake boot prior to installing intake seal ange.

25.3 Securely plug or tape over the clutch needle roller lubrication port on the crankshaft.

Clutch cup and needle roller must be removed. See Clutch Cup and Rim Sprocket Section (section 8).

87

695GC/F4 SERVICE MANUAL

TROUBLESHOOTING

25.4 Install the exhaust seal ange.

Use the mufer mounting screws to install the ange.

Be sure the spark plug is secure and the decompression valve is pulled out.

25. CRANKCASE LEAKS

25.5 Install the intake seal ange.

Use M4 x 20 screws w/ washers (not supplied) to secure the seal ange.

Install the pressure gauge and pressurize the crankcase to 7 psi (0.5 bar). If the pressure does not hold, use soapy water to nd the leak.

Note: it is recommended to pressure test the engine after a piston and cylinder rebuild, and or crank seal replacements.

88

APPENDIX ‑ SPARK PLUG

695GC/F4 SERVICE MANUAL

This appendix covers the removal, inspection, and installation of the spark plug for the 695GC & 695F4.

Remove the spark plug lead.

Clean area around the spark plug to prevent debris from entering the cylinder.

Remove the spark plug.

Inspect the spark plug.

If dirty, clean with a wire brush as shown.

89

695GC/F4 SERVICE MANUAL

Gap if necessary to 0.02” (0.5 mm).

695GC: Champion RCJ‑6Y

or N GK‑B PMR7A

695F4: Champion RCJ‑6Y

or N GK‑B PMR7A

Assemble in the reverse order.

APPENDIX ‑ SPARK PLUG

Make sure the plug boot is seated completely.

90

695 SERVICE MANUAL

ICS ‑ Blount Inc.

4909 SE International Way

Portland, OR 97222

Tel 800.321.1240 Fax 603.653.4393

icsbestway.com

ICS 695GC/F4 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual