ICS 603GC Install guide

603GC Gas Utility Saw
Shop Manual

TITLE603GC SHOP MANUAL
1
Copyright © May 24, 2006 ICS, Blount Inc.
TABLE OF CONTENTS
SECTION SECTION TITLE PAGE NUMBER
SHOP MANUAL USE 2
1 TOOLS 3
2 SAW SPECIFICATIONS 4
3 SERIAL NUMBER LOCATION 5
4 SPARE PARTS DIAGRAM (TORQUE AND LOCTITE®) 6
5 AIR INTAKE 19
6 SPARK PLUG 21
7 CLUTCH & RIM SPROCKET 23
8 STARTER SYSTEM 27
9 WALLWALKER 33
10 CYLINDER COVER 35
11 MUFFLER 39
12 CARBURETOR 41
13 CYLINDER & PISTON 43
14 WATER HOSE 52
15 IGNITION COIL 53
16 FLYWHEEL 55
17 FRONT HANDLE 57
18 FUEL TANK 58
19 CRANKCASE 60
20 BAR STUDS 68
21 TENSIONER 69
22 CARBURETOR TUNING 70
23 IDLE SPEED ADJUSTMENT 74
24 TROUBLESHOOTING DIAGRAMS 75
25 TROUBLESHOOTING: FUEL SYSTEM LEAKS 77
26 TROUBLESHOOTING: CRANKCASE LEAKS 80
APPENDIX
1. SPARK PLUG REFERENCE GUIDE 81

TITLE 603GC SHOP MANUAL
2Copyright © May 24, 2006 ICS, Blount Inc.
SHOP MANUAL USE
Shop Manual Use
This manual contains all the technical information necessary for carrying out repairs on the
603GC cut-off 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 cut-off 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 other.
• Mark mating parts as a reassembly reference.
• Keep component parts together as a group. Assemble screws and nuts into
appropriate subgroups.
• When reassembling, clean all parts carefully, lubricate moving parts and replace
all oil seals, o-rings, gaskets, washers and self-locking nuts.
• For best results, use only original ICS®replacement parts.
General Recommendations
• Some procedures in this manual require the use of special tools. A complete tool kit
for ICS®cut-off 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.

603GC SHOP MANUAL
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Copyright © May 24, 2006 ICS, Blount Inc.
1. TOOLS
KEY P/N DESCRIPTION
SERVICE 71572 TOOL KIT
1 71521 SCRENCH, 13-19mm
2 71541 PRESSURE GAUGE BULB
3 71542 COIL/FLYWHEEL TIMING SHIM
4 71543 CYLINDER ASSEMBLY CLAMPS & PISTON STOP
5 73462 MAIN BEARING DRIVER TOOL
6 71546 SHOCK ABSORBER TOOL
7 71547 SPARK TESTER
8 71548 FLYWHEEL PULLER TOOL
9 71550 LIMITER CAP REMOVAL TOOL
10 71565 ELECTRONIC TACHOMETER
11 71569 INDUCTION SEAL FLANGE W/ SCREWS
12 71570 EXHAUST SEAL FLANGE W/ SCREWS
13 71573 TUNING SCREWDRIVER
Gas Saw Service Tool Kit - P/N 71572
1 2 3 4
6 7 8 9 10
11 12 13
5

603GC SHOP MANUAL
4Copyright © May 24, 2006 ICS, Blount Inc.
2. SPECIFICATIONS
SPECIFICATIONS
Engine Type 2-Stroke Single Cylinder Air Cooled
Displacement 3.9 cu. in. (64 cc)
Horsepower 4.2 hp (3.1 kW) @ 9500 rpm
Engine Speed 12,500 ± 500 rpm, electronically governed
2800-3200 rpm @ idle
Weight 18.5 lbs. (8.4 kg) with bar and chain
Cutting Depth Up to 9 inches (23 cm)
Dimensions 18 inches (45 cm) length
11.5 inches (29 cm) height
10 inches (25 cm) width
Carburetor Walbro diaphragm HDA-225
Air Filtration Canister, polyester
Starter Dust and water shielded
Ignition Electronic speed governing, water sealed
Clutch Three-weight, single spring, centrifugal
Fuel Mix Ratio 25:1 gasoline to oil with brand name gasoline and
ICS®2-stroke engine oil, or other high quality 2-stroke
engine oil for air cooled engines.
Fuel Capacity (0.18 gal / 0.68 lit)
15-18 minute run time
Water Supply Minimum 20 psi (1.5 bar)
Noise Level 100 db @ 1 meter
Vibration Level 11.0 m/s
Spark Plug TYPE Champion RCJ-7Y (for spark plug reference guide see page 81)
Spark Plug Gap 0.02 inches (0.5 mm)
Sprocket Type 8-tooth rim sprocket

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Copyright © May 24, 2006 ICS, Blount Inc.
3. SERIAL # LOCATION
3 603GC Cut-Off serial number series.
603GC SHOP MANUAL

