Homelite 240 Chainsaw Repair Manual

The Homelite 240 is a lightweight, gas-powered chainsaw designed for general-purpose cutting, limbing, and pruning. This manual provides comprehensive repair, maintenance, and troubleshooting information for the Homelite 240 chainsaw, including engine specifications, fuel system, ignition system, chain and bar assembly, carburetor adjustment, and safety procedures. Below are key sections for safety, specifications, disassembly, troubleshooting, and maintenance.

1. Safety Precautions 2. Specifications 3. Tools Required 4. Engine Overview 5. Fuel System Repair 6. Ignition System 7. Chain & Bar Assembly 8. Carburetor Adjustment 9. Routine Maintenance 10. Troubleshooting 11. Parts List & Diagrams

Safety Precautions

Always prioritize safety when operating or repairing the Homelite 240 chainsaw.

Precaution	Description
Personal Protective Equipment (PPE)	Wear safety glasses, gloves, hearing protection, and chainsaw chaps.
Work Area	Ensure a clean, well-lit, and stable work surface free of flammable materials.
Fuel Safety	Drain fuel tank before repair; work in a ventilated area away from sparks or flames.
Chain & Bar	Always remove spark plug wire before servicing chain, bar, or drive components.
Sharpening	Secure the bar in a vise; use proper filing tools and maintain correct angles.

WARNING! Failure to follow safety procedures can result in serious injury or death. Disconnect spark plug before any repair.

Specifications

Engine Type: 2-stroke, single-cylinder, air-cooled.
Displacement: 40.2 cc (2.45 cu in).
Power Output: Approximately 2.0 HP.
Fuel/Oil Mix: 40:1 ratio (unleaded gasoline to 2-cycle oil).
Bar Length: 16 inches (standard); accepts 14" to 18".
Chain Pitch: 3/8" low-profile.
Chain Gauge: 0.050".
Ignition: Electronic (solid-state).
Weight: Approximately 10.5 lbs (without bar & chain).

Tools Required

Basic tools needed for most repairs:

Socket set (metric: 8mm, 10mm, 13mm).
Screwdrivers (flathead and Phillips).
Needle-nose pliers.
Spark plug wrench.
Compression tester.
Chain filing kit (round file, flat file, filing guide).
Carburetor adjustment tool (splined).

Note: Specialty tools (piston ring compressor, flywheel puller) may be required for major engine work.

Engine Overview

The Homelite 240 features a single-cylinder, 2-stroke engine with a diaphragm carburetor and electronic ignition.

Component	Function
Cylinder & Piston	Aluminum cylinder with chrome plating; piston rings for compression.
Crankcase	Houses crankshaft, connecting rod, and bearings.
Carburetor (Walbro WT Series)	Mixes fuel and air; adjustable via H (high), L (low), and idle screws.
Ignition Coil	Generates spark for the spark plug (NGK BPMR7A or equivalent).
Recoil Starter	Manual pull-start mechanism with rewind spring.

CAUTION! Engine components are precision-fitted; label parts during disassembly and keep clean.

Fuel System Repair

Common fuel system issues include clogged filters, leaking lines, and carburetor problems.

Fuel Tank: Inspect for cracks; clean sediment; replace fuel cap if vent is blocked.
Fuel Lines: Check for cracks/hardening; replace with ethanol-resistant line.
Fuel Filter: Replace if dirty or clogged (located inside tank).
Carburetor Diaphragm & Gaskets: Inspect for tears/stiffness; rebuild kit recommended.
Primer Bulb: Test for cracks; replace if not holding pressure.

Tip: Always use fresh fuel mix (less than 30 days old) to prevent varnish buildup.

Ignition System

Electronic ignition system includes coil, spark plug, and stop switch.

Spark Plug: Gap 0.025"; replace if fouled or worn.
Ignition Coil: Test with multimeter (primary: 0.5-2.0 Ω; secondary: 5k-15k Ω).
Stop Switch: Ensure wire is intact and not grounding out.
Flywheel & Key: Check for sheared key; clean magnets.

WARNING! Never crank engine with spark plug removed and wire grounded to cylinder—risk of ignition coil damage.

Chain & Bar Assembly

Proper chain tension and sharpening are critical for performance and safety.

Bar: Inspect for wear, especially groove and tip; rotate regularly.
Chain: Sharpen cutters at 30° angle; maintain depth gauges (rakers) at 0.025" below cutters.
Sprocket: Check drive sprocket for wear; replace if teeth are hooked.
Tensioning: Adjust so chain snaps back when pulled from bar; not too tight.
Lubrication: Fill oil tank with bar & chain oil; check oiler hole for clogs.

CAUTION! Always wear gloves when handling chain; teeth are extremely sharp.

Carburetor Adjustment

Initial settings (factory): H screw 1-1/4 turns out; L screw 1 turn out. Fine-tune with engine warm.

Low Speed (L): Adjust for smooth idle and quick acceleration.
High Speed (H): Adjust for maximum RPM without "leaning out" (4-stroking sound acceptable).
Idle Speed (T): Set so chain does not move at idle.
Final Check: Test under load; re-check after 5 minutes of operation.

Note: Use a tachometer for precise adjustment (max RPM ~12,500-13,500 no load).

Routine Maintenance

Regular maintenance ensures longevity and reliability.

Interval	Task
Before each use	Check chain tension, sharpness, bar oil level.
Every 10 hours	Clean air filter (foam); check spark plug.
Every 20 hours	Clean cooling fins; inspect fuel lines.
Every season	Replace fuel filter; clean carburetor; check compression.
As needed	Sharpen chain; replace bar & chain; grease sprocket bearing.

Tip: Store with empty fuel tank or use fuel stabilizer for periods over 30 days.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, flooded, fuel issue	Check spark plug, ignition coil; dry plug; clean carburetor.
Engine starts then dies	Clogged fuel filter, bad diaphragm	Replace fuel filter; rebuild carburetor.
Loss of power	Dirty air filter, exhaust clogged	Clean air filter; decarbonize muffler/spark arrestor.
Chain won't turn	Clutch worn, sprocket damaged	Inspect clutch shoes and springs; replace drive sprocket.
Excessive vibration	Loose components, unbalanced chain	Tighten all fasteners; balance chain by sharpening evenly.
Oil not lubricating	Clogged oiler, wrong oil	Clean oil passages; use proper bar & chain oil.

Compression Test: Should read at least 110 psi; below 90 psi indicates worn piston/rings.

Parts List & Diagrams

Refer to the official Homelite 240 parts manual for exploded views and part numbers. Key replacement parts include:

Piston Kit: Includes piston, rings, wrist pin, circlips.
Carburetor Rebuild Kit: Diaphragms, gaskets, needle valve.
Ignition Coil: Homelite part # XXXXXX.
Chain Brake Assembly: (if equipped).
Bar & Chain Combo: 16" bar, 3/8" LP chain, 0.050" gauge.

For parts ordering and technical support, contact Homelite at 1-800-242-4672 or visit www.homelite.com.