ICS 695XL User manual

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
695XL
SERVICE MANUAL

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
2
TABLE OF CONTENTS
SERVICE MANUAL USE................................................................ 3
1 TOOLS..................................................................................................... 4
2 POWER CUTTER SPECIFICATIONS....................................... 5
3 SERIAL NUMBER LOCATION..................................................... 6
4 SPARE PARTS DIAGRAM............................................................. 7
5 AIR INTAKE ........................................................................................... 18
6 SPARK PLUG ....................................................................................... 19
7 SIDE COVER & TENSIONER........................................................ 21
8 CLUTCH & RIM SPROCKET ........................................................ 23
9 STARTER SYSTEM........................................................................... 28
10 CARBURETOR REMOVAL............................................................ 33
11 MUFFLER............................................................................................... 37
12 GUIDE BAR STUD ............................................................................. 38
13 IGNITION MODULE.......................................................................... 39
14 STOP SWITCH .................................................................................... 40
15 WATER HOSE ...................................................................................... 42
16 CYLINDER, PISTON & DECOMPRESSION.......................... 43
17 BOTTOM GUARD/FRONT HANDLE ....................................... 49
18 REAR HANDLE.................................................................................... 51
19 FUEL TANK & COMPONENTS................................................... 55
20 CRANKCASE ....................................................................................... 63
21 CARBURETOR TUNING................................................................. 76
22 IDLE SPEED ADJUSTMENT80................................................. 78
23 DIAGRAMS ........................................................................................... 79
24 FUEL SYSTEM..................................................................................... 81
25 CRANKCASE LEAKS ...................................................................... 84
26 SPARK PLUG REFERENCE GUIDE .......................................... 86
SECTION SECTION TITLE PAGE NUMBER

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901 3
SERVICE MANUAL USE
Service Manual Use
This manual contains all the technical information necessary for
carrying out repairs on the 695XL power cutter. 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 power cutter.
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.
• 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
1.520.877.3000.

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
4
695XL SERVICE MANUAL 1. TOOLS
Key # Part No. Description
1 71541 Pressure Gauge Bulb
2 71543 Cylinder Assembly Clamps & Piston Stop
3 71565 Electronic Tachometer
4 546191 Workshop Key Torx T27
5 546192 Test Spark Plug
6 546193 Air Gap Gauge
7 546194 Flywheel Puller
8 547277 Piston Stop
9 546196 Wrist Pin Punch
10 546197 Cylinder Seal, Exhaust
11 546198 Cylinder Seal, Inlet Port
12 546289 Puller, Sealing Ring
13 546292 Universal Puller
14 546293 Grip Plate
15 546294 Bearing Puller
16 546295 Bearing Press
17 546307 Screwdriver, Idle
not shown 546659 Clutch Tool
not shown 544120 Flat Blade Scrench
not shown 544119 Torque Scrench
not shown 70249 14T Bar Nose Sprocket Repair Kit (for 695GC)
not shown 530046 FORCE4™ Bar Nose Sprocket Repair Kit (for 695F4)
not shown 571227 OIL, 2-STROKE 2.6 OZ(6-PACK)
not shown 571228 OIL, 2-STROKE 2.6 OZ (24-PACK)

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901 5
695XL SERVICE MANUAL
2. SPECIFICATIONS
Engine Type 2-stroke, Air Cooled
Displacement 94 cc (5.7 cu-in)
Horsepower 4.8 kW (6.4 hp) @ 9000 rpm
Torque 5.7 Nm (50.4 in-lbs) @ 7,200 rpm
Engine Speed 9,300 +/- 150 rpm (max)
2,700 +/- 100 rpm (idle)
Chain Speed at Maximum Power 28 m/s (5500 ft/min)
Weight 9.5 kg (21 lbs) powerhead only
Dimensions 46 cm (18 in) length 36 cm (14 in) height
30 cm (12 in) width
Air Filter Water resistant polyester
Carburetor Walbro RWJ-7
Starter Recoil, dust and water resistant
Ignition Special water resistant electronic ignition
Clutch Centrifugal, three shoe, three spring
Fuel ratio 2% (50:1) petrol-to-oil
Fuel Capacity 1 liter (0.26 gallon)
Water Supply Requirement Minimum 1.5 bar (20 psi)
Water Flow Requirement Minimum: 4lpm (1 gpm )
Guaranteed Sound Power Level, Lwa
(1) 115 dB(A); (Kwa=1.0 dB(A))
Equivalent Sound Pressure at the
Operator's Ear LpA
104.6 dB(A) (K=1.0 dB(A))
Vibration, ahv, eq Concrete Cutting (2) 3.6 m/s2(K=1.0 m/s2) Front Handle
3.1 m/s2(K=1.0 m/s2) Rear Handle
Vibration, ahv, eq Pipe Cutting (2) 5.62 m/s2(K=0.2 m/s2) Front Handle
5.28 m/s2(K=0.2 m/s2) Rear Handle
Engine Break-in Period One tank, without cutting, cycling throttle
Spark Plug NGK BPMR7A or Champion RCJ6Y
Electrode gap 0.5 mm (0.020 in)
(1) Measured in accordance with ANSI S12.51-2012/ISO3741:2010
(2) Measured in accordance with ISO5349-1:2001, ISO22867:2011 and ISO19432:2012

