I wouldn't move the shaft any closer to the strut, in fact I would move it out to 5mm clearance. Any closer to the strut will certainly bind the flexshaft under hard load. This is a strange situation, as I have the same boat and just upgraded to the same shaft and I swear the boat got faster with no other changes. Granted, I did install the new teflon liner that came with the shaft. I removed my old liner and cut the new one to the same length, then installed it. A few things to check: stuffing tube alignment with the motor collet. This shaft seems a bit pickier than the stock shaft regarding the alignment here. Also, do you grease the bushing before you install it? I grease the bushing, install it, then grease the cable and install it. This always seems to keep the bushing in the strut, right where I left it. The bushing is a floating design and needs to be able to move back and forth a bit to cope with the flex shaft "shrinking" under hard load. You may want to check inside the bushing for any burrs or scratches that could cause the shaft to "grab" onto it. Hope this helps, we'll figure this thing out
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Dumas 44' Coast Guard MLB (undergoing restoration)
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