603GC SHOP MANUAL
6Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
4 This section covers torque, Loctite®, and lubrication requirements of the individual
components. The key numbers used are not related to the key numbers in the
603GC Replacement Parts Price List.
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
6 WRIST PIN NEEDLE BEARING 505403
11 CYLINDER BLOCK BOLT & WASHER 1.1 95 X 73874
16 CYLINDER BASE GASKET 505439
17 SPARK PLUG 2.8 243 73199
25 COMPLETE CYLINDER & PISTON ASSEMBLY 505428
33 WASHER 73963
50 SCREW PLUG 73965
60 DECOMPRESSION VALVE 1.3 113 71642
CYLINDER & PISTON ASSEMBLY

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Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 CRANKCASE PLUG 505407
2 CRANKCASE 505410
3 CRANKCASE DOWEL PIN 73281
4 CHOKE LEVER 505409
5 BAR MOUNTING STUD 509555
6 CRANKCASE GROMMET 505408
7 WASHER 73897
9 BAR MOUNT PAD COVER PLATE 505467
12 CRANKCASE GASKET 505440
13 CHOKE LEVER BUSHING 73955
15 CRANKCASE BOLT 0.8 69 X 73930
18 SCREW, 5 X 50mm 0.5 43 X 509709
22 CRANKCASE 505427
25 TENSIONER 505393
27 CRANKSHAFT BEARING 505375
28 FUEL LINE GROMMET 505627
CRANKCASE ASSEMBLY

603GC SHOP MANUAL
8Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 CRANKSHAFT SEAL FLYWHEEL SIDE 73877
2 CRANKSHAFT BEARING 505375
4 CRANKSHAFT SEAL 505381
5 CRANKSHAFT BUSHING X 509487
6 WRIST PIN NEEDLE BEARING 505403
7 CRANKSHAFT ASSEMBLY 505397
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
8 CLUTCH SPRING 505434
10 CRANKCASE SEAL RETAINER 505423
11 CRANKSHAFT SEAL 505381
14 CLUTCH SPACER 505421
16 CLUTCH 3.4 295 505442
17 CLUTCH SPACER INSIDE 505436
20 CLUTCH BEARING 505378
21 8T RIM SPROCKET KIT 70949
23 OUTER CRANKCASE SEAL BODY SCREW 0.3 26 X 73940
24 WAVE WASHER, 4.5mm 73285
26 CLUTCH CUP WITH SPLINED ADAPTOR 505422
CLUTCH & CRANKCASE ASSEMBLY

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Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 MUFFLER SUPPORT BRACKET SCREW 0.9 78 X 73885
2 SERRATED WASHER 73327
3 MUFFLER SUPPORT BRACKET 505392
4 MUFFLER MOUNTING SCREW 1.0 87 73883
5 SCREW 0.4 35 71482
6 WASHER 73897
7 MUFFLER DEFLECTOR 505396
9 MUFFLER ASSEMBLY 505418
10 CYLINDER-TO-MUFFLER GASKET 505385
MUFFLER ASSEMBLY

603GC SHOP MANUAL
10 Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 SCREW 0.4 35 X 73866
2 INTAKE MANIFOLD CLAMP 73867
3 INTAKE MANIFOLD 505383
21 CARBURETOR PULSE TUBE 73898
32 CARBURETOR SPRING 73888
36 WASHER 73897
38 CARBURETOR ATTACHMENT SCREW 0.5 43 X 73902
49 OUTER INTAKE MANIFOLD FLANGE SCREW 0.4 35 X 73901
54 CARBURETOR MOUNTING BRACKET 505411
55 CARBURETOR 505654
63 OUTER INTAKE MANIFOLD FLANGE 505384
64 OUTER INTAKE MANIFOLD 507427
65 ADJUSTMENT GUIDE 505391
69 BREATHER TUBE BODY 71751
CARBURETOR ASSEMBLY

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Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 FUEL TANK 505655
2 REAR HANDLE HALF 505389
3 SCREW 0.1 9 73976
4 THROTTLE LEVER 73977
5 FUEL CAP ASSEMBLY, WITH OUTER SEAL RIING 71739
7 SHOCK ABSORBER WITH SCREW 505658
8 BREATHER TUBE BODY 71751
9 SCREW 0.9 78 X 73982
10 WASHER 73897
11 FRONT HANDLE BOLT 0.8 69 X 73983
12 FRONT HANDLE 505424
13 FUEL FILTER 73459
14 FUEL LINE 73375
15 FUEL CAP O-RING 73448
16 TRIGGER LOCKOUT LEVER 73987
17 TRIGGER LOCKOUT LEVER SPRING 73988
18 BUMPER, SHOCK ABSORBER, FUEL TANK TOP 73270
25 FUEL BREATHER COMPLETE 71748
27 REAR HANDLE SHOCK ABSORBER 505425
31 TUBE CLAMP, WITH TABS 71588
32 BREATHER TUBE ELBOW 71759
33 TUBE CLAMP, NO TABS 71760
35 FUEL BREATHER, REMOTE 71761
38 RUBBER WATER DEFLECTOR 505445
41 SHOCK ABSORBER 0.4 35 505387
FUEL TANK & HANDLE ASSEMBLY