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
6
695XL SERVICE MANUAL 3. SERIAL NUMBER LOCATION
3. This section shows the single location of the serial number.

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901 7
695XL SERVICE MANUAL
4. SPARE PARTS DIAGRAM
3. This section shows the single location of the serial number. 4. This section covers spare parts.
STARTER ASSEMBLY
Key # Part No. Description
A1 544013 STARTER COVER ASSEMBLY
A2 544127 STARTER PULLEY KIT
A3 543974 SCREW
A4 544021 RECOIL SPRING
A5 544023 STARTER CORD
A6 544024 STARTER HANDLE
A7 544012 SCREW
A8 544026 STARTER COVER SHIELD
A1
A3
A3
A4
A6
A5
A7
A8
A2

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
8
695XL SERVICE MANUAL 4. SPARE PARTS DIAGRAM
FLYWHEEL & IGNITION ASSEMBLY
Key # Part No. Description
B1 544030 STOP SWITCH SCREW
B2 544031 STOP SWITCH
B3 544032 STOP SWITCH CABLE
B4 544033 SPARK PLUG CAP
B5 544034 SPARK PLUG
B6 544035 PROTECTIVE SLEEVE
B7 544036 IGNITION MODULE
B8 544038 IGNITION MODULE SCREW
B9 544053 FLYWHEEL
B10 544125 STARTER PAWL KIT (INCL. TWO OF EACH ITEM)
B11 544058 STARTER WASHER
B12 544059 STARTER NUT
B6
B7
B4
B5
B8
B3
B2
B1
B11
B12
B9
B10

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901 9
695XL SERVICE MANUAL
CLUTCH ASSEMBLY & WALLWALKER®
Key # Part No. Description
C1 543905 RETAINING RING
C2 551384 SPLIT RETAINER, 695 (PAIR)
C3 543907 SPACER
C4 525496 695F4 FORCE4™ SPROCKET
C4 70949 695GC RIM SPROCKET
C5 543909 CLUTCH CUP
C6 543910 NEEDLE BEARING
C7 543911 BAR BRACKET SCREW
C8 543912 CRANK CASE BOLT
C9 544130 WALLWALKER®
C10 543920 WALLWALKER®SCREW
C11 543915 WATER PIPE
C12 546548 WATER PIPE SCREW
C13 543916 BAR BRACKET
C14 547856 CLUTCH KIT
C15 543928 CLUTCH SPRING
C16 544137 SHIELD
C5
C1
C3
C4
C6
C2
C14
C15
C11
C7
C8
C9
C10
C13
C16
C12
4. SPARE PARTS DIAGRAM

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
10
695XL SERVICE MANUAL
SIDE COVER & TENSIONER ASSEMBLY
Key # Part No. Description
D1 543899 SIDE COVER ASSEMBLY
D2 543900 SIDE COVER NUT
D3 543901 SIDE COVER NUT CIRCLIP
D4 543902 TENSIONER COVER PLATE
D5 543903 SCREW, SIDE COVER CAP
D6 543904 TENSIONER
D1
D2
D3
D4
D5
D6
4. SPARE PARTS DIAGRAM

