Homelite 240 Chainsaw Parts Manual

The Homelite 240 is a lightweight, gas-powered chainsaw designed for general-purpose cutting, pruning, and limbing. This parts manual provides detailed diagrams and part numbers for the complete assembly, including the engine, cutting system, fuel system, ignition, and controls. Below are key sections for safety, specifications, assembly diagrams, part numbers, maintenance, and troubleshooting.

1. Features at a Glance 2. Safety Information 3. Specifications 4. Assembly Diagrams 5. Parts List & Numbers 6. Maintenance Procedures 7. Fuel & Lubrication System 8. Cutting System 9. Ignition & Starting System 10. Troubleshooting 11. Ordering Parts

Features at a Glance

Key components: 2-cycle gasoline engine, guide bar, cutting chain, centrifugal clutch, manual oiler, anti-vibration system, and safety features.

Feature	Description
Engine Displacement	Approximately 40cc 2-cycle air-cooled engine
Guide Bar Length	Typically 16 inches (varies by model)
Chain Pitch & Gauge	.325" pitch, .050" gauge (common)
Fuel Capacity	Approximately 0.5 US quarts (0.47 liters)
Oil Capacity	Approximately 0.25 US quarts (0.24 liters)
Ignition System	Electronic ignition (CDI)
Starting System	Recoil starter with decompression valve
Safety Features	Chain brake, hand guard, throttle lockout
Weight (dry)	Approximately 10.5 lbs (4.8 kg)
Vibration Damping	Anti-vibration mounts on handles

Safety Information

Always wear appropriate PPE: safety glasses, hearing protection, gloves, chainsaw chaps, and sturdy boots.

Before Starting: Check chain tension, sharpness, and lubrication. Ensure all guards are in place.
During Operation: Maintain firm grip with both hands. Keep bystanders away. Do not operate above shoulder height.
Fueling: Stop engine and allow to cool. Refuel outdoors, away from ignition sources.
Kickback Zone: Be aware of the upper quadrant of the guide bar tip to avoid kickback.

WARNING! A chainsaw is a dangerous tool. Failure to follow safety instructions can result in serious injury or death. Read the operator's manual before use.

Specifications

Model: Homelite 240
Type: Gasoline-powered chainsaw
Engine: 2-cycle, single cylinder, air-cooled
Displacement: 40 cc (approx.)
Power Output: Approx. 2.0 HP
Fuel Mix: Unleaded gasoline with 2-cycle oil at 40:1 ratio (check manual)
Bar Length Options: 14", 16", 18"
Chain Type: Low-kickback safety chain
Spark Plug: Champion RCJ-6Y or equivalent
Idle Speed: 2,800 - 3,200 RPM
Max Power Speed: 9,500 - 10,500 RPM

Assembly Diagrams

Refer to the exploded-view diagrams for major assemblies. Diagrams are typically numbered for cross-reference with the parts list.

Diagram 1 - Complete Unit: Overview of main assemblies.

Diagram 2 - Engine Assembly: Cylinder, piston, crankshaft, carburetor, muffler.

Diagram 3 - Cutting Attachment: Guide bar, chain, sprocket, clutch drum, chain brake.

Diagram 4 - Handle & Control Assembly: Front/rear handles, throttle trigger, lockout, master control lever.

Diagram 5 - Fuel & Oil Tanks: Tank assembly, caps, fuel lines, filters, manual oil pump.

Parts List & Numbers

This list corresponds to the assembly diagrams. Use these numbers when ordering replacement parts.

Ref #	Part Description	Part Number	Qty
1	Cylinder Assembly (Complete)	HL-240-001	1
2	Piston & Ring Set	HL-240-002	1
3	Crankshaft Assembly	HL-240-003	1
4	Carburetor (Zama C1Q)	HL-240-004	1
5	Air Filter	HL-240-005	1
6	Muffler with Spark Arrestor	HL-240-006	1
7	Guide Bar, 16"	HL-240-007	1
8	Cutting Chain, .325"-050"-72DL	HL-240-008	1
9	Sprocket (Rim Type)	HL-240-009	1
10	Clutch Assembly (Centrifugal)	HL-240-010	1
11	Chain Brake Band/Spring	HL-240-011	1
12	Front Handle with Anti-Vibe	HL-240-012	1
13	Rear Handle & Tank Assembly	HL-240-013	1
14	Starter Assembly (Recoil)	HL-240-014	1
15	Ignition Module (CDI)	HL-240-015	1
16	Spark Plug (Champion RCJ-6Y)	HL-240-016	1
17	Fuel Cap Assembly	HL-240-017	1
18	Oil Cap Assembly	HL-240-018	1
19	Throttle Trigger/Lockout	HL-240-019	1
20	Master Control Lever	HL-240-020	1

Note: Part numbers are illustrative. Confirm with your dealer or parts distributor.

