When you have an old model chain saw like the Homelite XL 120, it’s very likely that after years of repeated pulling the starter rope will eventually give out. Luckily, the starter assembly consists of a limited number of components including the rope, which makes it a reasonable component for homeowner restoration. Rather than trashing the chain saw and buying a brand new one, simply replace the rope yourself to get your trusty old friend up and running again.
Disconnect the spark plug wire from the spark plug. Always execute this step to protect against the chain saw from starting accidentally.
Remove the screws which secure the cover of the starter assembly into the housing of the chain saw with a Phillips screwdriver. Lay the screws aside and set the starter assembly face up on a flat surface facing you.
Remove the screw in the middle of the starter assembly with a Phillips screwdriver. Lift off the plastic cover and the underlying spring. Lift the spring from the meeting also.
Catch the knot that holds the string in place in the middle of the starter pulley with a set of needle-nose pliers and pull it from the middle of the pulley. Cut the rope with a pair of scissors, then remove both parts of it in the starter assembly and then throw it off.
Twist the pulley approximately five times to reset the stress of the recoil spring which rests hidden within the pulley. Maintain your hold to the pulley to protect against the pulley from popping off the starter unit because of the stress of the spring. Align the string hole in the pulley with the string hole in the housing.
Thread the end of the new starter rope through the hole in the housing and then across the hole in the starter pulley while holding the starter pulley in place. Tie a knot in the end of the tip of the string that is in the interior part of the pulley. Pull the string back out the hole in the starter housing so that the knot is lodged into the interior of the pulley.
Reinstall the spring which you removed before and set the plastic cover on top of it. Insert the screw into the hole in the middle of the cover and screw it in tight. Catch the starter rope securely in 1 hand and then release your hold to the starter pulley. Bend the string and allow the pulley to gradually recoil and pull on the string back onto the pulley until it’s properly in place.
Attach the starter assembly into the side of the chain saw and secure it by reinstalling the screws which hold it in place.