TITLE 603GC SHOP MANUAL
12 Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
31 FLYWHEEL SHROUD 505438
45 FLYWHEEL 505399
48 NUT 3.0 260 73891
51 WAVE WASHER 73911
57 PLAIN WASHER 73912
71 STARTER PAWL ASSEMBLY 0.7 61 508852
FLYWHEEL ASSEMBLY

603GC SHOP MANUAL
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Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
39 WAVE WASHER, 4.5mm 73285
40 SPARK PLUG CAP & SPRING KIT 73241
41 SPARK PLUG SPRING 73917
43 IGNITION TOGGLE CABLE 73919
44 IGNITION COIL 505426
47 SWITCH, IGNITION TOGGLE 73237
53 SCREW 0.7 61 X 73914
56 PLAIN WASHER 0.3 26 73890
59 IGNITION TOGGLE SWITCH NUT 73239
61 IGNITION TOGGLE PLATE ON/OFF 73238
66 SWITCH GROUND CONNECTION PLATE 71449
IGNITION ASSEMBLY

603GC SHOP MANUAL
14 Copyright © May 24, 2006 ICS, Blount Inc.
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 SCREW 0.4 35 X 73866
26 STARTER ROPE HANDLE 505514
27 STARTER ROPE 508854
30 STARTER PULLEY SCREW 0.6 52 X 73907
34 RECOIL HOUSING SCREW 505380
35 STARTER PULLEY WASHER 73905
37 STARTER ROPE PULLEY 508857
42 STARTER ASSEMBLY 505416
58 STARTER COIL SPRING & HOUSING 73909
62 STARTER CASE PLATE 71451
72 STARTER ASSEMBLY CAP 508853
STARTER ASSEMBLY
4. SPARE PARTS DIAGRAM

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Copyright © May 24, 2006 ICS, Blount Inc.
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 CYLINDER COVER 505691
2 AIR FILTER CANISTER, POLY 71752
3 AIR FILTER COVER ASSEMBLY, 3 SCREW 0.4 35 71753
4 FILTER COVER SCREW 73992
5 FILTER SUPPORT 73338
6 FILTER COVER GASKET 71756
7 CYLINDER COVER SCREW 0.5 43 X 505429
8 PREFILTER PLASTIC, SECONDARY FILTER 73336
9 AIR FILTER FLANGE 71758
10 FILTER SUPPORT SCREW 0.3 26 X 505437
11 FILTER CANISTER GASKET 73335
12 O-RING 71472
13 TUBE CLAMP, NO TABS 71760
14 COMPENSATOR TUBE 505382
15 BREATHER GROMMET 71763
16 THROTTLE ASSEMBLY 71750
17 O-RING, AIR FILTER 73331
18 WASHER 73897
AIR FILTER ASSEMBLY
4. SPARE PARTS DIAGRAM

603GC SHOP MANUAL
16 Copyright © May 24, 2006 ICS, Blount Inc.
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 HOSE CLAMP 71465
2 WATER HOSE 509488
3 WATER HOSE COVER 71464
4 HOSE HANGER 71461
5 WATER SHUT-OFF VALVE 71458
6 WATER HOSE O-RING 71468
7 RING NUT 71457
8 FITTING 71467
19 WATER HOSE GASKET 71469
24 FITTING 71454
27 FITTING 71466
4. SPARE PARTS DIAGRAM
WATER DELIVERY SYSTEM

603GC SHOP MANUAL
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Copyright © May 24, 2006 ICS, Blount Inc.
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
9 SIDE COVER 505415
10 SIDE COVER NUT 1.2 104 73958
11 GUARD FLAP NUT 505468
12 SCREW 0.5 43 73982
13 GUARD FLAP MOUNTING BRACKET (BACK) 505490
14 GUARD FLAP MOUNTING BRACKET (FRONT) 505491
15 GUARD FLAP SCREW 71479
16 GUARD FLAP 505492
17 RUBBER BUMPER, COVER 73310
18 SCREW 71487
19 SIDE COVER PLATE 505419
20 SIDE COVER GASKET 505417
21 MOUNTING NUT 509852
22 RUBBER WALLWALKER 505493
23 FITTING X 71454
24 BOLT 73983
4. SPARE PARTS DIAGRAM
SIDE COVER ASSEMBLY

603GC SHOP MANUAL
18 Copyright © May 24, 2006 ICS, Blount Inc.
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
ABOVE CARBURETOR WALBRO HDA-225 517742
CARBURETOR REPAIR KIT 505441
CARBURETOR REPAIR KIT