This is somewhat common in the the "zip start" machines. The recoil pulley is 2 plastic housings with a round coil spring between them. It is designed to need less effort to pull and start the machine. When pulled on with great effort/frustration, the middle spring bends and damages the upper housing. The only semi-permanent solution is to replace the pulley assembly. The part is relatively cheap thru Homelite.com. If you can do it yourself, go for it. A repair shop will most likely charge you $20 to $40 in labor to do this.
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