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901 11
695XL SERVICE MANUAL
CYLINDER & EXHAUST ASSEMBLIES
Key # Part No. Description
E1 543942 CYLINDER/MUFFLER SCREW
E2 576169 PISTON/CYLINDER KIT
E3 543844 HEAT DEFLECTOR
E4 543938 MUFFLER GASKET
E5 543845 MUFFLER
E6 543846 LOWER MUFFLER MOUNTING SCREW
E7 543847 MUFFLER MOUNTING WASHER
E8 576166 DECOMPRESSION VALVE
E9 576165 CYLINDER BASE GASKET
E10 543949 NEEDLE BEARING
E11 543936 GASKET KIT
E12 543931 SEALING RING
E13 543933 CRANKCASE GASKET
E2
E4
E1
E6 E7
E9
E10
E8
E14
E1
E3
E5
E11
E13
E12 E9
E4
E1
E2
E4
E1
E6 E7
E9
E10
E8
E14
E1
E3
E5
E11
E13
E12 E9
E4
E1
4. SPARE PARTS DIAGRAM

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
12
695XL SERVICE MANUAL
CRANKCASE ASSEMBLY
Key # Part No. Description
F1 543929 CRANKCASE ASSEMBLY
F2 543930 CRANKCASE SCREW
F3 543931 SEALING RING
F4 543932 GUIDE BUSHING
F5 543933 CRANKCASE GASKET
F6 543934 MAIN BEARING
F7 543935 RUBBER BUSHING
F8 543936 GASKET KIT
F9 543937 CYLINDER BASE GASKET
F10 543938 MUFFLER GASKET
F11 544129 BAR STUD KIT
F12 543941 BAR BRACKET FASTENER
F7
F3
F1
F8
F5
F3 F9
F10
F12
F5
F6
F2
F3 F4
F11
F4
4. SPARE PARTS DIAGRAM

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901 13
695XL SERVICE MANUAL
CRANKSHAFT ASSEMBLY
Key # Part No. Description
G1 543952 CRANKSHAFT ASSEMBLY
G2 543934 MAIN BEARING
G3 543953 CRANKSHAFT SHIELD
G4 543949 NEEDLE BEARING
G1
G2
G2
G3
G3
G4
4. SPARE PARTS DIAGRAM

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
14
695XL SERVICE MANUAL
CARBURETOR & INTAKE ASSEMBLIES
Key # Part No. Description
I1 544069 INLET BOOT CLAMP
I2 544070 INLET BOOT
I3 544071 FLANGE
I4 544072 FLANGE CLUTCH SIDE SCREW
I5 544073 FLANGE BRACKET
I6 544065 SCREW
I7 544074 SEPARATOR PLATE
I8 544075 CARBURETOR (WALBRO RWJ-7)
I9 544111 THROTTLE CABLE LEVER
I10 576168 ADJUSTMENT GUIDE
I11 544112 MANIFOLD BRACKET
I12 544113 AIR INTAKE MANIFOLD
I13 544114 AIR FILTER BRACKET
I14 544115 CARBURETOR MOUNTING SCREW
I15 543975 THROTTLE CABLE ASSEMBLY
I16 544117 CHOKE LEVER
I17 576161 CARBURETOR REPAIR KIT (Only for 695XL, will not t 695GC/F4/PG)
U
I16
I1
I2
I3
I4
I5
I6
I7
I8
I11
I12
I13
I4
I14
I10
I15
I17
I9
4. SPARE PARTS DIAGRAM

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901 15
695XL SERVICE MANUAL
CYLINDER AND AIR FILTER ASSEMBLIES
Key # Part No. Description
J1 544060 FILTER COVER REAR SCREW
J2 544061 FILTER COVER FRONT SCREW
J3 576167 PLUG (may be required on older 695GC/F4 models)
J4 544062 FILTER COVER
J5 544063 AIR INTAKE INSERT
J6 544064 AIR FILTER
J7 544065 CYLINDER COVER SCREW
J8 544067 CYLINDER COVER SEALS
J9 544066 CYLINDER COVER ASSEMBLY
J7
J5
J1
J2
J1
J6
J9
J8
J8
J8
J7
J2
J4
J3
4. SPARE PARTS DIAGRAM