Maintenance Procedures

Regular maintenance ensures safe operation and extends saw life.

Daily/Pre-Use: Check chain tension and sharpness. Check bar/chain lubrication. Inspect for loose fasteners or damage.
Air Filter: Clean weekly (more often in dusty conditions). Replace if damaged.
Spark Plug: Clean and check gap (0.025") every 25 hours. Replace annually or as needed.
Fuel Filter: Replace every 50 operating hours or seasonally.
Chain Sprocket: Inspect for wear. Replace rim sprocket every 2-3 chains.
Bar Maintenance: Clean bar groove weekly. Flip bar weekly for even wear.
Carburetor Adjustment: Only adjust if necessary. Factory settings are typically optimal.

Fuel & Lubrication System

Fuel: Use fresh unleaded gasoline (87 octane minimum) mixed with a high-quality 2-cycle engine oil at a 40:1 ratio (3.2 oz oil per 1 US gallon gas). Do not use automotive oil or old fuel mix.

Bar & Chain Oil: Use a dedicated chainsaw bar oil. Check oil level before each use. Manual oiler: Press the plunger periodically during cutting.

Fuel System Parts: Tank, cap, fuel line, filter, carburetor, primer bulb (if equipped).

CAUTION! Gasoline is extremely flammable. No smoking. Allow engine to cool before refueling.

Cutting System

Components: Guide bar, cutting chain, drive sprocket, clutch, chain brake, oil pump.

Chain Tensioning: Loosen bar nuts. Adjust tensioning screw until chain fits snugly against bar but can be pulled around by hand. Retighten bar nuts.
Chain Sharpening: Use correct round file size (.325" chain uses a 5/32" file). Maintain correct filing angle (typically 30°). File all cutters evenly.
Chain Direction: Ensure cutting teeth face forward on top of bar.
Chain Brake Test: With engine off, engage brake by pushing front hand guard forward. It should lock chain. Disengage to release.

Ignition & Starting System

Ignition Module (CDI): Provides spark. Part # HL-240-015.

Spark Plug: Champion RCJ-6Y, gap 0.025".

Starter Assembly: Recoil mechanism with rope, pulley, and springs. Part # HL-240-014.

Starting Procedure:

Engage chain brake.
Set master control lever to COLD START (Choke) position.
Pull starter rope briskly until engine 'pops'.
Move lever to RUN position.
Pull starter rope again to start.
Allow brief warm-up at idle before cutting.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine will not start	No spark, old fuel, flooded, improper starting procedure	Check spark plug & gap. Use fresh fuel mix. Follow correct starting steps. Wait if flooded.
Engine starts but dies	Clogged fuel filter, dirty air filter, carburetor adjustment	Replace fuel filter. Clean air filter. Check carburetor settings (L & H screws).
Chain does not turn	Chain brake engaged, clutch worn, chain too tight, sprocket damaged	Disengage chain brake. Inspect clutch shoes/drum. Adjust chain tension. Replace sprocket.
Poor cutting performance	Dull chain, improper filing, low chain speed, insufficient oil	Sharpen or replace chain. Check chain lubrication system. Ensure engine reaches full RPM.
Excessive vibration	Loose components, unbalanced chain, damaged anti-vibe mounts	Tighten all nuts/bolts. Balance chain by filing all cutters evenly. Inspect mounts.
Chain throws oil but doesn't lubricate bar	Clogged oil passage in bar, wrong oil viscosity, faulty oil pump	Clean bar groove and oil holes. Use correct bar oil. Inspect/replace oil pump.

Ordering Parts

Always use genuine Homelite replacement parts for optimal performance and safety.

Identify Part: Use the exploded diagram and parts list in this manual to identify the correct part number.
Contact: Order from an authorized Homelite service dealer or parts distributor.
Provide Information: Have your model number (Homelite 240) and the part number ready.
Online: Parts may be available through authorized online retailers.

Support: For technical assistance or to locate a dealer, visit the Homelite website or contact customer service.