I do it 2-3 times a year. I don’t even feel like I’m pulling that hard. On the bright side I’ve got pretty good at replacing it.
Uma said:
I’m a frayed knot.
God damn it.
Uma said:
I’m a frayed knot.
You mfer 
Uma said:
I’m a frayed knot.
You are clever.
Uma said:
I’m a frayed knot.
Sigh…
Assuming you’re using new cord each time (“new” as in not old cord that might have weakened with age), perhaps something sharp is rubbing against it when you pull the cord?
Wolf said:
Assuming you’re using new cord each time (“new” as in not old cord that might have weakened with age), perhaps something sharp is rubbing against it when you pull the cord?
This is my guess. OP might be using rope from the same 40-year-old spool every time.
@Sage
Nah I replace it every time. I think like someone else said it’s just rubbing something sharp close to the end of the knot.
Oh, muscles marinara ovah heah!
Is it rubbing on something sharp? This could cause it to weaken and explain why it happens so frequently.
Blayne said:
Is it rubbing on something sharp? This could cause it to weaken and explain why it happens so frequently.
Yeah, I bet it’s rubbing on a rough spot of the ring attached to the push bar.
I’ve broken two cords in 30 years. How hard are you pulling?
You.
Use a stronger cord on your next replacement maybe? And don’t yank it as hard. I just pull lightly but quickly, and I get a good start every time.
Check that it’s not rubbing against something on the cord stop.
Avery said:
Check that it’s not rubbing against something on the cord stop.
I think this might be it. I’ve had this mower for almost 20 years and the regular breaking just started in the last 2-3. I’m not pulling any harder than I ever have before, just a quick short pull. I think I remember seeing a sharp edge along the hole that feeds it into the engine housing. When I replace it this time I’ll keep an eye out and grind it down if I have to.
@Nyx
I’ve broken two replacements in the last couple of years. I think the cords are different than they used to be also.
Some rope and PVC should fix you up.
Yes, those things only last 15 years or so. They don’t make 'em like they used to!