I'm guessing that you have a halyard wrap.
This happens when the lead angle to the top furler swivel is too low, and the halyard wraps around the track (extrusion) as you pull out. Be careful, you can seriously damage the forestay. Play with your halyards, or go up the mast on the main halyard if needed.
Often as Joe notes having a pendant on a shorter luffed sail correctly this angle.