Homelite 240 Chainsaw Service Manual

The Homelite 240 is a lightweight, gas-powered chainsaw designed for general homeowner use. This manual provides essential information for safe operation, routine maintenance, troubleshooting, and repair procedures. Key sections include safety warnings, specifications, assembly instructions, operation guidelines, maintenance schedules, and detailed troubleshooting steps for common issues.

1. Safety Warnings & Precautions 2. Specifications & Features 3. Assembly & Initial Setup 4. Controls & Operation 5. Fuel & Lubrication 6. Routine Maintenance 7. Chain & Bar Care 8. Carburetor Adjustment 9. Ignition System 10. Troubleshooting Guide 11. Parts List & Exploded Views

Safety Warnings & Precautions

Operating a chainsaw involves serious risks. Always follow these fundamental safety rules to prevent injury or death.

Hazard	Precaution
Kickback	Always grip saw firmly with both hands. Use a low-kickback chain. Do not saw with the tip.
Hearing Damage	Wear approved hearing protection during operation.
Eye Injury	Always wear safety glasses or a face shield.
Fire/Explosion	Refuel in a well-ventilated area with engine off and cool. Wipe spills.
Carbon Monoxide	Operate only in well-ventilated outdoor areas.
Vibration	Take frequent breaks to avoid Hand-Arm Vibration Syndrome (HAVS).

WARNING! Never operate a chainsaw when fatigued, under the influence, or in poor weather conditions. Keep bystanders and pets at a safe distance.

Specifications & Features

Engine: 2-cycle, air-cooled gasoline engine.
Displacement: 40.2 cc (2.45 cu. in.).
Fuel: Unleaded gasoline mixed with high-quality 2-cycle oil at a 40:1 ratio.
Bar Length: 16 inches (standard).
Chain Pitch/Gauge: .325" pitch, .050" gauge.
Ignition: Electronic ignition (CDI).
Carburetor: Diaphragm type with adjustable H, L, and idle screws.
Weight: Approximately 10.5 lbs (without bar & chain).
Features: Automatic oiler, manual oiler override, chain brake, anti-vibration system.

Assembly & Initial Setup

Assembling your chainsaw from the box.

Attach Guide Bar & Chain: Place bar over studs. Loop chain over sprocket and onto bar groove, ensuring cutting teeth face forward on top. Install clutch cover and tighten nuts finger-tight. Adjust chain tension, then fully tighten nuts.
Fill Bar & Chain Oil: Use recommended bar & chain oil. Fill reservoir.
Prepare Fuel Mix: Mix unleaded gasoline (89 octane minimum) with 2-cycle oil at 40:1 ratio in an approved container. Shake well.
Fill Fuel Tank: Add fuel mix to tank. Secure cap tightly.

CAUTION! Do not use automotive motor oil or old/dirty gasoline. Ensure chain moves freely and is properly tensioned before starting.

Controls & Operation

Familiarize yourself with all controls before starting the engine.

Main Controls: On/Off Switch, Choke Lever, Throttle Trigger, Throttle Lockout, Primer Bulb, Chain Brake Lever, Manual Oiler Button.

Starting Procedure (Cold Engine):

Engage chain brake. Place saw on firm, flat ground.
Move On/Off switch to "I" (On).
Pull choke lever fully out. Press primer bulb 5-6 times.
Place foot in rear handle, grip front handle with left hand. Pull starter rope sharply until engine "pops."
Push choke lever halfway in. Pull starter rope again until engine starts.
Allow to warm up for 30 seconds, then push choke fully in. Disengage chain brake.

Stopping: Release throttle, move On/Off switch to "O" (Off).

Fuel & Lubrication

Proper fuel and lubrication are critical for performance and engine life.

Fuel Mix: 40:1 ratio. Use a high-quality 2-cycle oil meeting JASO FD or ISO-L-EGD standards.
Bar & Chain Oil: Use a dedicated chainsaw bar oil for proper adhesion. Do not use waste oil.
Storage: For long-term storage, run the engine dry of fuel or add fuel stabilizer. Empty bar oil tank.

