Check out the big brain on oldsaw!
I took the pull cord assembly off again tonight and noticed that the when wound in the cord was over lapping itself. Thus binding and being a B I T C H in itself. The pulley does have a slight crack on the inside allowing it to splay wider than it should be and so the cord wraps over itself when you pull it tight. I'm gonna get a new pulley tomorrow, hopefully. I was using a 4.5 mm dia. cord, which looked to be a straight replacement for the one that was already on it. Is this the right size or should I be using a thicker cord?