I have a 1997 ski-doo formula s 380 and the recoil rope keeps breaking. I pull it over and the rope comes flying out all frayed. This has happend to be about once every year and i have to put a new rope in it.
High quality re-coil rope can't be bought in hardware stores. Look in a sail boat shop for either no-stretch or pre-stretched line which isn't made of nylon rope. I'm surprised Ski-Doo doesn't have woven stainless steel re-coil cable line like Polaris sheds have had for 45 years.
Is there a rough edge where the rope feeds through this could be abrading the rope and causing it to wear prematurely, or Are you using high quality nylon cord? some rope just isn't as good quality and just won't last long.