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Sorry for the delay in reply, the weather up here has been like winter for the last week and I have not been able to even look at the motor. I do appreciate the help though and I will continue looking at the issue today and report back.
To answer the last two questions the length that I pull the cord out does not seem to matter. It seems to jam either way.
In order to get the knot small enough so that it does not rub, I tied it as tight as I could using two pairs of vice grips and then I melted it down with heat and squeezed it with pliers until it was fit into the groove without rubbing. Admittedly the rope is kinda old, might not be a bad idea for me th source a new pull rope actually.
The more I look at it the more I suspect what Fleetwin had already mentioned about something not being right at the bottom with that little plastic tab groove or perhaps a bad spring.