You can purchase cast pulleys as an aftermarket part. If you do get diameters that are either identical or very close. Make sure you get the correct size for the output shaft of your motor.
This is the first time I've heard of a pulley "breaking", maybe you should buy a lottery ticket, it sounds like you may have used up all your "bad luck points" for a while.
I read your story, sounds like a lot of frustration. One thing to take from the starter motor part of the story is that if something doesn't seem right try and figure it out, machines don't "get better" on their own. Of course a lot of that is experience and it seems you've been gaining a lot with this machine.
This message was modified Mar 4, 2007 by nibbler