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
16
695XL SERVICE MANUAL
FUEL TANK ASSEMBLY
Key # Part No. Description
K1 543812 FUEL TANK ASSEMBLY
K2 543813 PARALLEL PIN
K3 543814 CABLE LEVER
K4 543815 THROTTLE LOCK OUT LEVER
K5 543816 REAR HANDLE COVER
K6 543818 CLIP
K7 543993 FUEL LINE
K8 543994 CHECK VALVE TUBE
K9 543969 CHECK VALVE
K10 543970 HOSE CLAMP
K11 543971 FUEL FILTER
K12 544990 TANK VENT ELBOW
K13 544122 TANK VENT
K14 543972 REAR HANDLE GROUND SUPPORT
K15 543973 PURGE BULB
K16 543974 REAR HANDLE SCREW
K17 543975 THROTTLE CABLE ASSEMBLY
K18 543976 THROTTLE TRIGGER
K19 543977 TRIGGER SPRING
K20 543995 PURGE BULB TUB
K21 543979 GAS TANK CAP ASSEMBLY
K22 543981 SHOCK ABSORBER SCREW
K23 543982 SHOCK ABSORBER CLUTCH SIDE
K24 543983 SHOCK ABSORBER FRONT
K25 543984 SHOCK ABSORBER FLYWHEEL SIDE
K25
K2
K22
K18
K4
K19
K8 (76 mm)
K8 (102 mm)
K9
K7
K6
K12
K13
K16
K15
K14
K20
K24
K22
K23
K22
K21
K17
K2
K3
K1
K5
K11
K10
4. SPARE PARTS DIAGRAM

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901 17
695XL SERVICE MANUAL
Key # Part No. Description
K1 543812 FUEL TANK ASSEMBLY
K2 543813 PARALLEL PIN
K3 543814 CABLE LEVER
K4 543815 THROTTLE LOCK OUT LEVER
K5 543816 REAR HANDLE COVER
K6 543818 CLIP
K7 543993 FUEL LINE
K8 543994 CHECK VALVE TUBE
K9 543969 CHECK VALVE
K10 543970 HOSE CLAMP
K11 543971 FUEL FILTER
K12 544990 TANK VENT ELBOW
K13 544122 TANK VENT
K14 543972 REAR HANDLE GROUND SUPPORT
K15 543973 PURGE BULB
K16 543974 REAR HANDLE SCREW
K17 543975 THROTTLE CABLE ASSEMBLY
K18 543976 THROTTLE TRIGGER
K19 543977 TRIGGER SPRING
K20 543995 PURGE BULB TUB
K21 543979 GAS TANK CAP ASSEMBLY
K22 543981 SHOCK ABSORBER SCREW
K23 543982 SHOCK ABSORBER CLUTCH SIDE
K24 543983 SHOCK ABSORBER FRONT
K25 543984 SHOCK ABSORBER FLYWHEEL SIDE
Key # Part No. Description
L1 543996 WATER HOSE VALVE ASSEMBLY
L2 547969 HOSE HANGER
L3 543999 WATER HOSE WITH PROTECTIVE COVERING
L4 544000 CLAMP, WATER HOSE
L5 544001 CLAMP, WATER HOSE VALVE SIDE
L6 544002 FRONT HANDLE
L7 544003 SHOCK ABSORBER, FRONT HANDLE
L8 543981 SCREW, SHOCK ABSORBERS
L9 544008 CLIP, FRONT HANDLE
L10 544009 SCREW, FRONT HANDLE
L11 576679 MUD FLAP
L12 544011 BACKING PLATE, MUD FLAP
L13 544012 SCREW, MUD FLAP
L10
16
L7
L11
L12
L9
L9
L10
L8
L10
L13
L13
L1
L4
L5
L2
L3
L6
L10
L10
16
L7
L11
L12
L9
L9
L10
L8
L10
L13
L13
L1
L4
L5
L2
L3
L6
L10
WATER DELIVERY SYSTEM
4. SPARE PARTS DIAGRAM

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
18
695XL SERVICE MANUAL
5. This section covers the removal, inspection, and assembly of the air intake.
5.2
Loosen air lter screw.
• Inspect air lter for dirt or damage.
• Replace with P/N 544064.
5. AIR INTAKE
5.1
Loosen the air lter cover screws and
remove the air lter cover.

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901 19
695XL SERVICE MANUAL
5. This section covers the removal, inspection, and assembly of the air intake. 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.
6. SPARK PLUG

©2017 ICS - Blount Inc, Specications subject to change without notice. REV19JUNE2017 P/N 598901
20
695XL SERVICE MANUAL 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.