ICS 613GC User manual

613GC
© 2008 ICS, Blount Inc.
SERVICE MANUAL
F/N 71537 Jan O8

TITLE613GC SHOP MANUAL
1
© 2008 ICS, Blount Inc.F/N 71537 Jan O8
TABLE OF CONTENTS
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 15
6 SPARK PLUG 17
7 CLUTCH & RIM SPROCKET 19
8 STARTER SYSTEM 23
9 WALLWALKER 29
10 CYLINDER COVER 31
11 MUFFLER 34
12 CARBURETOR 36
13 CYLINDER & PISTON 38
14 WATER HOSE 47
15 IGNITION COIL 49
16 FLYWHEEL 51
17 BOTTOM GUARD 53
18 FRONT HANDLE 54
19 FUEL TANK 55
20 CRANKCASE 57
21 BAR STUDS 65
22 TENSIONER 66
23 CARBURETOR TUNING 67
24 IDLE SPEED ADJUSTMENT 71
25 TROUBLESHOOTING DIAGRAMS 72
26 TROUBLESHOOTING: FUEL SYSTEM LEAKS 74
27 TROUBLESHOOTING: CRANKCASE LEAKS 77
APPENDIX
1. SPARK PLUG REFERENCE GUIDE 78
2. ENGINE REBUILD TIPS 79
SECTION SECTION TITLE PAGE NUMBER

TITLE 613GC SHOP MANUAL
2© 2008 ICS, Blount Inc. F/N 71537 Jan O8
SHOP MANUAL USE
Shop Manual Use
This manual contains all the technical information necessary for carrying out repairs on the
613GC 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,
orings, 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.

613GC SHOP MANUAL
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© 2008 ICS, Blount Inc.F/N 71537 Jan O8
1. TOOLS
P/N DESCRIPTION
171521 SCRENCH
271541 PRESSURE GAUGE BULB
371542 COIL/FLYWHEEL TIMING SHIM
471543 CYLINDER ASSEMBLY CLAMPS & PISTON STOP
571546 613 SHOCK ABSORBER TOOL
671547 SPARK TESTER
771548 613 FLYWHEEL DISASSEMBLY TOOL
871550 LIMITER CAP REMOVAL TOOL
971565 ELECTRONIC TACHOMETER
10 71569 613GC INDUCTION SEAL FLANGE W/ SCREWS
11 71570 613GC EXHAUST SEAL FLANGE W/SCREWS
12 71573 TUNING SCREWDRIVER
13 73410 633GC FLYWHEEL PULLER
14 73425 633GC FUEL PRESSURE CAP
15 73428 613GC & 633GC MAIN BEARING DRIVER TOOL
16 73429 633 MAIN BEARING SPACING TOOL
17 73430 633GC SHOCK ABSORBER TOOL
18 73431 633GC INTAKE PORT COVER TOOL
19 73432 633GC EXHAUST PORT COVER TOOL
Gas Saw Service Tool Kit - P/N 71700
12345
678910
11 12 13 14 15
16 17 18 19

613GC SHOP MANUAL
4© 2008 ICS, Blount Inc. F/N 71537 Jan O8
2. SPECIFICATIONS
SPECIFICATIONS
Engine Type 2-Stroke Single Cylinder Air Cooled
Displacement 4.9 cu. in. (80.7 cc)
Horsepower 5.7 hp (4.2 kW) @ 9000 rpm
Engine Speed 12,000 ±500 rpm, electronically governed
2800-3200 rpm @ idle
Chain Speed 5300 fpm (27 m/s), free running
4000 fps (20 m/s), in the cut
Weight 21 lbs. (9.5 kg) with bar and chain
Cutting Depth Up to 12 inches (30 cm)
Dimensions 18 inches (45 cm) length
11.5 inches (29 cm) height
10 inches (25 cm) width
Carburetor Walbro diaphragm WJ-85B
Air Filtration Dry nylon
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 0.23 gal (0.88 liter)
15-18 minute run time
Water Supply Minimum 20 psi (1.5 bar)
Noise Level 100 dB @ 1 meter
Vibration Level 10.5 m/s
Spark Plug TYPE Champion RCJ-7Y (for spark plug reference guide see page 78)
Spark Plug Gap 0.02 inches (0.5 mm)
Sprocket Type 8-tooth rim sprocket

