I would look into how you have your bearings/seals setup as well. Your front seal is a mile from where it needs to be to ride on the sealing (polished) potion of the shaft.
650 is just a lot easier due to the built-in pump shoe......an FX scoop even bolts right up like it was made for it! There's really no difference in the pumps from a performance perspective, so the easier path wins.
start switch or solenoid. try unplugging the start switch connector when it's happening and if it stops, it's the switch....if it doesn't, it's the solenoid.
Wow...I just looked at your pics again and that's definitely the problem. You should have about .350-.400" of machined surface before the threads start.
Was your new prop "setback" or standard? If setback, they may not have machined it properly.....I 've seen one done this way and the result was the same.
A good worked 440 can be a lot of fun and can rival a 550. It will never have the punch of a SJ but it will let you learn to ride a lightweight hull and learn "power management". If you learn to ride a 440 it will make a SJ feel like a barge and you'll have a very easy transition.
That's working for me but usually when I bring up the site the home page has a link called "new posts" right under my avatar located the left of the screen. As it is now, when I bring up the site I get the forum view vs normal homepage.
Not a big deal, but figured you should know something...
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