Thanks for the speedy reply Bruce.
Yes, the gaurd is in place and has been since day one.
Yes, the flywheel nut is tight, I check it every time I have the machine apart.
It is as though the teeth on the pulley are being damaged during the starting process. I can feel the slippage while pulling on the cord and once it starts doing that, another pulley replacement is inevitable. The trimmer starts easy, on the third or forth pull, so I'm not yanking my arm off to start the thing. I've measured the distance of the pulley teeth in relation to the flywheel paws and find that there is only about .125" paw engagement at best. I thought that there should be more engagement since the pulley teeth are about .250 deep. I also question the angle of the engagement end of the paws were they are bent over.
In general, I like the machine but would sure like to fix this problem. I've even considered machining a new pulley out of light weight aluminum.
Thanks again,
Doug