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© 2008 ICS, Blount Inc.F/N 71537 Jan O8
3. SERIAL # LOCATION
3 613GC Cut-Off serial number series.
613GC SHOP MANUAL

613GC SHOP MANUAL
6© 2008 ICS, Blount Inc. F/N 71537 Jan O8
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
613GC Replacement Parts Price List.
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1SCREW 3.95 35 X73866
2 STARTER ROPE HANDLE 505514
3 STARTER ROPE 73904
4 STARTER COIL SPRING & HOUSING 73909
5 STARTER CASE PLATE 71451
6 STARTER COIL SPRING & HOUSING SCREW 73910
7 STARTER ROPE PULLEY 73913
8 STARTER PULLEY WASHER 73905
9 STARTER PULLEY SCREW 5.87 52 X73907
10 STARTER COVER ASSEMBLY 71415
11 STARTER COVER AIR DEFLECTOR 73908
12 NUT 29.37 260 73891
13 WASHER 73911
14 WAVE WASHER 73912
15 FLY WHEEL AS SE MB LY 6.89 61 509163
16 STARTER PAWL ASSEMBLY 509207
18 SCREW 2.93 26 X73914
19 SWITCH, IGNITION TOGGLE 73237
20 IGNITION TOGGLE CABLE 73919
21 SCREW 73914
22 WAVE WASHER 73285
23 PLAIN WASHER 73890
24 SPARK PLUG CAP 73241
25 SPARK PLUG SPRING 73917
26 IGNITION COIL WITH SPARK PLUG LEAD & PRIMARY 73920
27 SWITCH GROUND CONNECTION PLATE 71449

613GC SHOP MANUAL
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© 2008 ICS, Blount Inc.F/N 71537 Jan O8
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 REAR MANIFOLD CLAMP 73867
2REAR MANIFOLD 73868
3 WRIST PIN NEEDLE BEARING 73869
4 COMPLETE PISTON/CYLINDER ASSEMBLY 71413
5 CYLINDER BASE GASKET ASSEMBLY 71412
6SPARK PLUG 27.4 5 243 73199
7 CYLINDER TO MUFFLER GASKET 73881
9 CARBURETOR ATTACHMENT SCREW WASHER 73327
10 MUFFLER ASSEMBLY 71411
11 CYLINDER BLOCK BOLT 10.73 95 X73874
12 MUFFLER MOUNTING SCREW 9.82 87 73883
13 CARBURETOR PULSE TUBE 73898
14 MUFFLER SUPPORT BRACKET 73884
15 MUFFLER SUPPORT BRACKET SCREW 8.81 78 73885
16 COMPLETE CARBURETOR WJ-85B 71762
17 INTAKE MANIFOLD FLANGE SCREW 3.95 35 X73901
18 WASHER 73250
19 CARBURETOR SUPPORT BRACKET 73895
20 DECOMPRESSION VALVE 12.76 113 71642
21 INTAKE MANIFOLD FLANGE 73947
22 INTAKE MANIFOLD 71735
23 CARBURETOR PULSE TUBE PROTECTOR 73888
24 WASHER 73897
25 CARBURETOR ATTACHMENT SCREW 4.85 43 73902
26 SCREW 3.95 35 X73866
27 SCREW GUIDE 5.87 52 73899
28 MUFFLER DEFLECTOR 71481
29 SCREW 3.95 35 71482

