Cover won't go on.round metal strip won't fit on round spindle that turns chain.E-235.Do I need the break bar?It doesn't line up either. DB

Hi, hold the cover in a vice where the bar nuts normally tighten up to, then pull the chainbrake lever back in the direction the handle bar would be. You will feel a click and the lever will stay back and the brake band will be released. Then refitted cover to the saw. Regards Phil.

The first thing I would do is check to be sure you didn't trip the chain break.

Sounds like the cover was taken off with the brake on. On some of the Huskies, the brake is engaged with a three-part metal piece that fits into a corresponding shaped part on the cover and is engaged with a firm click on or off. The piece looks a little like the old nuclear bomb shelter signs, like three pie wedges with the narrow parts meeting in the middle. Be careful not to strip the plastic part when trying to marry these two sections together or you will be buying a new cover. I lined up both parts, made sure it was in as far as possible, put a knee on it, and snapped the chain brake off. This opened the band, and it fit once again. Note: I did this correctly the second time it happened to me. The first time resulted in a brand new pretty cover for my used saw because I tried forcing it and stripped the plastic part it the metal piece fits into. Good luck.

Check that the chain brake is in disengaged position by
moving the front hand guard towards the front handle.
Remove the bar nuts and remove the clutch cover (chain
brake). Take off the transportation ring.
Fit the bar over the bar bolts. Place the bar in its rearmost
position. Place the chain over the drive sprocket locate it in
the groove on the bar. Begin on the top edge of the bar.

Make sure that the edges of the cutting links are facing
forward on the top edge of the bar.
Fit the clutch cover (chain brake) and locate the chain
adjuster pin in the cut-out in the bar. Check that the drive
links of the chain fit correctly on the drive sprocket and that
the chain is in the groove on the bar. Tighten the bar nuts
finger-tight.
Tension the chain by turning the chain tensioning screw
clockwise using the combination spanner. The chain
should be tensioned until it does not sag from the
underside of the bar.
The chain is correctly tensioned when it does not sag from
the underside of the bar, but can still be turned easily by
hand. Hold up the bar tip and tighten the bar nuts with the
combination spanner.
When fitting a new chain, the chain tension has to be
checked frequently until the chain is run-in. Check the
chain tension regularly. A correctly tensioned chain
ensures good cutting performance and long life.

The round lever is to remove the panel that covers the end of the bar and chain. You need to remove the panel and you'll find a little bolt on the inside of it that pulls the bar tight. The bolt has a nut on it that can be turned to loosen or tighten the chain. Before you put the panel back on be sure that the teeth of the chain are fitted into the sprocket so that when you pull the chain the sprocket turns.

if u have the bar to far extended,it will make the chain to tight and it wont turn.

It was a bad idea, there is a retro fit gear in metal part no.525884201 it is available from any Husqvarna dealer as it fits the Husqvarna 235/236/240

It can be a little tricky!

If you are referring to chain break band

Tools you will need:
1/2 Socket (to remove bar nuts)
T25(torq) or you can use a Flathead screw driver but is a little harder.

Remove 2 bar nuts,Clutch cover,bar,chain, 2 screws on black bar handle right behind clutch cover(this is needed because there is a hidden screw there for the chain break) You will need a new chain brake (my guess is that it is part # 530071893 aprox $15) but you will want to verify that with your model number.

You should see the chain break assembly, 3 - T25 screws are visible after the clutch cover is removed(note sometimes you have to clean saw dust to make screw head visible) the other T25 screw is hidden under the black bar handle. Once you remove all 4 screws on the chain brake you will be able to pull it off.

Installing the new one is the tricky part because if it is set(or break is on) you will have a hard time putting it on.One of the easiest ways is to focus on it near the muffler you will see that a metal 3 pronged gear fits into the plastic part of the chain break handle.and if the band is too tight to fit over the clutch drum you will have to carefully reset it by applying pressure onto the area that has the 3 pronged gear and chain break handle make sure that the handle is pushed forward all the way while you apply pressure then slowly pull chain break handle back till you hear a "snap" this resets the chain brake spring and the band should now fit over the clutch drum.Now, proceed with putting back together 4 chain brake assembly screws,2 handle screws,and bar,chain,clutch cover,and 2 bar nuts.

Please note it is important that you apply quite a bit of pressure onto chain break area where metal (3 pronged) gear fits into handle while resetting or when you reset it the metal part can cut into and damage the plastic piece in the chain break handle.

You can see a breakdown here: http://www.searspartsdirect.com/partsdirect/part-model/Poulan-Parts/Chainsaw-Parts/Model-P4018WT/1324/1503220/P0506041/00002?blt=06&prst=0&shdMod=P4018WT

Hope this helps!

The metal band is the chain brake . It must be compressed so you need to move the brake handle forward.

That metal band you see which is preventing you from putting on the cover is part of the chain break mechanism. You were suppose to disengage the break before taking off the cover (I did the same thing). To get it back together you need to disengage the break by a tricky procedure and that will make the band diameter larger so it fits over the clutch. To force the band open, you need to first place the cover over the two bolts that hold the bar. As you already know, the back of the cover will not be able to fit over the clutch. Now in this angled position, bend (force) the break lever down (gray thing on top) until you can force together the sproket in the cover onto the mating pastic fitting built into the break lever. Now you can use the break lever to force down the internal spring and open the metal band. That will expand the stainless steel band and it will fit around the clutch. If you now push down on the back of the cover it will snap in over the clutch. Once you see how it is done, it is not so hard, but it is tricky because you are forcing some of the parts slightly out of position to get it back together. .