Tip: Always shake fuel mix container before refueling. Check bar oil level frequently during use.

Routine Maintenance

Regular maintenance ensures safe and reliable operation.

Interval	Task
Daily / Before Use	Check chain tension, sharpness, and lubrication. Inspect for loose fasteners. Check air filter.
Every 10 Hours	Clean air filter (replace if damaged). Check spark plug condition.
Every 20 Hours	Clean cooling fins, exhaust port, and clutch area. Inspect fuel filter.
Seasonally / 50 Hours	Replace spark plug (NGK BPMR7A). Clean/replace fuel filter. Check carburetor adjustment.

WARNING! Perform all maintenance with the engine off, spark plug wire disconnected, and the chain brake engaged.

Chain & Bar Care

A sharp, well-maintained chain is essential for safe and efficient cutting.

Tensioning: Chain should be snug against the bar but pull freely by hand. Re-tension when cool.
Sharpening: Use a round file matching chain pitch (5/32" for .325"). Maintain correct filing angle (typically 30°). File all cutters to equal length.
Depth Gauges: File down depth gauges (rakers) with a flat file to maintain proper height (0.025" below cutter).
Bar Maintenance: Flip bar weekly for even wear. Clean bar groove and oil holes. Dress bar rails with a flat file if burred.

Carburetor Adjustment

The carburetor has three adjustment screws: L (Low speed), H (High speed), and T or LA (Idle).

Preliminary Settings (if lost): Gently turn L and H screws clockwise until lightly seated, then turn counterclockwise 1-1/4 turns out.

Fine-Tuning Procedure:

Start engine and warm up for 5 minutes.
Idle Speed (T): Adjust so chain does not move, but engine runs smoothly.
Low Speed (L): Turn screw for fastest, smoothest idle. Then turn clockwise (leaner) 1/8 turn.
High Speed (H): With saw at full throttle (no load), adjust for peak RPM. Then turn clockwise (leaner) 1/8 turn to set.
Re-check idle speed.

CAUTION! An overly lean mixture can cause severe engine damage. If unsure, have adjustments made by a qualified technician.

Ignition System

The CDI module provides the spark. Common components: Spark Plug, Ignition Coil (CDI), Stop Switch, Flywheel.

Spark Plug Check: Remove plug. Check electrode gap (0.025"). Replace if electrodes are worn, fouled, or cracked.

Testing for Spark: Disconnect spark plug wire. Insert a known-good spark plug into boot and ground its base to the cylinder. Pull starter rope. A bright blue spark should be visible. No spark indicates a faulty plug, wire, coil, or flywheel key sheared.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine will not start	No fuel, flooded, no spark, clogged air filter	Check fuel, spark plug (wet/dry). Clean air filter. Ensure switch is on.
Engine starts then dies	Clogged fuel filter, dirty carburetor, faulty fuel line	Replace fuel filter. Clean carburetor. Inspect fuel lines for cracks.
Engine lacks power/overheats	Dirty air filter, clogged muffler, improper carb adjustment, dull chain	Clean air filter & muffler screen. Adjust carburetor. Sharpen chain.
Chain does not oil	Empty oil tank, clogged oil passages, faulty oil pump	Fill tank. Clean bar oil holes and saw's oil ports. Check pump drive.
Chain turns at idle	Idle speed set too high	Adjust idle speed screw (T) counterclockwise.
Excessive vibration	Loose components, unbalanced/damaged chain, worn anti-vibration mounts	Tighten all fasteners. Inspect chain. Check rubber mounts.

Parts List & Exploded Views

Refer to the official Homelite parts catalog for detailed exploded views and part numbers for the 240 series. Common replacement parts include:

Air Filter (Part # XXXXX)
Spark Plug (NGK BPMR7A)
Fuel Filter (Part # XXXXX)
Complete Chain Loop (16", .325", .050")
Guide Bar (16", .050" gauge)
Recoil Starter Assembly
Carburetor Repair Kit

Service: For technical support or genuine parts, contact Homelite or visit an authorized service center.