613GC SHOP MANUAL
8© 2008 ICS, Blount Inc. F/N 71537 Jan O8
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 CRANKSHAFT SEAL FLYWHEEL SIDE 73877
2CRANKSHAFT BEARING 73209
3 CRANKSHAFT FLYWHEEL WOODRUFF KEY 73878
4CRANKSHAFT ASSEMBLY 71410
5 WRIST PIN NEEDLE BEARING 73869
6CLUTCH SIDE MAIN BEARING SEAL-INSIDE 73289
7CRANKSHAFT BUSHING 71452
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 OUTER CRANKCASE SEAL CLUTCH SIDE 73931
2 OUTER CRANKCASE SEAL BODY 73949
3 OUTER CRANKCASE SEAL BODY SCREW 2.93 26 73940
4WASHER 73285
5 CLUTCH SPACER WASHER 73945
6 8T RIM SPROCKET KIT 70949
7 CLUTCH NEEDLE BEARING 73939
8 613GC CLUTCH DRUM ASSEMBLY 71520
9 CLUTCH SPACER WASHER, INSIDE 73941
10 CLUTCH 33.33 295 71419
11 CLUTCH SPRING 73943

613GC SHOP MANUAL
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© 2008 ICS, Blount Inc.F/N 71537 Jan O8
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1GUARD FLAP 71534
2WALLWALKER®LEVER ARM 71532
3 GUARD FLAP CLAMP 71531
4WASHER 73951
5WALLWALKER®LEVER ARM SCREW 4.85 43 X71478
6 GUARD FLAP SCREW 4.85 43 X71479
7 GUARD FLAP WASHER 71483
8 GUARD FLAP SPACER 71480
9 WATER HOSE GASKET 71469
10 FITTING 71467
11 RING NUT 71457
12 WATER HOSE O-RING 71468
13 WATER SHUT-OFF VALVE 71458
14 FITTING 71454
15 WATER HOSE 71455
16 HOSE CLAMP 71465
17 HOSE HANGER 71461
18 WATER HOSE COVER 71464
19 WATER HOSE SCREW 19.65 174 71463
20 FITTING 71453
21 COPPER WASHER 71456
22 WATER TANK CAP 73923
23 FUEL CAP O-RING 73448
24 TUBE 71459
25 FITTING 71470
26 FITTING 71471
27 O-RING 71472
28 HOSE HANGER BUTTON 7174 4

613GC SHOP MANUAL
10 © 2008 ICS, Blount Inc. F/N 71537 Jan O8
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1FUEL LINE GROMMET (CRANKCASE) 73390
2 CRANKCASE ASSEMBLY, LEFT HALF 71736
3 CRANKCASE DOWEL PIN 73281
4CRANKSHAFT BEARING 73209
5 CRANKCASE ASSEMBLY, RIGHT HALF 71747
7 CHOKE LEVER SPLIT PIN 73927
8CRANKCASE GASKET 73934
9 CRANKCASE BOLT 7.79 69 X73930
10 WASHER 73897
11 BOTTOM COVER 73950
12 BAR MOUNT PAD SPACER 71740
13 COVER GUARD MOUNTING BOLT 7.79 69 X73397
14 SCREW (CRANKCASE) 4.85 43 X73379
15 BAR MOUNTING STUD 11.75 104 73933
16 SCREW 7.79 69 73284
17 BAR MOUNT PAD COVER PLATE 71738
18 PREMIUM TENSIONER KIT (REPLACES 73283), ASSEMBLY 73935
19 TENSIONER SCREW RETAINER 73936
20 CHOKE LEVER 73928
21 CRANKCASE GROMMET, RIGHT SIDE 71741
22 CHOKE LEVER BUSHING 73955

613GC SHOP MANUAL
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© 2008 ICS, Blount Inc.F/N 71537 Jan O8
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 SIDE COVER INSERT, TOP 71743
2 SIDE COVER NUT 11.75 104 73958
3 CHAIN COVER CAP 71462
4MOUNTING NUT 73367
5 WALLWALKER® SIDE ARM 71533
6WASHER 73951
7 WALLWALKER® SIDE ARM SCREW 507355
8SCREW 2.93 26 X71487
9 SIDE COVER PLATE 71447
10 LOWER GUARD 73957
11 SIDE COVER INSERT, BOTTOM REAR 73972
12 SIDE COVER INSERT, TOP REAR 73948
13 SIDE COVER GROMMET 73310
14 SIDE COVER ASSEMBLY, COMPLETE 71420

TITLE 613GC SHOP MANUAL
12 © 2008 ICS, Blount Inc. F/N 71537 Jan O8
4. SPARE PARTS DIAGRAM

613GC SHOP MANUAL
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© 2008 ICS, Blount Inc.F/N 71537 Jan O8
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 CYLINDER COVER ASSEMBLY, WITH AIR INTAKE 71754
2 AIR FILTER CANNISTER, POLYESTER 71752
3 AIR FILTER COVER ASSEMBLY, 3 SCREW 71753
4 FILTER COVER SCREW 73992
5 FILTER SUPPORT 73338
6 FILTER COVER GASKET 71756
7 SCREW, CYLINDER COVER, LONG, SOCKET HEAD X X X 71771
8 PREFILTER PLASTIC, SECONDARY FILTER 73336
9 AIR FILTER FLANGE 71758
10 FILTER SUPPORT SCREW 2.93 26 X73337
11 FILTER CANNISTER GASKET 73335
12 O-RING 71472
13 TUBE CLAMP, NO TABS 71760
14 COMPENSATOR TUBE 71775
15 BREATHER GROMMET 71763
16 THROTTLE ASSEMBLY 71750
17 O-RING, AIR FILTER 73331

613GC SHOP MANUAL
14 © 2008 ICS, Blount Inc. F/N 71537 Jan O8
4. SPARE PARTS DIAGRAM
KEY DESCRIPTION TORQUE LOCTITE® PART NUMBER
Nm in‑lbs. 242
1 FUEL TANK ASSEMBLY (REQUIRES P/N 71739) 71421
2 REAR HANDLE HALF 73975
3SCREW 1.01 973976
4 THROTTLE LEVER 71749
5 FUEL CAP ASSEMBLY, WITH OUTER SEAL RING 71739
6 FUEL CAP O-RING 73448
7 FUEL FILTER 73459
8 TRIGGER LOCKOUT LEVER 73987
9 TRIGGER LOCKOUT LEVER SPRING 73988
0WASHER 73897
11 SCREW 8.81 78 X73982
12 SHOCK ABSORBER 3.95 35 73980
13 TUBE CLAMP, WITH TABS 71588
14 FUEL LINE 73375
15 SHOCK ABSORBER, REAR HANDLE 71745
16 BUMPER, SHOCK ABSORBER, FUEL TANK TOP 73270
17 FRONT HANDLE BOLT 7.79 69 X73983
18 FRONT HANDLE 71422
19 FUEL BREATHER COMPLETE 71748
20 WATER DEFLECTOR, BOTTOM 71766
21 BREATHER TUBE BODY 71751
22 BREATHER TUBE ELBOW 71759
23 FUEL BREATHER, REMOTE 71761
24 BREATHER TUBE EXTENSION 71777
25 TUBE CLAMP, NO TABS 71760

© 2008 ICS, Blount Inc.F/N 71537 Jan O8
TITLE613GC SHOP MANUAL
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5. AIR INTAKE
5 This section covers the
disassembly, inspection, and
assembly 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
5.3 Clean filter with cleaning solution and
a nylon brush.
A Clean filter with cleaning solution and
water.
B Let dry and reinstall.

© 2008 ICS, Blount Inc. F/N 71537 Jan O8
TITLE 613GC SHOP MANUAL
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5. AIR INTAKE
5.4 Inspect air filter cover gasket.
A 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.

© 2008 ICS, Blount Inc.F/N 71537 Jan O8
TITLE613GC SHOP MANUAL
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6. SPARK PLUG
6 This section covers the removal,
inspection, and installation of
the spark plug.
6.1 Remove the spark plug lead.
6.2 Clean area around the spark plug
to prevent debris from entering the
cylinder.
6.3 Remove the spark plug.
6.4 Inspect the spark plug.
A If dirty, clean with a wire brush as
shown.

© 2008 ICS, Blount Inc. F/N 71537 Jan O8
TITLE 613GC SHOP MANUAL
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6. SPARK PLUG
B Gap 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 78 to
select the correct replacement
plug.
6.5 Assemble in the reverse order.
A Make sure the plug boot is seated
completely.